randyman, you intrigued me enough to get the book out, and I learned something!
It turns out I'm wrong about the engine temp being irrelevant - it does matter! The minimum thresholds seem to be very dependent on your powertrain. I've owned Toyotas for years, and their behavior certainly makes it seem like the trans fluid temp is the only thing that matters.
I don't have service manual pages going back to 1991, but here's what I did learn:
- On the 3.3L V6 powertrain used in some 2004-2006 Toyota/Lexus models, the overdrive won't kick in unless the ATF is at 28 degrees F (yes, that's 28 - it's not a typo unless the book is wrong) _and_ the engine coolant is at 154 degrees F and you're moving at least 43 mph.
- On the 3.4L V6 powertrain used in 3rd Gen 4Runners and Tacomas, the overdrive won't kick in unless the engine coolant is at 140 degrees F. It doesn't mention the ATF temp as being a factor, although it does say that "normal" temp for the ATF is 122-176 degrees F.
I'm not sure how much that helps you, other than the fact that the engine temp does matter. Maybe that's another direction to check into.