[Elle__Rav4]

I think the solenoid pictured in the first post may be what the A540H service manual calls the "lock-up solenoid." Go to https://www.rav4world.com/attachments/a540h-pdf.149761/ . Proceed to pdf page 122 (document page AT-85).

I am not certain, but I think some sites also call this the:
"SLD solenoid"
"ST solenoid" (see A540H Solenoid Identification).
"shift solenoid valve SLD" (from service manual section 1996Rav4diag.pdf)

This photo adds more confusion:

https://d2q1ebiag300ih.cloudfront.net/uploads/mercury_image/image/2570/A540H_Tech_Info__Solenoid_ID.jpg

[Edit: mistake about A540h trannies deleted]

These might be aftermarket replacements:
www.rockauto.com/en/moreinfo.php?pk=6087576&cc=1317533&pt=17903&jsn=421&jsn=421

Automatic Transmission Control Solenoid-Auto Trans Control Solenoid ATP RE-15 | eBay

ATP (Automatic Transmission Parts Inc.). Warranty Duration. Money Back. You need to MOUSE OVER the left column to read the complete text. Part Numbers. AUTOZONE/ATP, PIONEER INC., TOYOTA OE, TRANSTAR.

www.ebay.com

KNote72, what are the wire colors on the electrical connector for the solenoid pictured?

Also, can you remove the bracket and look for a p/n on the solenoid?

Regarding reverse, from wikipedia and other sites: The A540H "has a weak reverse – prone to noise and failure – failure included problems with 1st brake."

 

[Elle__Rav4]

Knote72, my mistake regarding the A540H. Every A540H serves AWD (and not FWD). I corrected my post above.

Regarding the use of "AWD" and "4x4" on the first generation Rav4: See How to operate 4wd (rav4 1996) , post #3 by Mick Hatzo, and the links he provides. I play loose with the descriptor "AWD." Mick's links also address the ECT button.

After looking at a lot of Toyota parts sites and A540H sites, I am thinking the better bet is to maybe forget about getting the OEM part for now. Instead work with one of the many automatic tranny re-build shops on the net to get the right part. Your photos are excellent, and I bet the folks at the re-build shops can nail this down and tell you how to get the part.

I might also be digging through youtube for videos on re-builds of A540H transmissions. I have not had a chance to do this yet.

I checked my wiring diagram for the 1998-2000 Rav4. Just in case there is yet another name [wink] for that solenoid for which you provided multiple photos. If you want the wiring diagram, go to www.rav4world.com/threads/98-toyota-rav4-electrical-issues.292825/ , post #18 and download the attachment 1999Rav4wiringsearchable.pdf . The wiring diagram's pdf page 66, in the lower left, shows a yellow wire connecting a solenoid on the transmission to pin 17 of the engine computer's largest connector. On the wiring diagram pin 17's label is "S1". And because I would hate for today's post to be boring, pin 16 is labeled "ST".

For the archives: For the 1996-1997 Rav4, the computer pins and wiring colors for the auto tranny solenoids are somewhat different.

 

[Elle__Rav4]

I notice at 12:20 on the box it says "Aisin 85420-32111" but can't find anything related to that. Would I call up a toyota dealer for that p/n?

I think you nailed it. One can google on just the p/n and see this is a Toyota OEM p/n. (I think you and I have the "85420" part of the p/n memorized at this point.) Aisin is a well-known OEM parts manufacturer for Toyota.

The toyodiy.com and jp-carparts.com site for the SXA11 frame (A540H transmission) call p/n 85420-32111 'transmission solenoid assembly no. 2.' I believe this is the same as solenoid valve SL, a.k.a. the lock-up solenoid. Toyotapartsdeal.com notes that
85420-32111 replaces {85420-32121, 85420-32120 and 85420-32110}.

Right next to this p/n the toyodiy.com and jp-carparts.com sites list 85420-32102 'transmission solenoid assembly No.1.' But this is kind of misleading: Googling the latter p/n shows two solenoid valves connected. I think 85420-32102 consists of the two solenoids connecting to the computer's S1 and S2 pins, as shown in the wiring diagrams.

Are you sure the wire connecting to the valve you want is yellow? Might it be yellow with a black stripe? If it is yellow with a black stripe, then this is solenoid valve SL, at least according to the 1996 diagnostics manual and 1996 and 1999 wiring diagrams.

Can you say which valve the attached drawing indicates your valve is?

The 1996 Rav4 service manual section for the A540h appears here: http://aelectrik.ru/wp-content/uploads/2020/01/A540H.pdf . I think this service manual section is quite helpful for finding the solenoids.

I see also that doing the following google search of the rockauto.com site can turn up some of the more commonly needed solenoids for the A540H :

"a540h" site:rockauto.com

I am putting this and more info on my web site, in the "Automatic Transmission Notes" guide.

 

[Elle__Rav4]

This site indicates the failed solenoid valve shown in the video is the lock-up solenoid (a.k.a. solenoid SL): https://rostrapowertrain.com/wp-content/uploads/Manuals/Form4645C.pdf

I have seen enough in the various Toyota service manuals and other A540H guides to believe the Sonnax site's photo is wrong.

I cannot quite picture exactly why the fit is wrong. Can you swap brackets from the old solenoid to the new one?

Maybe consider trying to send GasDiesel Garage at youtube a message asking where he bought the Aisin part. Or call rostra or sonnax and ask if they have the Aisin part.