1996 TOYOTA RAV4 stop start

Position
DNORMAL
Solenoid valve
No. 2
ONGear
L 2ON ONOFF
ON OFF
OFF OFF
OFF ON
ON ON
OFF ON
ON OFF
ON ON1st
2nd
3rd
O/D
1st
2nd
3rd
1st
2ndSolenoid valve
No. 1 No. 2
X
X
X
X
X
X
X
X
XON
ON
ON
OFF
ON
ON
ON
OFF
ONGear
3rd
3rd
3rd
O/D
3rd
3rd
3rd
1st
2ndNo. 1 No. 2Solenoid valve
Gear
1st ON X
X
X
X
X
X
X
X
X OFF
OFF
OFF
ON ON OFF OFFON SHIFT SOLENOID NO.1
MALFUNCTIONINGSHIFT SOLENOID NO.2
MALFUNCTIONING
O/D
O/D
O/D
1st
1st
1stMALFUNCTIONING BOTH SOLENOIDS
Gear when shift selector is
manually operated
O/D
O/D
O/D
O/D
3rd
3rd
3rd
1st
1st
X: Malfunctions3rd
3rd No. 1
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−147
1996 RAV4 (RM447U)
DTC P0753, P0758 Shift Solenoid A/B Electrical Malfunc-
tion (Shift Solenoid Valve No. 1/No. 2)
CIRCUIT DESCRIPTION
Shifting from 1st to O/D is done in combination with ON and OFF of the shift solenoid valves No. 1 and No.
2 controlled by ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls
the remaining normal shift solenoid valve to allow the vehicle to be operated safely (Fail safe function).
Fail Safe Function:
If either of the shift solenoid valve circuits develops an open or a short, the ECM turns the other shift solenoid
ON and OFF to shift to the gear positions shown in the table below. The ECM also turns the shift solenoid
valve SL OFF at the same time. If both solenoids are malfunction, hydraulic control cannot be done electroni-
cally so it must be done manually.
Manual shifting as shown in the following table must be done. (In the case of a short circuit, the ECM stops
sending current to the short circuited solenoid).
HINT:
Check the shift solenoid valve No. 1 when DTC P0753 is output and check the shift solenoid valve No. 2
when DTC P0758 is output.
DTC No.DTC Detecting ConditionTrouble Area
P0753
P0758
The ECM checks for an open or short circuit in the shift sole-
noid valves No. 1 and No. 2 circuit when it changes
The ECM records DTC P0753 or P0758 if condition a) or b) is
detected once, but it does not light up the MIL
After ECM detects condition a) or b) continuously 2 times or
more in one−trip, it causes the MIL light up until condition a) or
b) disappears
After that, if the ECM detects condition (a) or (b) once, it starts
lighting up the MIL again
(a) Solenoid resistance is 8 Ω or less short circuit when sole-
noid is energized
(b) Solenoid resistance is 100 kΩ or more open circuit when
solenoid is not energized
Open or short in shift solenoid valve No. 1/No. 2 circuit
Shift solenoid valve No. 1/No. 2
ECM
DI40I−01

DI−178
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
(6) Check for the lock−up mechanism.
Drive in the D position, O/D gear, at a steady speed (lock−up ON) of about 75 km/h (47
mph).
Lightly depress the accelerator pedal and check that the engine speed does not change
abruptly.
If there is a big jump in engine speed, there is no lock−up.
(b) 2 position test.
Shift into the 2 position and, while driving with the accelerator pedal held constantly at the full throttle
valve opening position, push in one of the pattern selectors and check on the following points.
(1) Check to see that the 1 → 2 up−shift takes place and that the shift point conforms to that shown
on the automatic shift schedule (See page SS−35).
(2) While running in the 2 points and 2nd gear, release the accelerator pedal and check the engine
braking effect.
Evaluation:
ProblemPossible cause
If these is no engine braking effect2nd coast brake is defective
(3) Check for abnormal noises during acceleration and deceleration, and for shock at up−shift and
down−shift.
(c) L position test.
(1) While running in the L position, check to see that there in no up−shift to 2nd gear.
(2) While running in the L position, release the accelerator pedal and check the engine braking ef-
fect.
Evaluation:
ProblemPossible cause
If these is no engine braking effect1st and reverse brake defective
(3) Check for abnormal noises during acceleration and deceleration.
(d) R position test.
Shift into the R position and, while starting at full throttle, check for slipping.
CAUTION:
Before conducting this test ensure that the test area is free from personnel an obstructions.
(e) P position test.
Stop the vehicle on a gradient (more than 5°) and after shifting into the P position, release the parking
brake. Then check to see that the parking lock pawl holds the vehicle in place.

Q06077NRP
Q06078
Neutral
Basic
Line
Groove
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−183
1996 RAV4 (RM447U)
(3) Return the lever 2 notches to the NEUTRAL posi-
tion.
(4) Set the shift lever in the N position.
(5) While holding the lever lightly toward the ”R” posi-
tion side, tighten the shift lever nut.
(i) Adjust the park/neutral position switch.
If the engine will start with the shift selector in any position other
than the N or P position, adjustment is required.
(1) Loosen the park/neutral position switch bolts and
set the shift selector to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolts.
Torque: 5.4 N·m(55 kgf·cm,48 in·lbf)
(j) Inspect the idle speed.
Idle speed: 750 ± 50 rpm (In N position and A/C OFF)
8. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed.
The object of this test is to check the overall performance of the transaxle and engine by measuring
the stall speeds in the D and R positions.
NOTICE:
Do the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear, level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Connect OBD II scan tool or TOYOTA hand−held tester to the DLC3.
(3) Fully apply the parking brake.
(4) Keep your left foot pressed firmly on the brake pedal.
(5) Start the engine.
(6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot.
Quickly read the stall speed at this time.
Stall speed: 2,400 ± 150 rpm
(7) Do the same test in R position.
Stall speed: 2,400 ± 150 rpm
Evaluation:
ProblemPossible cause
Stall speed low in D and R positions
Engine output may be insufficient
Stator one−way clutch is operating properly
HINT:
If more than 600 rpm below the specified value, the torque converter clutch could
be faulty

DI−184
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U) Stall speed high in D position
Line pressure too low
Forward clutch slipping
No. 2 one−way clutch not operating properly
O/D one−way clutch not operating properly
Stall speed high in R position
Line pressure too low
Direct clutch slipping
1st and reverse brake slipping
O/D clutch slipping
Stall speed high in D and R positions
Line pressure too low
Improper fluid level
O/D one−way clutch not operating properly
(b) Measure the time lag.
When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before
the shock can be felt. This is used for checking the condition of the O/D direct clutch, forward clutch,
direct clutch, and 1st and reverse brake.
NOTICE:
Do the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
Be sure to allow 1 minute interval between tests.
Take 3 measurements and take the average value.
(1) Fully apply the parking brake.
(2) Start the engine and check idle speed.
Idle speed: 750 ± 50 rpm (In N position and A/C OFF)
(3) Shift the shift lever from the N to D position. Using a stop watch, measure the time it takes from
shifting the lever until the shock is felt.
Time lag: N → D Less than 1.2 seconds
In the same way, measure the time lag for N → R.
Time lag: N → R Less than 1.5 seconds
If N → D or N → R time lag is longer than specified:
Evaluation:
ProblemPossible cause
N → D time lag is longer
Line pressure too low
Forward clutch worn
O/D one−way clutch not operating properly
N → R time lag is longer
Line pressure too low
Direct clutch worn
1st and reverse brake worn
O/D one−way clutch not operating properly
9. Line Pressure:
HYDRAULIC TEST
(a) Preparation.
(1) Warm up the ATF.
(2) Remove the test plug on the transaxle case and connect SST (See page AX−18 for the location
to connect SST).
SST 09992−00094 (09992−00230)

D02249
1
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−185
1996 RAV4 (RM447U)
CAUTION:
Perform the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
The line pressure test should always be carried out in parts. One should observe the conditions
of wheels or wheel stopper outside the vehicle while the other is performing the test.
(b) Measure the line pressure.
(1) Fully apply the parking brake and chock the 4 wheels.
(2) Start the engine and check idling speed.
(3) Step down strongly on the brake pedal with your left foot and shift into the D position.
(4) Measure the line pressure when the engine is idling speed.
(5) Press the accelerator pedal all the way down. Quickly read the highest line pressure when engine
speed reaches stall speed.
(6) Only when the shift solenoid valve ST is opened:
Apply battery positive voltage between terminal of the solenoid connector and body ground.
(7) In the same way, perform the test in the R position.
Automatic Transaxle Idling kPa (kgf/cm2, psi) Stall kPa (kgf/cm2, psi)
* D position (Shift solenoid valve ST open)530 − 706 (5.4 − 7.2, 76 − 102)1,324 − 1,549 (13.5 − 15.8, 192 − 225)
D position (Shift solenoid valve ST close)363 − 442 (3.7 − 4.3, 53 − 61)736 − 863 (7.5 − 8.8, 106 − 125)
R position530 − 706 (5.4 − 7.2, 76 − 102)1,324 − 1,549 (13.5 − 15.8, 192 − 225)
*: When battery voltage is supplied to terminal 4 of the solenoid connector and body ground, the shift sole-
noid valve ST valve is open.
If the measured pressures are not with in the specification, recheck the throttle cable adjustment and perform
a retest.
(8) Clear the DTC’s after the test.
Evaluation:
ProblemPossible cause
If the measured values at all positions are higher than speci-
fiedThrottle cable out of adjustment
Throttle valve defective
Regulator valve defective
If the measured value in all positions are lower than speci-
fied
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
Oil pump defective
O/D direct clutch defective

DI−186
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U) If pressure is low in the D position only
D position circuit fluid leakage
Forward clutch defective
If pressure is low in the R position only
R position circuit fluid leakage
Direct clutch defective
1st and reverse brake defective
10. Center Differential Control Clutch:
HYDRAULIC TEST
(a) Preparation.
(1) Warm up the ATF.
(2) Remove the test plug and connect SST (See page AX−18 for the location to connect SST).
SST SST 09992−00094 (09992−00111)
CAUTION:
Perform the test at normal operating ATF temperature 50 − 80°C (122 − 176°F)
The line pressure test should always be carried out in pairs. One should observe the conditions
of wheels or wheel stoppers outside the vehicle while the other is performing the test.
(b) Measure the center differential clutch control pressure.
(1) Start the vehicle and open the accelerator open 50 % or more and check that the center differen-
tial clutch control pressure is in the range from more than 294 kPa (3.0 kgf/cm
2, 42 psi).
(2) Fully close the accelerator and check that the SST registers 9.8 kPa (0.1 kgf/cm
2, 1.4 psi) or less.
CAUTION:
Confirm safety of the road before checking.
Take care to avoid slip when you start the vehicle on a paved road.
Check the pressure at normal driving ATF temperature 50 − 80°C (122 − 176°F).
Reference:
To measure center differential control pressure to be measured with the solenoid opened by applying voltage
to it, refer to the following:
Prepare a sub−assembly for checking as follows:
Prepare a supply connector (Part No. 90980−10629, or 90980−11143)
Connect a harness of 2 − 3 m (6.6 − 9.8 ft) to terminal 1 of the connector.
Place a bulb of 24W in between the harness.
Connect a harness of 2 − 3 m (6.6 − 9.8 ft) to terminal 3 of the connector.
Connect the inspection’s sub−harness assembly to the solenoid connector of the transfer.
Connect terminal 1 of the sub−harness to the battery’s positive (+) terminal, and terminal 3 of the sub−
harness to the battery’s negative (−) terminal.
Measure the center differential control pressure at idling and when performing the stall test (When 1st
gear).
Engine speedSub−harnessLine pressure kPa (kgf/cm2, psi)
IdlingConnected363 − 422 (3.7 − 4.3, 53 − 61)
Stall (Shift solenoid valve SLD OFF)Connected735 − 863 (7.5 − 8.8, 107 − 125)
Stall (Shift solenoid valve SLD ON)Connected1,324 − 1,549 (13.5 − 15.8, 192 − 225)
All rpmNot connected9.8 (0.1, 1.4) or less

DI40X−02
DI−192
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
PROBLEM SYMPTOMS TABLE
If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the
circuits for each symptom in the order given in the charts on the following pages and proceed to the page
given for troubleshooting.
The Matrix Chart is divided into 3 chapters.
Chapter 1: Electronic Circuit Matrix Chart
Chapter 2: On−Vehicle Repair Matrix Chart
Chapter 3: Off−Vehicle Repair Matrix Chart
When troubleshooting, check Chapter 1 first. If instructions are given in Chapter 1 to proceed to chapter 2
or 3, proceed as instructed.
(1) If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow
chart for each circuit, proceed to the circuit with the next highest number in the table to continue
the check.
(2) If the trouble still occurs even though there are no abnormalities in any of the other circuits, then
check and replace the ECM.
Chapter 1: Electronic Circuit Matrix Chart
SymptomSuspect AreaSee page
No up−shift (A particular gear, from 1st to 3rd gear, is not up−
shifted)2. ECMDI−191
No up−shift (3rd → O/D)
1. O/D main switch & O/D OFF indicator light circuit
2. O/D cancel signal circuit
3. ECMDI−223
DI−221
DI−191
No down−shift (O/D → 3rd)
1. O/D main switch & O/D OFF indicator light circuit
2. O/D cancel signal circuit
3. ECMDI−223
DI−221
DI−191
No down−shift (A particular gear, from 1st to 3rd gear, is not
down−shifted)1. ECMDI−191
No lock−up1. Stop light switch circuit
2. ECMDI−227
DI−191
No lock−up off1. ECMDI−191
Shift point too high or too low1. Pattern select switch circuit
2. ECMDI−229
DI−191
Up−shifts to O/D from 3rd while O/D main switch is OFF1. O/D main switch & O/D OFF indicator light circuit
2. ECMDI−223
DI−191
Up−shifts to O/D from 3rd while engine is cold1. ECMDI−191
No kick−down1. ECMDI−191
Engine stalls when starting off or stopping1. ECMDI−191
”A/T OIL” indicator light does not light up or does not goes off1. A/T temperature switchDI−191
Chapter 2: On−Vehicle Repair
(: A540H Automatic Transaxle Repair Manual Pub. No. RM488U)
SymptomSuspect AreaSee page
Vehicle does not move in R position
1. 1−2 shift valve
2. 2−3 shift valve
3. Throttle valve
4. Off−vehicle repair matrix chart


−
Vehicle does not move in any forward position or reverse position
1. Manual valve
2. Primary regulator valve
3. Secondary regulator valve
4. Off−vehicle repair matrix chart


−

DI−194
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U) Front or rear wheel is slipping
1. Shift restrict reverse ball
2. Solenoid modulator valve
3. Differential control valve
4. Off−vehicle repair matrix chart


−
Shift point too high or too low1. Secondary regulator valve
Chapter 3: Off−Vehicle Repair
(: A540H Automatic Transaxle Repair Manual Pub. No. RM488U)
SymptomSuspect AreaSee page
Vehicle does not move in any forward position
1. Forward clutch (C1)
2. No. 2 one−way clutch (F
2)
3. 1st and reverse brake (B
3)
4. 2nd coast brake (B
1)
5. 2nd brake (B
2)
6. Direct clutch (C
2)






Vehicle does not move in reverse position
1. 2nd coast brake (B1)
2. Front planetary gear
3. Rear planetary gear
4. Direct clutch (C
2)
5. O/D direct clutch (C
0)
6. 1st and reverse brake (B
3)






Vehicle does not move in any forward position and reverse posi-
tion
1. Parking lock pawl
2. Oil pump
3. O/D one−way clutch (F
0)
4. O/D direct clutch (C
0)
5. O/D brake (B
0)
6. Front planetary gear
7. Rear planetary gear
8. O/D planetary gear








No lock−up1. Torque converter clutchAX−22
No lock−up OFF1. Torque converter clutchAX−22
Large shock during lock−up1. Torque converter clutchAX−22
E/G stalls when starting off and stopping1. Torque converter clutchAX−22
No up−shift (1st → 2nd)1. 2nd brake (B2)
2. No. 1 one−way clutch (F
1)


No up−shift (2nd → 3rd)1. Direct clutch (C2)
No up−shift (3rd → O/D)1. O/D brake (B0)
No down−shift (2nd → 1st)1. 2nd coast brake (B1)
Harsh engagement (N → R)1. Direct clutch (C2)
2. 1st and reverse brake (B
3)


Harsh engagement (N → D)1. Forward clutch (C1)
Harsh engagement (1st → 2nd (D position))1. 1st and reverse brake (B3)
Harsh engagement (2nd → 3rd)1. 2nd coast brake (B1)
Harsh engagement (3rd → O/D)
1. O/D direct clutch (C0)
2. O/D brake (B
0)
3. O/D planetary gear



Slip on shudder (Forward and reverse (After warm−up))
1. Torque converter clutch
2. Oil pump
3. No. 1 one−way clutch (F
1)
4. O/D direct clutch (C
0)
AX−22



Slip on shudder (Forward and reverse (Direct after E/G start))1. Torque converter clutchAX−22