brake rotor TOYOTA RAV4 1996 Service Repair Manual

Fig. 6: Testing ABS Actuator Solenoid Coils
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
DTC 31, DTC 32, DTC 33 & DTC 34: SPEED SENSOR CIRCUIT
Circuit Description
Speed sensor detects wheel speed and sends appropriate signals to ABS ECU. These signals are used to control
ABS system. Front and rear sensor rotors each have 48 teeth. When rotor rotates, magnetic field emitted by
permanent magnet in speed sensor generates an AC voltage. Since frequency of this AC voltage changes in
direct proportion to speed of rotor, frequency is used by ABS ECU to detect speed of each wheel. If
malfunction occurs in speed sensor circuit, ABS ECU cuts off current to ABS control relay and prohibits ABS
control.
DTC Detecting Condition
Detection of any of the following conditions may set DTCs 31-34:
Vehicle speed is 6 MPH or more and pulses are not input for 30 seconds.
Momentary interruption of speed sensor signal occurs at least 7 times during one ignition cycle.
Abnormal fluctuation of speed sensor signals when vehicle speed is 12 MPH or more.
Diagnostic Procedure
NOTE: To determine which speed sensor circuit is malfunctioning, see DTC

1999 Toyota RAV4
1999-2000 BRAKES Anti-Lock - RAV4
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1. Disconnect front speed sensor connector. Measure resistance between speed sensor connector terminals.
Resistance should be 1.4-1.8 k/ohms. Measure resistance between ground and each speed sensor
connector terminal. Resistance should be one megohm or more. If resistance is as specified, go to step 3 .
If resistance is not as specified, replace speed sensor.
2. Disconnect rear speed sensor connector. Measure resistance between speed sensor connector terminals.
Resistance should be 1.28-1.48 k/ohms. Measure resistance between ground and each speed sensor
connector terminal. Resistance should be one megohm or more. If resistance is as specified, go to next
step. If resistance is not as specified, replace speed sensor.
3. Check for open or short circuit in wiring harness between affected speed sensor and ABS ECU. See
WIRING DIAGRAMS
. Repair as necessary. If wiring harness is okay, go to next step.
4. Check speed sensor installation. Ensure mounting bolt is tightened to specification. See TORQUE
SPECIFICATIONS . Ensure zero clearance exists between sensor and front steering knuckle or rear axle
carrier. Replace speed sensor if necessary. If speed sensor installation is okay, check speed sensor signal.
See SPEED SENSOR DIAGNOSTICS
under DIAGNOSIS & TESTING. If signal is normal, go to next
step.
5. If oscilloscope is available, check speed sensor signal wave form. Remove ABS ECU. Do not disconnect
electrical connectors. Connect oscilloscope between GND terminal and terminals FR+, FL+, RR+ and
RL+ at ABS ECU connector. See Fig. 3
. Drive vehicle at 19 MPH and observe signal wave form. Signal
should be smooth and consistent without any irregular wave forms. If wave form is smooth and
consistent, replace ABS ECU. If wave form is not smooth and consistent, go to next step.
6. Check speed sensor rotor for missing teeth or damage. Check sensor tip for scratches, damage or foreign
objects. Replace components as necessary. If rotor and sensor are okay, replace ABS ECU.
DTC 37: TIRES OF DIFFERENT SIZE (2WD MODELS ONLY)
DTC Detecting Condition
Detection of the following condition may set DTC 37:
Driving vehicle at speed of more than 12 MPH for more than 20 seconds with one or 2 tires of different
sizes, 3 different times continuously will set DTC 37.
Diagnostic Procedure
Ensure vehicle tires are all the same size and correct size for vehicle. Replace tires as necessary. If tire size is
okay, replace ABS ECU.
DTC 41: LOW BATTERY VOLTAGE
Circuit Description
Circuit is power source for ABS ECU, which includes actuator. If malfunction occurs in power source circuit,
ABS ECU cuts off current to ABS control relay and prohibits ABS control. DEFINITIONS
under DIAGNOSIS & TESTING. For front speed sensor diagnosis,
start at step 1 . For rear speed sensor, start at step 2 .

1999 Toyota RAV4
1999-2000 BRAKES Anti-Lock - RAV4
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Fig. 11: Exploded View of ABS Actuator
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
ABS ECU
Removal & Installation
Ensure ignition is off. Disconnect negative battery cable. Access ABS ECU, located at right side of passenger
compartment. See Fig. 1
. Disconnect ABS ECU connectors. Remove ABS ECU from vehicle. To install,
reverse removal procedure.
FRONT SENSOR ROTOR
Removal & Installation
Front sensor is part of front hub. For removal and installation of front hub, see AXLE SHAFTS - RAV4 article
in DRIVE AXLES.
REAR SENSOR ROTOR
Removal & Installation
Rear sensor rotor is pressed onto axle shaft. For axle shaft removal and installation procedure, see AXLE
SHAFTS - RAV4 article in DRIVE AXLES.
FRONT WHEEL SPEED SENSORS
Removal & Installation
1. Raise and support front of vehicle. Remove front wheel. Remove inner fender panel. Disconnect wheel
speed sensor connector. Remove clamp bolts holding sensor harness to body, strut assembly and steering
knuckle.
2. Remove wheel speed sensor mounting bolt. Remove wheel speed sensor from steering knuckle. To
install, reverse removal procedure. Ensure wheel speed sensor is flat against knuckle when bolt is
tightened. Tighten wheel speed sensor mounting bolt to specification. See TORQUE
SPECIFICATIONS .
REAR WHEEL SPEED SENSORS
Removal & Installation
1. Remove rear seat cushion and side trim panel. Raise and support vehicle. Remove wheel. Unplug wheel
speed sensor connector and remove wire harness from grommet. Disconnect parking brake cable from
suspension arm. Remove clamp bolts holding sensor wiring harness to body and suspension arm.
2. Remove wheel speed sensor. To install, reverse removal procedure. Ensure wheel speed sensor is flat NOTE: Front hub must be removed to service sensor rotor.

1999 Toyota RAV4
1999-2000 BRAKES Anti-Lock - RAV4
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Fig. 16: Compressing 1st & Reverse Brake Piston Springs
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Differential & Drive Pinion Removal
1. Using INCH-lb. torque wrench, measure and record differential total preload. See Fig. 17 . Remove left
differential bearing retainer. Ensure case or retainer is not damaged if prying is necessary.
2. On A-540E and A-541E transaxles, remove right bearing retainer. On all transaxles, remove carrier cover
bolts in crisscross pattern. Remove cover. Remove apply port gasket at lower portion of case. Remove
differential assembly.
3. From converter side of case, remove drive pinion cap. Using INCH-lb. torque wrench, measure drive
pinion preload. See Fig. 17
. Starting preload should be 4.3-6.9 INCH lbs. (.5-.8 N.m). Subtract drive
pinion preload from total preload.
4. If difference is not 1.1-1.7 INCH lbs. (about .1 N.m), differential side bearing preload may not have been
within specification. Carefully inspect condition of all bearings and replace as needed. See appropriate
component disassembly and reassembly procedure under OVERHAUL.
5. Bend back locking washer securing nut on drive pinion shaft. Secure driven gear and remove nut. Using
appropriate puller, remove driven gear and bearing. Using appropriate 2-jaw puller, remove outer race,
spacer and oil slinger. On A-540E transaxle, remove sensor rotor.
6. On all transaxles, remove snap ring. Turn transaxle case, converter side facing up. Install appropriate bar
into hole in drive pinion. Press out drive pinion shaft. Remove bearing cage from drive pinion. Press off
bearing if replacement is needed.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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1999-2000 DRIVE AXLES
AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
DESCRIPTION & OPERATION
On RAV4 models, axle shafts transfer power from transaxle to front wheels (FWD), or front and rear wheels
(AWD). MR2 are a mid-engine, RWD design. Axle shafts transfer power from transaxle to rear wheels. Axle
shaft consists of axle shaft with flexible Constant Velocity (CV) joint at each end. On RAV4 models, front inner
CV joint is splined to transaxle. Rear inner CV joint is bolted to differential. Outer CV joint is splined to front
or rear hub assembly. On MR2 models, rear inner CV joint is splined to transaxle and Outer CV joint is splined
to rear hub assembly.
Inner and outer CV joints are enclosed by a CV joint boot. Boot maintains lubrication in CV joint and prevents
contamination of CV lubricant. Boots must be replaced if cracked, torn or damaged. Inner CV joint can be
repaired without replacing assembly but outer CV joint must be replaced as an assembly.
TROUBLE SHOOTING
REMOVAL & INSTALLATION
FRONT AXLE SHAFTS
Removal (RAV4)
1. Raise and support vehicle. Remove front wheel. Remove engine undercover. Drain gear oil from
transaxle into proper container. Remove ABS speed sensor (if equipped). Remove cotter pin and lock cap.
See Fig. 1
or Fig. 2 . Apply brakes, and remove axle shaft nut from end of axle shaft. Release brakes.
2. Remove cotter pin and nut from tie rod end. Using Tie Rod End Remover (SST 09610-20012), disconnect
tie rod end from steering knuckle. Disconnect stabilizer bar link from lower suspension arm. Remove bolt
and 2 nuts, and separate lower ball joint from suspension arm.
3. Using a plastic hammer, tap axle shaft from hub. Pull steering knuckle outward, and disconnect axle shaft
from steering knuckle.
4. To remove axle shaft (except left side on AWD), use a brass drift and hammer and tap on inner joint to
separate from transaxle. Slide axle shaft toward steering knuckle until free of transaxle assembly. NOTE: See DRIVE AXLE NOISE DIAGNOSIS article in GENERAL INFORMATION.
NOTE: DO NOT damage oil seal, axle shaft boots or Anti-Lock Brake System (ABS)
speed sensor rotor when removing axle shaft.
NOTE: On FWD vehicles, removal of right-side axle shaft requires disassembly of
center bearing axle support. See Fig. 3
or Fig. 4 .

1999 Toyota RAV4
1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2

1999 Toyota RAV4
1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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1. To install, reverse removal procedure. Before installing axle shafts, install NEW snap ring on end of axle
shaft (except right side). Coat axle shaft seals in transaxle with grease. Coat axle shaft splines and sliding
surfaces with Dexron-II. Position snap ring on end of axle shaft, with opening facing downward.
2. Install axle shaft by lightly tapping axle shaft into transaxle. Ensure axle shaft will move inward and
outward approximately .079-.120" (2.00-3.00 mm), and cannot be pulled from transaxle.
3. To install remaining components, reverse removal procedure. Tighten fasteners to specification. See
TORQUE SPECIFICATIONS
. Fill transaxle with 75W-90 gear oil with API GL-3, GL-4 or GL-5
rating.
REAR AXLE SHAFTS
Removal (MR2)
1. Raise and support vehicle. Remove rear wheels. Remove engine undercovers. Drain differential oil into
proper container. Unstake drive shaft lock nut. Apply brakes and remove nut. Remove bolt and brake flex
hose bracket from shock absorber. Loosen 2 lower shock absorber bolts and nuts.
2. Remove mounting bolts/nuts and disconnect strut rod from axle carrier. Remove mounting bolts/nuts
from No. 1 lower suspension arm. Remove nut and No. 2 lower suspension arm. Remove 2 lower shock
absorber bolts and nuts. See Fig. 8
. Using plastic hammer, remove drive shaft from axle hub. DO NOT
damage oil seal, boots or dust seal. NOTE: DO NOT damage oil seal, axle shaft boots or Anti-Lock Brake System (ABS)
speed sensor rotor when removing axle shaft.

1999 Toyota RAV4
1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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TORQUE SPECIFICATIONS (TACOMA)
TORQUE SPECIFICATIONS (TUNDRA)
ApplicationFt. Lbs. (N.m)
Brake Hose-To-Caliper11 (15)
Brakelines-To-Master Cylinder11 (15)
Caliper Mounting Bolts/Slide Pins
2WD65 (88)
4WD91 (123)
Caliper Mounting Torque Plate-To-Knuckle Bolts
2WD80 (108)
4WD90 (122)
Hub-To-Rotor Bolts (2WD)47 (64)
LSVP
Load Sensing Spring Assembly Nuts13 (18)
Shackle Bracket Bolts22 (30)
Shackle No. 1-To-No. 2 Nut18 (24)
Rear Axle Retainer & Backing Plate Nuts50 (68)
Wheel Lug Nuts76 (103)
INCH Lbs. (N.m)
Brake Bleeder Screw97 (11)
LSPV-To-Bracket Nuts115 (13)
LSPV Bracket Mounting Bolts257 (29)
Master Cylinder Piston Stopper Bolt
With ABS89 (10)
Without ABS71 (8)
Master Cylinder-To-Booster Nuts115 (13)
Power Brake Unit Mounting Nuts115 (13)
Wheel Cylinder Mounting Bolts89 (10)
ApplicationFt. Lbs. (N.m)
Brake Hose-To-Caliper11 (15)
Brakeline Fittings11 (15)
Caliper Mounting Bolts90 (122)
Load Sensing Spring Assembly At Shackle No. 113 (18)
LSPV & BPV Bracket(1)
LSPV & BPV Bracket-To-Frame21 (29)
LSPV & BPV-To-Load Sensing Spring Assembly13 (18)
Rear Axle Retainer & Backing Plate Nuts51 (69)
Shackle No. 1-To-Shackle No. 2(1)
Shackle No. 2-To-Shackle Bracket(1)

1999 Toyota RAV4
1999-2000 BRAKES Disc & Drum - Trucks & Vans
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WHEEL BEARING INSPECTION
Raise and support vehicle. Remove wheel and brake drum, or rotor (if equipped). Position dial indicator with
stem against center of axle hub. Move axle hub in and out while observing dial indicator. Replace hub if axial
play exceeds .002" (.05 mm). Measure hub axial runout. Replace hub if runout exceeds .0028" (.07 mm).
WHEEL BEARING ADJUSTMENT
Hubs must be replaced if axle end play or runout are not within specification. No adjustment is available. See
WHEEL BEARINGS (HUBS)
under REMOVAL & INSTALLATION
REMOVAL & INSTALLATION
AXLE BEAM
Removal (ECHO)
1. Raise and support vehicle. Remove rear wheels and brake drums. Disconnect brakelines from flex hoses,
remove retaining clips from shock absorbers and plug openings. Disconnect ABS sensor and remove
harness clamp from axle beam. Disconnect parking brake cable from backing plate and remove cable
clamp from axle beam. Remove axle hub assemblies. Remove backing plate assemblies, with brake shoes
still attached.
2. Remove high-mounted stop light from rear package tray. Remove 2 clips and remove package tray.
Remove rear seat. Remove door scuff plate and door opening trim. See Fig. 5
. Remove rear seat outer
seat belts and remove quarter trim panels. On 2 door models, remove outer anchor for front seat shoulder
belt and remove roof side inner garnish. On all models, remove room partition board.
3. Using 2 floor jacks, support rear axle beam under each coil spring. While holding shock absorber shaft,
remove the 2 upper nuts, disconnecting lower suspension supports from body. Lower jacks slowly.
Remove coil springs and insulators. Remove axle beam-to-
body bolts. Remove axle beam. NOTE: See SPECIFICATIONS & PROCEDURES
in WHEEL ALIGNMENT article.

1999 Toyota RAV4
1999-2000 SUSPENSION Rear - Front Wheel Drive
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2. On disc brake models, remove rotor and caliper. Leaving flex hose attached, suspend caliper aside. On all
models, remove 4 axle hub-to-axle carrier bolts, axle hub and "O" ring.
3. Note position of nuts on suspension arms and strut rods for installation reference. Disconnect strut rod
from axle carrier. Disconnect No. 1 and No. 2 lower suspension arms from axle carrier. Remove 2 bolts
and nuts, and remove axle carrier.
Installation (Avalon, Camry, Camry Solara, Celica & Corolla)
To install, reverse removal procedure. Coat NEW "O" ring with grease and install hub. Tighten all fasteners to
specification. See TORQUE SPECIFICATIONS
. Bleed brake system. Check rear wheel alignment.
Removal (RAV4)
1. Raise and support vehicle. Remove rear wheel and brake drum. On 4WD models, remove drive axle.
Remove ABS speed sensor (if equipped). Remove drive axle lock nut. Place matchmarks on drive axle
and differential gear shaft. Remove the 4 nuts and remove drive axle from differential side gear. On FWD
models, disconnect ABS sensor and remove harness clamp (if equipped). On all models, remove 2
brakeline clamps from rear No. 1 suspension arm. Remove parking brake cable clamp. See Fig. 4
.
2. Remove 4 bolts and remove axle hub and backing plate, leaving brake shoes attached. Disconnect lower
end of shock absorber. Using Ball Joint Puller (09628-62011), disconnect upper and lower suspension
arms from rear No. 1 suspension arm. Place matchmarks on camber adjusting cam and suspension
member and remove bolt. See Fig. 6
. Place matchmarks on toe adjusting cam and body and loosen bolt.
See Fig. 7
. Remove coil spring and upper insulator. Remove loosened toe adjusting cam bolt. Remove
rear No. 1 suspension arm. NOTE: Bounce vehicle several times to stabilize suspension. Tighten axle carrier-to-
shock absorber assembly and suspension arm bolts to specification with
vehicle at normal operating height.

1999 Toyota RAV4
1999-2000 SUSPENSION Rear - Front Wheel Drive
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2. Using a floor jack, support suspension member. Remove suspension member nuts, bolts and stoppers.
Lower suspension member. Remove No. 1 lower suspension arm.
Installation
1. To install, reverse removal procedure. Be sure to install components in their original locations. On all
models except Corolla, suspension arms are marked with paint. Install suspension arms with paint marks
facing rearward. On Corolla models, suspension arms have left hand threads on one side. Install
suspension arms with left hand threads to the axle carrier side.
2. Install all nuts and bolts, but DO NOT tighten. Install wheels. Lower vehicle. Bounce vehicle several
times to stabilize suspension. Tighten all nuts and bolts to specification, with vehicle weight on
suspension. See TORQUE SPECIFICATIONS
. Check rear wheel alignment. See SPECIFICATIONS
& PROCEDURES article in WHEEL ALIGNMENT.
WHEEL BEARINGS (HUBS)
Removal (Avalon, Camry, Camry Solara, Celica, Corolla & RAV4 FWD)
1. Raise and support vehicle. Remove rear wheels. On drum brake models, remove brake drum. On disc
brake models, remove rotor. Remove caliper, leaving flex hose attached, suspend aside. Disconnect ABS
sensor (if equipped).
2. On all models, check wheel hub axial play and runout. See WHEEL BEARING INSPECTION
under
ADJUSTMENTS & INSPECTION. Remove 4 bolts and remove axle hub and "O" ring.
Installation
Coat NEW "O" ring with grease and install hub. To complete installation, reverse removal procedure. Tighten
all nuts and bolts to specification. See TORQUE SPECIFICATIONS
.
Removal (RAV4 4WD)
1. Raise and support vehicle. Remove rear wheel and brake drum. Using a dial indicator, check wheel
bearing end play and runout. End play should not exceed .002" (.05 mm). Runout should not
exceed .0028" (.07 mm). If axle hub end play or runout exceed specification, replace hub with bearing.
2. Remove bolt and ABS sensor. Remove drive axle. Remove drive axle lock nut. Place matchmarks on
drive axle and differential side gear shaft. Remove 4 nuts and remove drive axle. Disassemble rear brake
shoes. Disconnect brakeline from wheel cylinder. Remove parking brake cable. Remove 4 bolts and
remove axle hub with bearing and backing plate. See Fig. 10
.
3. Using Puller (09950-40011) and Replacer Set (09950-60011), remove bearing from axle hub. Remove
bearing race from axle hub. See Fig. 11. NOTE: Wheel bearings and wheel hub, is a one piece assembly and must be replaced
as a single unit.

1999 Toyota RAV4
1999-2000 SUSPENSION Rear - Front Wheel Drive
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