Replace the torque converter clutch solenoid on a 2019-2024 Toyota RAV4 2.5L I4 FWD by removing the transmission pan and valve body to access the solenoid.

Warnings

Tools required

Parts

• Torque converter clutch solenoid × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Valve body gasket × 1 — Use OEM specification
• Transmission filter (if replacement recommended) × 1 — Use OEM specification
• Transmission drain plug crush washer × 1 — 90044-32080

Fluids

• Toyota WS ATF — 10 qt

Preparation

1. Ensure transmission is cool to the touch before beginning work
2. Raise vehicle on lift or safely support on jack stands at all four corners at a comfortable working height
3. Remove engine under covers and splash shields to access transmission
4. Clean external surface of transmission pan and surrounding areas to prevent contamination
5. Position large drain pan under transmission, centered beneath pan and drain plug
6. Have all replacement parts, gaskets, and fresh ATF ready before disassembly

Procedure

1. 1

   Drain transmission fluid
   Remove the transmission drain plug at the rear of the transmission pan using a 10mm hex socket. Allow fluid to drain completely into drain pan. This will drain approximately 4-5 quarts initially. Once drained, reinstall drain plug with new crush washer.
   Torque spec

   Transmission Drain Plug30 Nm (22 lb-ft)
2. 2

   Remove transmission pan bolts
   Locate all transmission pan bolts around the perimeter (approximately 16-19 bolts depending on configuration). Loosen all bolts in a criss-cross pattern, turning each bolt 2-3 turns before moving to the next. Once all are loose, remove all but two bolts at opposite corners. Carefully remove remaining bolts while supporting the pan, as additional fluid will drain when pan is lowered. Lower pan slowly and drain remaining fluid into drain pan.
   Torque spec

   Pan Bolts16 Nm (12 lb-ft)
3. 3

   Clean and inspect transmission pan
   Remove old gasket material from pan and transmission housing using plastic scraper. Inspect pan for metal debris or clutch material. Minor fine metallic dust is normal, but large particles or chunks indicate internal damage. Clean pan thoroughly with brake cleaner and lint-free towels. Inspect magnet in pan and clean thoroughly. Set pan aside on clean surface.
4. 4

   Remove transmission filter
   Locate transmission filter attached to valve body. Remove filter mounting bolts using appropriate socket. Carefully pull filter straight down to remove. Additional ATF will drain from filter cavity. Inspect filter for excessive debris. Set aside old filter.
5. 5

   Remove valve body cover
   Locate valve body cover (lower plate) secured with multiple small bolts. Remove all cover screws in a criss-cross pattern, noting locations as some may be different lengths. Carefully lower cover plate, being mindful that small check balls or springs may be present. Keep cover and bolts organized.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
6. 6

   Access valve body
   With valve body cover removed, you now have access to the valve body assembly. Identify the torque converter clutch solenoid location. On the U760E/U660E transmission used in this RAV4, the TCC solenoid is typically located on the valve body assembly itself. Take photos before disassembly for reference during reassembly.
7. 7

   Disconnect solenoid electrical connector
   Locate the electrical connector for the torque converter clutch solenoid. Press release tab and carefully disconnect connector. Note routing of wire harness for reinstallation. If connector is difficult to access, you may need to remove additional valve body mounting bolts to create access.
8. 8

   Remove torque converter clutch solenoid
   Remove the solenoid mounting bolts (typically 2 bolts per solenoid). Carefully extract the solenoid from the valve body, pulling straight out to avoid damage to the valve body bore. Note orientation and any O-rings or seals. Inspect valve body bore for damage or debris. Clean bore with lint-free cloth if needed.
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)
9. 9

   Install new torque converter clutch solenoid
   Inspect new solenoid and ensure all O-rings are properly seated and lightly lubricated with clean ATF. Insert new solenoid into valve body bore in same orientation as original, ensuring it seats fully. Install solenoid mounting bolts and tighten evenly in a cross pattern.
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)
10. 10

    Reconnect solenoid electrical connector
    Reconnect electrical connector to new solenoid, ensuring positive engagement with audible click. Verify connector is fully seated and secure. Route harness in original position.
11. 11

    Reinstall valve body cover
    Install new valve body gasket if required. Carefully position valve body cover, ensuring proper alignment. Install all cover screws hand-tight first, then tighten in criss-cross pattern.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
12. 12

    Install transmission filter
    Install new or cleaned transmission filter to valve body. Ensure filter is properly seated and oriented correctly. Install filter mounting bolts and tighten to specification.
13. 13

    Install transmission pan with new gasket
    Position new transmission pan gasket on transmission housing, ensuring all bolt holes align. Carefully raise transmission pan into position. Install all pan bolts hand-tight first, then tighten in criss-cross pattern starting from center and working outward.
    Torque spec

    Pan Bolts16 Nm (12 lb-ft)
14. 14

    Refill transmission with ATF
    Locate transmission fill plug or use dipstick tube for filling. Using fluid transfer pump, add approximately 5 quarts of Toyota WS ATF initially (the amount drained from pan and filter). Start engine and allow to reach operating temperature. With engine running, cycle through all gear positions (P-R-N-D-S) pausing 3-5 seconds in each position. Return to Park. Check fluid level and add additional ATF as needed to bring level to proper range on dipstick (engine running, transmission at operating temperature). Total fluid capacity is approximately 10 quarts when performing this service.
15. 15

    Clear diagnostic codes and test drive
    Using a scan tool, clear any stored transmission diagnostic trouble codes. Reinstall under covers and splash shields. Test drive vehicle through various driving conditions including city and highway speeds. Monitor for proper torque converter clutch engagement (typically occurs above 40 mph in top gears). Verify no transmission slipping, harsh shifting, or abnormal sounds. After test drive, recheck ATF level and top off if necessary.

Reassembly

1. Tighten all fasteners to specified torque values in proper sequence
2. Ensure all electrical connectors are fully seated and secured
3. Double-check that no tools or parts were left inside transmission pan
4. Verify transmission pan has no leaks before lowering vehicle
5. Reinstall all under covers and splash shields removed during access

Verification

• Start engine and verify no ATF leaks from transmission pan or drain plug
• Check ATF level with engine at operating temperature and running in Park position
• Use scan tool to verify torque converter clutch solenoid is responding to commands (no DTCs present)
• Test drive vehicle and confirm smooth torque converter lockup operation without shudder or slip
• Monitor transmission temperature and shift quality during extended driving
• Verify no new transmission fault codes are present after test drive
• Recheck ATF level after test drive and top off if needed

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