AX1

AUTOMATIC TRANSAXLE (A241E) AUTOMATIC TRANSAXLE SYSTEM

AUTOMATIC TRANSAXLE SYSTEM

PRECAUTION
AX05002

When working with FIPG material, you must observe the followings. S Using a razor blade and a gasket scraper, remove all the old FIPG material from the gasket surfaces. S Thoroughly clean all components to remove all the loose material. S Clean both sealing surfaces with a nonresidue solvent. S Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface. S Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied.

If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section.

1996 RAV4 (RM447U)

AX2
AUTOMATIC TRANSAXLE (A241E) AUTOMATIC TRANSAXLE SYSTEM
AX05102

OPERATION
Forward Clutch (C1) No.2 OneWay Clutch (F2) 1st & Reverse Brake (B3) 2nd Brake (B2) 2nd Coast Brake (B1)

Direct Clutch (C2)

Front Planetary Gear Unit Rear Planetary Gear Unit U/D Planetary Gear Unit No.1 OneWay Clutch (F1)

U/D Brake (B4)

U/D Clutch (C3) U/D OneWay Clutch (F3) Shift Lever Position P R N Gear Park Reverse Neutral 1st D 2nd 3rd O/D 1st 2 2nd 3rd* L 1st 2nd* Shift Solenoid Valve No.1 ON ON ON ON ON OFF OFF ON ON OFF ON ON Shift Solenoid Valve No.2 OFF OFF OFF OFF ON ON OFF OFF ON ON OFF ON F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F C1 C2 C3 B1 B2 B3 B4 F F F F F F F F F F F F1 F2 F3

F : Operating *: Downshift only in the 3rd gear for the 2 position and 2nd gear for the L position no upshift
F00484

1996 RAV4 (RM447U)

AX3
AUTOMATIC TRANSAXLE (A241E) VEHICLE SPEED SENSOR

VEHICLE SPEED SENSOR

ONVEHICLE REPAIR
1. REMOVE NO.2 ENGINE UNDER COVER

AX0T402

2. (a) (b)

DISCONNECT VEHICLE SPEED SENSOR ASSEMBLY Disconnect the vehicle speed sensor connector. Remove the bolt and vehicle speed sensor assembly.

Q08740

Vehicle Speed Sensor Driven Gear

(c) (d) 3. (a) (b)

Clip
Q08741

(c)

(d) 4.

Remove the clip and speedometer driven gear from the vehicle speed sensor. Remove the Oring from the vehicle speed sensor. INSTALL VEHICLE SPEED SENSOR ASSEMBLY Coat a new Oring with ATF and install it to the vehicle speed sensor. Install the speedometer driven gear to the vehicle speed sensor and clip. Install the vehicle speed sensor assembly and torque the bolts. Torque: 5.4 Nm (55 kgfcm, 48 in.lbf) Connect the vehicle speed sensor connector. INSTALL NO.2 ENGINE UNDER COVER

1996 RAV4 (RM447U)

AX4
AUTOMATIC TRANSAXLE (A241E) PARK/NEUTRAL POSITION (PNP) SWITCH

PARK/NEUTRAL POSITION (PNP) SWITCH

ONVEHICLE REPAIR
1. 2. 3. (a) (b) (c) (d) (e)

AX0T501

REMOVE NO.2 ENGINE UNDER COVER DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR REMOVE PARK/NEUTRAL POSITION SWITCH Remove the nut and disconnect the shift control cable. Remove the nut and shift control lever. Using a screwdriver, pry off the lock plate. Remove the nut and lock plate. Remove the 2 bolts and pull out the park/neutral position switch.

Q06565

4. (a) (b) (c)

INSTALL PARK/NEUTRAL POSITION SWITCH Temporarily install the park/neutral position switch with the 2 bolts. Install a new lock plate and tighten the nut. Torque: 6.9 Nm (70 kgfcm, 61 in.lbf) Stake the nut with the lock plate.

Q07898

(d)
Neutral Basic Line

Adjust the park/neutral position switch (See page DI127).

HINT: Align the groove and park/neutral basic line. (e) Tighten the 2 bolts. Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)

Groove
Q07907

(f) (g) 5. 6.

Install the shift control lever with the nut. Connect the control cable with the nut. Torque: 13 Nm (135 kgfcm, 10 ftlbf) CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR INSTALL NO.2 ENGINE UNDER COVER

Q07906

1996 RAV4 (RM447U)

AX5
AUTOMATIC TRANSAXLE (A241E) VALVE BODY ASSEMBLY

VALVE BODY ASSEMBLY

ONVEHICLE REPAIR
1. REMOVE DRAIN PLUG AND DRAIN ATF

AX0T602

2. REMOVE OIL PAN AND GASKET Remove the 18 bolts. NOTICE: Some fluid will remain in the oil pan. Remove all pan bolts, and carefully remove the oil pan assembly. Discard the gasket.

Q05259

3. EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the pan and the magnet to anticipate what type of wear you will find in the transaxle. S Steel (magnetic): bearing, gear and plate wear S Brass (nonmagnetic): bearing wear

Q05234

4. REMOVE OIL STRAINER AND APPLY PIPE BRACKET NOTICE: Be careful as some fluid will come out with the oil strainer. (a) Remove the 3 bolts, oil strainer and gasket. (b) Remove the 2 bolts and apply pipe bracket.

Q06417

5. (a) (b)

REMOVE OIL PIPE CLAMP AND OIL PIPES Remove the bolt and oil pipe clamp. Pry up the both pipe ends with a large screwdriver and remove the 5 pipes. NOTICE: Be careful not to bend or damage the pipe.

Q06418

1996 RAV4 (RM447U)

AX6
AUTOMATIC TRANSAXLE (A241E) VALVE BODY ASSEMBLY

6. REMOVE MANUAL DETENT SPRING Remove the bolt and manual detent spring. 7. REMOVE 3 SOLENOID CONNECTORS

AT8584

8. (a)

REMOVE VALVE BODY Disconnect the throttle cable.

AT8586

A A A B B B A A
Z11664

(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 B

(c) (d)

Disconnect the manual valve connecting rod. Remove the valve body.

AT3327

A B

9. (a) (b) 10. (a) (b)

Q06411

REMOVE 3 SOLENOID VALVES Remove the 3 solenoid valves. Remove the Orings from each of the solenoid valves. INSTALL SHIFT SOLENOID VALVE Coat new Orings with ATF and install them to the each of the solenoid valve. Install the 3 shift solenoid valves with the 2 bolts. Torque: Bolt A: 6.4 Nm (65 kgfcm, 56 in.lbf) Bolt B: 10 Nm (100 kgfcm, 7 ftlbf)

1996 RAV4 (RM447U)

AX7
AUTOMATIC TRANSAXLE (A241E) VALVE BODY ASSEMBLY

11. (a) (b)

INSTALL VALVE BODY Install the valve body. Connect the manual valve connecting rod.

AT3327

A A B B B A A
Z11664

(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 Nm (100 kgfcm, 7 ftlbf)

C B

(d) 12.

Connect the throttle cable. CONNECT 3 SOLENOID CONNECTORS

AT8586

13. INSTALL MANUAL DETENT SPRING Install the manual detent spring with the bolt. Torque: 10 Nm (100 kgfcm, 7 ftlbf) HINT: Check that the manual valve lever is in contact with the center of the roller at the tip of the detent spring.

AT8584

14. (a) (b)

INSTALL OIL PIPE CLAMP AND OIL PIPES Install the 5 pipes with a large screwdriver. Install the oil pump clamp with the bolt. Torque: 10 Nm (100 kgfcm, 7 ftlbf)

Q06418

1996 RAV4 (RM447U)

AX8
AUTOMATIC TRANSAXLE (A241E) VALVE BODY ASSEMBLY

15. INSTALL OIL STRAINER AND APPLY PIPE BRACKET Install the oil strainer, gasket with the 3 bolts. Torque: 10 Nm (102 kgfcm, 7 ftlbf) HINT: Replace used the gasket with a new one.

Q06417

16.

INSTALL 2 MAGNETS IN OIL PAN

Q05234

17. (a) (b) 18. 19.

Q05259

INSTALL OIL PAN AND GASKET Install a new gasket to the oil pan. Install the oil pan with the 18 bolts. Torque: 4.9 Nm (50 kgfcm, 43 in.lbf) INSTALL DRAIN PLUG Torque: 17 Nm (175 kgfcm, 13 ftlbf) FILL ATF AND CHECK ATF (See page DI127)

1996 RAV4 (RM447U)

AX9
AUTOMATIC TRANSAXLE (A241E) THROTTLE CABLE

THROTTLE CABLE
ONVEHICLE REPAIR
1. 2. 3. 4.
Q06117

AX05502

DISCONNECT THROTTLE CABLE FROM ENGINE REMOVE NO.2 ENGINE UNDER COVER REMOVE PARK/NEUTRAL POSITION SWITCH (See page AX4) REMOVE VALVE BODY (See page AX5)

5. (a) (b)

REMOVE THROTTLE CABLE Remove the retaining bolt and plate. Pull out the cable from the transaxle case.

AT5641

200 mm (7.87 in.)

0.81.5 mm (0.0310.059 in.)

Q05731

6. INSTALL THROTTLE CABLE If throttle cable is new, do the following operations (a) (c). (a) Bend the cable so there is a radius of about 200 mm (7.87 in.). (b) Pull theinner cable lightly until a slight resistance is felt, and hold it. (c) Stake the stopper 0.8 1.5 mm (0.031 0.059 in.) from the end of outer cable. (d) Be sure to push it in all the way. (e) Install the bolt. 7. INSTALL VALVE BODY (See page AX5) 8. INSTALL PARK/NEUTRAL POSITION SWITCH (See page AX4) 9. INSTALL NO.2 ENGINE UNDER COVER 10. CONNECT THROTTLE CABLE 11. ADJUST THROTTLE CABLE (See page DI127) 12. FILL ATF AND CHECK ATF (See page DI127)

1996 RAV4 (RM447U)

AX10
AUTOMATIC TRANSAXLE (A241E) DIFFERENTIAL OIL SEAL

DIFFERENTIAL OIL SEAL

ONVEHICLE REPAIR
1. 2. 3. DRAIN ATF REMOVE ENGINE UNDER COVER REMOVE LH AND RH DRIVE SHAFTS (See page SA20)

AX05603

SST

4. REMOVE LH AND RH SIDE OIL SEALS Using SST, drive out the both side oil seals. SST 0930800010

Z02840

LH Side

5. (a)

SST

Z02841

SST

(b) 6. 7. 8.

INSTALL LH AND RH SIDE OIL SEALS Using SST and a hammer, drive in a new oil seal until its surface is flush until the case surface. SST LH side 0935032014 (0935132111, 0935132130) RH side 0935032014 (0935132130, 0935132150) Oil seal drive in depth: LH side: 5.2 0.5 mm (0.205 0.020 in.) RH side: 0 0.5 mm (0 0.020 in.) Coat the oil seal lip with MP grease. INSTALL LH AND RH DRIVE SHAFTS (See page SA31) FILL ATF AND CHECK ATF LEVEL (See page DI127) INSTALL ENGINE UNDER COVER

Z02842

1996 RAV4 (RM447U)

AX11
AUTOMATIC TRANSAXLE (A241E) SHIFT LOCK SYSTEM

SHIFT LOCK SYSTEM

LOCATION
AX04X02

Stop Light Switch Key Interlock Solenoid

Shift Lock Override Button Cover HINT: S The shift indicator housing ordered as supply parts does not include the cover of the shiftlock override button. So, if you replace the shift indicator housing, install cover from the old housing into the new housing. S Install the cover with its cutout facing toward the rear of the vehicle.

Shift Lock Solenoid Shift Lock Control Switch Shift Lock Control ECU

Q08861

1996 RAV4 (RM447U)

AX12
AUTOMATIC TRANSAXLE (A241E) SHIFT LOCK SYSTEM
AX0T702

A IG ACC STP E KLS+

B SLS+ P1 SLS

C P P2

INSPECTION

1. INSPECT SHIFT LOCK CONTROL ECU Using a voltmeter, measure the voltage at each terminal. HINT: Do not disconnect the ECU connector.

Wire Harness Side

Z19320

Connector

Terminal 5 4 (ACC E) 1 4 (IG E) Ignition switch ACC Ignition switch ON

Measuring condition

Voltage (V) 10 14 10 14 10 14 0 7.5 11 5.5 10 0 8.5 14 0 0 10 14 10 14 0

2 4 (STP E)

Depress brake pedal 2. Ignition switch ACC and P position

6 4 (KLS+ E)

3. Ignition switch ACC and except P position 4. (Afterapprox. 1 second) 1. Ignition switch ON and P position

12

(SLS+

SLS)

2. Depress brake pedal 3. Except P position

1 2 (P1 P) C 3 2 (P2 P)

1. Ignition switch ON, P position and depress brake pedal 2. Shift except P position under condition above 1. Ignition switch ACC and P position 2. Shift except P position under condition above

2. (a) (b)

INSPECT SHIFT LOCK SOLENOID Disconnect the solenoid connector. Using an ohmmeter, measure the resistance between the terminals. Standard resistance: 26 33 If resistance value is not as specified, replace the solenoid.

AT5027

(c)

Apply battery positive voltage between the terminals. Check that the solenoid can be heard operating. If solenoid operation is not as specified, replace the solenoid.

Battery

AT5029

1996 RAV4 (RM447U)

AX13
AUTOMATIC TRANSAXLE (A241E) SHIFT LOCK SYSTEM

3. (a) (b)

INSPECT KEY INTERLOCK SOLENOID Disconnect the solenoid connector. Using an ohmmeter, measure the resistance between the terminals. Standard resistance: 12.5 16.5 If resistance value is not as specified, replace the solenoid.

Q09052

(c)

Apply battery positive voltage between the terminals. Check that the solenoid can be heard operating. If solenoid operation is not as specified, replace the solenoid.

1
Q09053

4. INSPECT SHIFT LOCK CONTROL SWITCH Inspect that there is continuity between each terminal.
Shift position P position (Release button is not pushed) P position (Release button is pushed) R, N, D, 2, L position
Z19339

Tester connection 2 3 (P P1) 2 3 (P P1) 2 1 (P P2) 2 1 (P P2)

Specified value Continuity Continuity Continuity

3 (P1)

2 (P)

1 (P2)

If continuity is not as specified, replace the switch.

1996 RAV4 (RM447U)

AX14
AUTOMATIC TRANSAXLE (A241E) AUTOMATIC TRANSAXLE UNIT

AUTOMATIC TRANSAXLE UNIT

COMPONENTS
Air Intake Connector ABS Relay Engine Coolant Reservoir Tank
64 (650, 47) 64 (650, 47) 25 (250, 18) 27 (280, 20) 64 (650, 47) 19 (194, 14) 46 (470, 34)
AX0T801

RH Drive Shaft

Air Cleaner Case Assembly

Torque Converter Clutch

25 (250, 18) 9.0 (95, 78 in.lbf)

x6

Stiffener Plate

Rear End Plate

64 (650, 47)

z Snap Ring z Gasket LH Drive Shaft

PS Gear Assembly

37 (380, 27)

Clip
9.0 (95, 78 in.lbf)

49 (500, 36)

13 (135, 10)

Plug for Line Pressure Test Shift Control Cable

64 (650, 47)

Engine Wire Clamp

39 (400, 29)

z Cotter Pin

Lock Cap z Cotter Pin

Starter z Gasket z Gasket

7.0 (75, 65 in.lbf) 48 (490, 35) 216 (2,200, 159)

62 (630, 46)

Front Exhaust Pipe

Engine Mounting Center Member

113 (1,150 83)

35 (360, 26)

Front Suspension Crossmember Assembly with Stabilizer Bar

72 (730, 53) 73 (740, 54) 137 (1,400, 101) 206 (2,100, 152) 127 (1,300, 94)

RH Engine Under Cover LH Engine Under Cover Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part

Z18886

1996 RAV4 (RM447U)

AX15
AUTOMATIC TRANSAXLE (A241E) AUTOMATIC TRANSAXLE UNIT
AX12701

REMOVAL

D02186

1. DISCONNECT THROTTLE CABLE 2. REMOVE ENGINE COOLANT RESERVOIR TANK 3. REMOVE AIR CLEANER ASSEMBLY (a) Disconnect the connector and ABS relay. (b) Remove the 3 bolts and air cleaner assembly. 4. REMOVE GROUND CABLE Remove the bolt from the transaxle. Torque: 19 Nm (194 kgfcm, 14 ftlbf) 5. REMOVE SET NUT OF ENGINE WIRE CLAMP

Q08747

6. (a) (b) (c)

REMOVE STARTER Disconnect the connector and nut from the starter. Remove the 2 bolts and disconnect the engine wire. Torque: 39 Nm (400 kgfcm, 29 ftlbf) Remove the starter.

Q08761

7.

REMOVE 3 UPPER SIDE TRANSAXLE MOUNTING BOLTS Torque: 64 Nm (650 kgfcm, 47 ftlbf)

D02187

8.

INSTALL ENGINE SUPPORT FIXTURE

Q08763

1996 RAV4 (RM447U)

AX16
AUTOMATIC TRANSAXLE (A241E) AUTOMATIC TRANSAXLE UNIT

9.

10. 11. 12.

Q08764

REMOVE ENGINE LEFT MOUNTING BOLT AND NUTS Torque: Bolt: 64 Nm (650 kgfcm, 47 ftlbf) Nut: 64 Nm (650 kgfcm, 47 ftlbf) REMOVE LEFT AND RIGHT ENGINE UNDER COVERS DRAIN ATF REMOVE LEFT AND RIGHT DRIVE SHAFTS (See page SA20)

13. (a)

REMOVE FRONT EXHAUST PIPE Remove the 2 bolts and gasket from the exhaust pipe. Torque: 48 Nm (490 kgfcm, 35 ftlbf)

Q08765

HINT: At the time of installation, please refer to the following item. Replace used gasket with new gasket. (b) Remove the 3 nuts, front exhaust pipe and gasket. Torque: 62 Nm (630 kgfcm, 46 ftlbf) HINT: At the time of installation, please refer to the following item. Replace used nuts and gasket with new nuts and gasket.

14. (a) (b)

DISCONNECT SHIFT CONTROL CABLE Remove the nut from the control shaft lever. Torque: 13 Nm (135 kgfcm, 10 ftlbf) Remove the clip and disconnect the control cable.

Q08766

(c)

Remove the 2 shift cable mounting bolts. Torque: 7.0 Nm (75 kgfcm, 65 in.lbf)

Q08767

1996 RAV4 (RM447U)

AX17
AUTOMATIC TRANSAXLE (A241E) AUTOMATIC TRANSAXLE UNIT

15.
S S S

DISCONNECT FOLLOWING CONNECTORS Shift solenoid valve SL connector Park/neutral position switch connector Vehicle speed sensor connector

Q08774

16. DISCONNECT 2 OIL COOLER HOSES Loosen the 2 clips and disconnect the 2 oil cooler hoses.

Q08768

17.

REMOVE 2 POWER STEERING GEAR MOUNTING BOLTS AND NUTS Torque: 113 Nm (1,150 kgfcm, 83 ftlbf) NOTICE: Support the power steering gear housing securely.

D01757

C D D A Nut B B B
Q08769

18.

Nut

REMOVE FRONT SUSPENSION CROSSMEMBER ASSEMBLY WITH STABILIZER BAR Remove the 10 bolts, 2 nuts and front suspension crossmember assembly with stabilizer bar. Torque: A bolt: 206 Nm (2,100 kgfcm, 152 ftlbf) B bolt: 137 Nm (1,400 kgfcm, 101 ftlbf) C bolt: 35 Nm (360 kgfcm, 26 ftlbf) D bolt: 72 Nm (730 kgfcm, 53 ftlbf) Nut: 73 Nm (740 kgfcm, 54 ftlbf) 19. REMOVE STIFFENER PLATE Remove the 3 bolts and stiffener plate. Torque: 37 Nm (380 kgfcm, 27 ftlbf)

Q08770

1996 RAV4 (RM447U)

AX18
AUTOMATIC TRANSAXLE (A241E) AUTOMATIC TRANSAXLE UNIT

20. REMOVE REAR END PLATE Remove the 4 bolts and rear end plate. Torque: A bolt: 9.0 Nm (95 kgfcm, 78 in.lbf) B bolt: 19 Nm (195 kgfcm, 14 ftlbf)

A B A
Z18887

21.

Q08772

REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLT Turn the crankshaft to gain access and remove the 6 bolts with holding the crankshaft pulley set bolt by a wrench. Torque: 27 Nm (280 kgfcm, 20 ftlbf) 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 Nm (250 kgfcm, 18 ftlbf) B bolt: 46 Nm (470 kgfcm, 34 ftlbf)
B

Q08773

1996 RAV4 (RM447U)

AX19
AUTOMATIC TRANSAXLE (A241E) AUTOMATIC TRANSAXLE UNIT
AX05903

INSTALLATION

AT3412

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 AX15). HINT: After installation, check and inspect items as follows. S Fluid level (See page DI127) S Front wheel alignment (See page SA4) S Road test the vehicle

1996 RAV4 (RM447U)

AX20
AUTOMATIC TRANSAXLE (A241E) TORQUE CONVERTER CLUTCH AND DRIVE PLATE

SST

TORQUE CONVERTER CLUTCH AND DRIVE PLATE

INSPECTION
1. (a) (b)
AT0953

AX05A02

INSPECT ONEWAY CLUTCH Install SST into the inner race of the oneway clutch. SST 0935032014 (0935132010) Install SST so that it fits in the notch of the converter clutch hub and outer race of the oneway clutch. SST 0935032014 (0935132020)

(c)
Hold

Lock

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.

Turn

Free
AT3306

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 Nm (850 kgfcm, 61 ftlbf)
D00776

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.
AT4184

1996 RAV4 (RM447U)

AX21
AUTOMATIC TRANSAXLE (A241E) TORQUE CONVERTER CLUTCH AND DRIVE PLATE

HINT: Mark the position of the torque converter clutch to ensure correct installation.

1996 RAV4 (RM447U)