1996 TOYOTA RAV4 manual transaxle

AT8584
AT8586
Z11664
B A
B
B A
B A
A A CA
AT3327
Q06411
BA AX−6
− AUTOMATIC TRANSAXLE (A241E)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
6. REMOVE MANUAL DETENT SPRING
Remove the bolt and manual detent spring.
7. REMOVE 3 SOLENOID CONNECTORS
8. REMOVE VALVE BODY
(a) Disconnect the throttle cable.
(b) Remove the 11 bolts and wire retainer.
Bolt length:
Bolt A: 20 mm (0.79 in.)
Bolt B: 30 mm (1.18 in.)
Bolt C: 55 mm (2.17 in.)
(c) Disconnect the manual valve connecting rod.
(d) Remove the valve body.
9. REMOVE 3 SOLENOID VALVES
(a) Remove the 3 solenoid valves.
(b) Remove the O−rings from each of the solenoid valves.
10. INSTALL SHIFT SOLENOID VALVE
(a) Coat new O−rings with ATF and install them to the each
of the solenoid valve.
(b) Install the 3 shift solenoid valves with the 2 bolts.
Torque:
Bolt A: 6.4 N·m (65 kgf·cm, 56 in.·lbf)
Bolt B: 10 N·m (100 kgf·cm, 7 ft·lbf)

AT3327
Z11664
B A
B
B A
B A
A A C
AT8586
AT8584
Q06418
− AUTOMATIC TRANSAXLE (A241E)VALVE BODY ASSEMBLY
AX−7
1996 RAV4 (RM447U)
11. INSTALL VALVE BODY
(a) Install the valve body.
(b) Connect the manual valve connecting rod.
(c) Install the 17 bolts and wire retainer.
Bolt length:
Bolt A: 20 mm (0.79 in.)
Bolt B: 30 mm (1.18 in.)
Bolt C: 55 mm (2.17 in.)
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
(d) Connect the throttle cable.
12. CONNECT 3 SOLENOID CONNECTORS
13. INSTALL MANUAL DETENT SPRING
Install the manual detent spring with the bolt.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
HINT:
Check that the manual valve lever is in contact with the center
of the roller at the tip of the detent spring.
14. INSTALL OIL PIPE CLAMP AND OIL PIPES
(a) Install the 5 pipes with a large screwdriver.
(b) Install the oil pump clamp with the bolt.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)

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.

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.

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.)

Z13390A B
Z13391
A
BA
B
Q06019
Q06064
AX−12
− AUTOMATIC TRANSAXLE (A540H)VALVE BODY ASSEMBLY
1996 RAV4 (RM447U)
(d) Place the detent springs on the manual valve body and
hand−tighten the 2 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: 14 mm (0.55 in.)
Bolt B: 37 mm (1.46 in.)
(e) Check that the manual valve lever is touching the center
of the detent spring tip roller.
18. INSTALL PIPE BRACKET AND OIL STRAINER
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: 53 mm (2.09 in.)
19. INSTALL MAGNETS IN PLACE
NOTICE:
Make sure that the magnets do not interfere with the oil
pipes.
20. INSTALL OIL PAN WITH NEW GASKET
(a) Install a new gasket and oil pan.
(b) Install and tighten 17 bolts.
Torque: 7.9 N·m (80 kgf·cm, 70 in.·lbf)
21. FILL ATF AND CHECK FLUID LEVEL
(a) Using a 10 mm hexagon wrench, install a new gasket and
the drain plug.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
(b) Fill the ATF and check the fluid level (See page DI−173).
22. INSTALL NO.2 ENGINE UNDER COVER

DI409−02
Vehicle Brought to Workshop
P.DI−126
Connect the OBD ll Scan Tool or TOYOTA Hand−Held Tester to DLC3
If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have
connected the scan tool/TOYOTA hand−held tester, inspect DLC3 P. DI−127
Check DTC and Freeze Frame Data (Pre−check)
Record or Print DTC and Freeze Frame Data P. DI−127
Clear DTC and Freeze Frame Data P. DI−127 Customer Problem Analysis
Visual Inspection
DTC CheckSymptom Simulation Setting the Check Mode Diagnosis P. DI−127
Problem Symptom Confirmation
P. IN−20 Symptom does
not occur
OK Codethe page number indicated in the bottom portion. See the
indicated pages for detailed explanations.
Preliminary Checkare titles of pages in the manual, with Item inside
Mechanical System Tests DTC Chart
Chapter 1
(Electronic)Manual Shifting Test
Matrix Chart of Symptoms Problems − P. DI−140
(On−vehicle)
 Pattern Select Signal Check  O/D Signal Check
InspectionCircuit(Off−vehicle) Chapter 2 Chapter 3
END Repair
Confirmation Test
Identification of ProblemParts Inspection P. DI−127
P. DI−127P. DI−127
P. DI−127
P. DI−127
P. DI−145 − DI−168 P. DI−141 1
2
P. DI−141P. DI−141 3
4
5
6
78
9
1011
12
13
14
16
18 15
17
Symptom occurs
OKNG
OKNG
NG
OK
OK OK
NG
NGNG
Step 2, 3, 4, 6, 9, 15, 18:
Diagnostic steps permitting the use of the TOYOTA
hand−held tester or TOYOTA brake−out−box.
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−125
1996 RAV4 (RM447U)
AUTOMATIC TRANSAXLE (A241E)
HOW TO PROCEED WITH TROUBLESHOOTING
Trobleshoot in accordance with the procedure on the follwoing pages.