1996 TOYOTA RAV4 Service Repair Manual

Q08739
AX04N−01
Q06120
Vehicle Speed
SensorO−Ring
Clip Driven Gear
Q08737
Q06119O−Ring
AX−4
− AUTOMATIC TRANSAXLE (A540H)VEHICLE SPEED SENSOR
1996 RAV4 (RM447U)
VEHICLE SPEED SENSOR
ON−VEHICLE REPAIR
1. REMOVE FRONT SPEED SENSOR
(a) Remove the air cleaner assembly.
(b) Disconnect the front speed sensor connector.
(c) Remove the bolt and front speed sensor assembly.
(d) Remove the clip and speedometer driven gear from the
front speed sensor.
(e) Remove the O−ring from the front speed sensor.
2. INSTALL FRONT SPEED SENSOR ASSEMBLY
(a) Coat a new O−ring with ATF and install it to the front
speed sensor.
(b) Install the speedometer driven gear to the front speed
sensor with the clip.
(c) Install the front speed sensor assembly with the bolt.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(d) Connect the front speed sensor connector.
(e) Install the air cleaner assembly.
3. REAR SPEED SENSOR
(a) Remove the air cleaner assembly.
(b) Disconnect the rear speed sensor connector.
(c) Remove the bolt and rear speed sensor.
(d) Remove the O−ring from the rear speed sensor.
4. INSTALL REAR SPEED SENSOR
(a) Coat a new O−ring with ATF and install it to the rear speed
sensor.
(b) Install the rear speed sensor with the bolt.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(c) Connect the rear speed sensor connector.
(d) Install the air cleaner assembly.

Q08865
AX04O−01
− AUTOMATIC TRANSAXLE (A540H)ATF TEMPERATURE SWITCH
AX−5
1996 RAV4 (RM447U)
ATF TEMPERATURE SWITCH
ON−VEHICLE REPAIR
1. REMOVE NO.2 ENGINE UNDER COVER
2. REMOVE ATF TEMPERATURE SWITCH
(a) Disconnect the ATF temperature switch connector.
(b) Remove the ATF temperature switch.
3. INSTALL ATF TEMPERATURE SWITCH
(a) Install the ATF temperature switch.
(b) Connect the ATF temperature switch connector.
4. INSTALL NO.2 ENGINE UNDER COVER

Q08738
AX128−01
Q06066
Q06109
Q06077NRP AX−6
− AUTOMATIC TRANSAXLE (A540H)PARK/NEUTRAL POSITION (PNP) SWITCH
1996 RAV4 (RM447U)
PARK/NEUTRAL POSITION (PNP)
SWITCH
ON−VEHICLE REPAIR
1. REMOVE NO.2 ENGINE UNDER COVER
2. DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR
3. REMOVE PARK/NEUTRAL POSITION SWITCH
(a) Remove the nut and disconnect the shift control cable.
(b) Remove the nut and shift control lever.
(c) Using a screwdriver, pry off the lock plate.
(d) Remove the nut and lock plate.
(e) Remove the 2 bolts and pull out the park/neutral position
switch.
4. INSTALL AND ADJUST PARK/NEUTRAL POSITION
SWITCH
(a) Install the park/neutral position switch to the manual valve
shaft with the 2 bolts and nut.
(b) Install a new lock plate and tighten the nut.
Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf)
(c) Stake the nut with the lock plate.
(d) Temporarily install the manual valve lever shaft.
(e) Turn the lever counterclockwise until it stops, then turn it
clockwise 2 notches.
(f) Remove the shaft control lever.

Q06078
Neutral
Basic
Line
Groove
Q08738
− AUTOMATIC TRANSAXLE (A540H)PARK/NEUTRAL POSITION (PNP) SWITCH
AX−7
1996 RAV4 (RM447U)
(g) Adjust the park/neutral position switch
(See page AX−6).
HINT:
Align the groove and park/neutral basic line
(h) Tighten the 2 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(i) Install the shaft control lever with the nut.
Torque: 12.7 N·m (130 kgf·cm, 9 ft·lbf)
(j) Connect the control cable with the nut.
5. CONNECT PARK/NEUTRAL POSITION SWITCH CON-
NECTOR
6. INSTALL NO.2 ENGINE UNDER COVER

Q06064
AX129−01
AT0103
D00691
D00692
AX−8
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
VALVE BODY ASSEMBLY
ON−VEHICLE REPAIR
1. REMOVE NO.2 ENGINE UNDER COVER
2. DRAIN ATF
Using a 10 mm hexagon wrench, remove the drain plug, and
drain the ATF into a suitable container.
3. REMOVE OIL PAN AND GASKET
(a) Remove the 17 bolts.
(b) Remove the oil pan by lifting transaxle case.
NOTICE:
Some fluid remain in the oil pan.
4. EXHAUST PARTICLES IN PAN
Remove the magnet and use it to collect any steel chips.
Lock carefully at the chips and particles in the oil pan and on the
magnet to anticipate when type of wear you will find in the trans-
axle.
Steel (magnetic): bearing, gear and plate wear
Brass (non−magnetic): bushing wear
5. REMOVE OIL PIPE BRACKET AND STRAINER
(a) Remove the 2 bolts and oil pipe bracket.
(b) Remove the 3 bolts and strainer.
(c) Remove the gasket from the strainer.
6. REMOVE MANUAL VALVE BODY
(a) Remove the 2 bolts and detent spring.

D00693
Q05896
Q05897
D00645
Q05899
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
AX−9
1996 RAV4 (RM447U)
(b) Remove the 5 bolts and manual valve body with the
manual valve.
(c) Remove the manual valve from the manual valve body.
7. REMOVE OIL PIPE
(a) Remove the bolt and retainer.
(b) Pry up both pipe ends with a large screwdriver and re-
move the 8 pipes.
NOTICE:
Be careful not to bend or damage the pipes.
8. DISCONNECT 3 SOLENOID CONNECTORS
9. REMOVE CONNECTOR CLAMP AND PIPE RETAINER
10. REMOVE B
3 APPLY PIPE
Pry up the pipe with a screwdriver and remove the pipe.
NOTICE:
Be careful not to bend or damage the pipes.

D00694
OR0038
Z13387A B CDC
C
D00696
AX−10
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
11. REMOVE VALVE BODY
(a) Remove the 10 bolts.
(b) Disconnect the throttle cable from the cam and remove
the valve body.
12. INSTALL VALVE BODY TO TRANSAXLE CASE
(a) While holding the cam down with your hand, slip the cable
end into the slot.
(b) Raise up the valve body into place.
NOTICE:
Do not entangle the solenoid wire.
(c) Install and tighten the 10 bolts.
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Hand−tighten the 10 bolts first, then torque with a torque
wrench.
Bolt length:
Bolt A: 22 mm (0.87 in.)
Bolt B: 32 mm (1.26 in.)
Bolt C: 43 mm (1.69 in.)
Bolt D: 55 mm (2.17 in.)
13. INSTALL B
3 APPLY PIPE
NOTICE:
Be careful not to bend or damage the pipe.

Z13388
A
B
Q05897
Q05896
Z13389A B
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
AX−11
1996 RAV4 (RM447U)
14. INSTALL CONNECTOR CLAMP AND PIPE RETAINER
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
Bolt A: 39 mm (1.54 in.)
Bolt B: 43 mm (1.69 in.)
15. CONNECT 3 SOLENOID CONNECTORS
16. INSTALL OIL PIPE
(a) Using a plastic hammer, install the 8 pipes into their posi-
tions.
NOTICE:
Be careful not to bend or damage the pipes.
(b) Install and tighten the bolt and retainer.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
17. INSTALL MANUAL VALVE BODY AND DETENT
SPRING
(a) Align the manual valve with the pin on the manual shaft
lever.
(b) Lower the manual valve body into place.
(c) Hand−tighten the 5 bolts first. Then, tighten them with a
torque wrench.
Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
Bolt A: 22 mm (0.87 in.)
Bolt B: 37 mm (1.46 in.)