1996 TOYOTA RAV4 clutch

AX051−02
F00484
PositionC1C2C3B1B2Shift Lever
GearShift
Solenoid
Valve No.1 No.2 One−Way Clutch (F
2)
1st & Reverse Brake (B
3)
U/D Brake (B
4)
U/D One−Way Clutch (F
3)U/D Clutch (C
3) Direct Clutch (C
2) 2nd Brake (B
2)Forward Clutch (C
1)
2nd Coast Brake (B
1)
Shift
Solenoid
Valve No.2B
4B3
Front Planetary Gear Unit
F
1F2F3
ON OFF
ON
ON ON
ON OFF OFF ONON ON ON
ON ON OFF
OFFONOFF OFF
OFF OFF OFF
ON
ON
 
 
 
 
 
 


 

 
 
   
  
 
 
 
 

 2nd Neutral ReversePark
1st
O/D3rd
2nd* 2nd 1st
3rd*
1st P
R
N
D
2
L
 : Operating
*: Down−shift only in the 3rd gear for the 2 position and 2nd gear for the L position − no up−shift Rear Planetary Gear Unit
U/D Planetary Gear Unit
No.1 One−Way Clutch (F1)
AX−2
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE SYSTEM
1996 RAV4 (RM447U)
OPERATION

AX0T8−01
Z18886
RH Drive Shaft
LH Drive Shaft  Snap Ring
64 (650, 47)
 Cotter Pin
Lock Cap
216 (2,200, 159)
 Gasket
49 (500, 36)
7.0 (75, 65 in.·lbf)
62 (630, 46)
48 (490, 35)
Front Exhaust PipeEngine Mounting
Center MemberPS Gear Assembly
Front Suspension Crossmember
Assembly with Stabilizer Bar
RH Engine Under Cover
LH Engine Under Cover
137 (1,400, 101)
206 (2,100, 152)
127 (1,300, 94)
72 (730, 53)

73 (740, 54)
N·m (kgf·cm, ft·lbf)
: Specified torque
 Non−reusable part
113 (1,150 83)
 Cotter Pin
 Gasket
35 (360, 26)
64 (650, 47)
64 (650, 47)
19 (194, 14)
25 (250, 18)
46 (470, 34)
27 (280, 20)
25 (250, 18)
9.0 (95, 78 in.·lbf)
64 (650, 47)
9.0 (95, 78 in.·lbf)
37 (380, 27)
13 (135, 10)
39 (400, 29)64 (650, 47)
 GasketStarterEngine Wire
Clamp Plug for Line
Pressure Test
Shift Control
Cable ClipRear End Plate Stiffener Platex 6 Torque Converter
ClutchEngine Coolant Reservoir TankABS RelayAir Intake Connector
Air Cleaner
Case Assembly AX−14
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
AUTOMATIC TRANSAXLE UNIT
COMPONENTS

Z18887
A
A
A
B
Q08772
Q08773
A
B AX−18
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
20. REMOVE REAR END PLATE
Remove the 4 bolts and rear end plate.
Torque:
A bolt: 9.0 N·m (95 kgf·cm, 78 in.·lbf)
B bolt: 19 N·m (195 kgf·cm, 14 ft·lbf)
21. REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLT
Turn the crankshaft to gain access and remove the 6 bolts with
holding the crankshaft pulley set bolt by a wrench.
Torque: 27 N·m (280 kgf·cm, 20 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
First install the gray bolt. Then install 5 black bolts while turning
the crankshaft to grain access.
22. SUPPORT TRANSAXLE WITH A TRANSMISSION
JACK
23. REMOVE TRANSAXLE
Remove the rear side transaxle mouting 2 bolts and transaxle.
Torque:
A bolt: 25 N·m (250 kgf·cm, 18 ft·lbf)
B bolt: 46 N·m (470 kgf·cm, 34 ft·lbf)

AT3412
AX059−03
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
AX−19
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL TORQUE CONVERTER CLUTCH
Using calipers and a straight edge, measure from the installed
surface to front surface of the transaxle housing.
Correct distance: More than 12.75 mm (0.502 in.)
2. INSTALL TRANSAXLE
Installation is in the reverse order of removal (See page
AX−15).
HINT:
After installation, check and inspect items as follows.
Fluid level (See page DI−127)
Front wheel alignment (See page SA−4)
Road test the vehicle

AT0953
SST
AX05A−02
AT3306
Hold
Lock
Free
Turn
D00776
AT4184
AX−20
− AUTOMATIC TRANSAXLE (A241E)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
1996 RAV4 (RM447U)
TORQUE CONVERTER CLUTCH
AND DRIVE PLATE
INSPECTION
1. INSPECT ONE−WAY CLUTCH
(a) Install SST into the inner race of the one−way clutch.
SST 09350−32014 (09351−32010)
(b) Install SST so that it fits in the notch of the converter clutch
hub and outer race of the one−way clutch.
SST 09350−32014 (09351−32020)
(c) With the torque converter clutch standing on its side,the
clutch locks when turned counterclockwise, and rotates
freely and smoothly clockwise.
If necessary, clean the converter clutch and retest the clutch.
Replace the converter clutch if the clutch still fails the test.
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
Set up a dial indicator, measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification or if the ring gear is
damaged, replace the drive plate. If installing a new drive plate,
note the orientation of spacers and tighten the bolts.
Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)
3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE
RUNOUT
Temporarily mount the torque converter clutch to the drive
plate. Set up a dial indicator, measure the torque converter
clutch sleeve runout.
Maximum runout: 0.30 mm (0.0118 in.)
If the runout is not within the specification, try to correcting by
reorienting the installation of the converter clutch.

− AUTOMATIC TRANSAXLE (A241E)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
AX−21
1996 RAV4 (RM447U)
HINT:
Mark the position of the torque converter clutch to ensure cor-
rect installation.

AX04L−01
D00690
Planetary Gear Unit
O/D Direct
Clutch (C
0)O/D Brake (B0)1st & Reverse
Brake (B
3)
One−Way Clutch
No.2 (F
2)2nd Brake (B
2)
Forward
Clutch (C
1)2nd Coast
Brake (B
1)
Direct Clutch (C
2)
Input Shaft Front Planetary
Gear
One−Way Clutch
No.1 (F
1) Rear Planetary
Gear
Intermediate
Shaft Counter
Drive Gear
O/D Planetary
Gear O/D One−Way
Clutch (F
0)
Shift Lever
PositionGear Position
C
0C1C2B0B1B2B3F0F1F2
P Parking
Reverse
Neutral
1st
2nd
3rd
O/D R
N
D
2
L1st
2nd
*3rd
1st
*2nd








































*Down−shift only − no up−shift
 : Operating AX−2
− AUTOMATIC TRANSAXLE (A540H)AUTOMATIC TRANSAXLE SYSTEM
1996 RAV4 (RM447U)
OPERATION

Q06113
AX04U−02
Q05857
Z19463
Q05858
− AUTOMATIC TRANSAXLE (A540H)AUTOMATIC TRANSAXLE UNIT
AX−19
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE TRANSAXLE WITH ENGINE (See page
EM−68)
2. REMOVE STARTER
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
3. REMOVE STIFFENER PLATE
Remove the 3 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
4. REMOVE REAR END PLATE
Remove the 4 bolts and rear end plate.
Torque:
Bolt A: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
Bolt B: 25 N·m (250 kgf·cm, 18 ft·lbf)
5. REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLTS
Turn the crankshaft to gain access and remove the 6 bolts with
holding the crankshaft pulley nut by a wrench.
Torque: 27 N·m (280 kgf·cm, 20 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Coat the threads of the bolts with sealant.
Sealant: Part No. 08833 − 00070, THREE BONDS 1324
or equivalent
Tighten the bolts evenly.
First install dark green colored bolt and then the 5
bolts.
6. DISCONNECT CONNECTORS AND WIRE HARNESS
FROM TRANSAXLE