TOYOTA RAV4 1996 Service Repair Manual

MX−6
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
1996 RAV4 (RM447U)
25. REMOVE TRANSAXLE CASE PROTECTOR
Remove the 2 bolts and protector.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

MX05P−05
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
MX−7
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal.
(See page MX−3)
NOTICE:
When working with FIPG material, you must observe the following items.
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non−residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be re-
moved and reapplied.
HINT:
After installation, check and inspect items as follows.
Front wheel alignment (See page SA−4).
Do the road test.

MX05R−02
Q09030
Solenoid Hose No.1
Transfer Vacuum Actuator
Bracket
Transfer Vacuum Actuator Assembly
Right Transfer Stiffener Plate
Center Transfer Stiffener Plate
Differential Lock Indicator Switch Connector
Back−Up Light
Switch Connector
Vehicle Speed
Sensor Connector
Transaxle Case Protector
Starter Stiffener Plate
N·m (kgf·cm, ft·lbf): Specified torque
25 (250, 18)
37 (380, 27)
9.0 (95, 78 in.·lbf)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
46 (470, 34)
29 (300, 22)
25 (250, 18)
64 (650, 47)
39 (400, 29)
64 (650, 47)
35 (360, 26)
29 (300, 22)
Solenoid Hose No.0
Solenoid Hose No.2
Solenoid Hose No.0 MX−8
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (4WD)
1996 RAV4 (RM447U)
MANUAL TRANSAXLE UNIT (4WD)
COMPONENTS

MX05S−01
Q09031
B
A
C
FED A
A
C
Q08759
No.1
No.2 No.0
No.0
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (4WD)
MX−9
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE TRANSAXLE WITH ENGINE
(See page EM−80)
2. REMOVE TRANSAXLE CASE PROTECTOR
Remove the 2 bolts and transaxle case protector.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
3. REMOVE STARTER
(a) Disconnect the connector and wire from the starter.
(b) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
4. DISCONNECT DIFFERENTIAL LOCK INDICATOR
SWITCH, BACK−UP LIGHT SWITCH AND VEHICLE
SPEED SENSOR CONNECTORS
5. REMOVE TRANSFER VACUUM ACTUATOR BRACK-
ET
Remove the 4 bolts and bracket.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
6. REMOVE TRANSFER VACUUM ACTUATOR AS-
SEMBLY
(a) Disconnect the 4 solenoid hoses from the transfer vacu-
um actuator assembly.
NOTICE:
At the time of installation, please refer to the following item.
Check that the hose No.0, No.1 and No.2 are securely
installed to the solenoid.
(b) Remove the 2 bolts and transfer vacuum actuator assem-
bly.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
7. REMOVE RIGHT TRANSFER STIFFENER PLATE
Remove the 5 bolts and right transfer stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
8. REMOVE CENTER TRANSFER STIFFENER PLATE
Remove the 3 bolts and center transfer stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
9. REMOVE STIFFENER PLATE
Remove the 2 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
10. REMOVE TRANSAXLE FROM ENGINE
(a) Remove the 9 transaxle mounting bolts from the engine.
Torque:
Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf)
Bolt B: 35 N·m (360 kgf·cm, 26 ft·lbf)
Bolt C: 29 N·m (300 kgf·cm, 22 ft·lbf)
Bolt D: 46 N·m (470 kgf·cm, 34 ft·lbf)
Bolt E: 25 N·m (250 kgf·cm, 18 ft·lbf)
Bolt F: 9.0 N·m (95 kgf·cm, 78 in.·lbf)

Q06187
Q06188
Q06189
MX−10
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (4WD)
1996 RAV4 (RM447U)
(b) Pull straight until there is a gap of about 60−80 mm
(2.4−3.1 in.) between the engine and transaxle case.
(c) Move the transmission case cover in the direction, as
shown in the illustration.
(d) While holding transfer output, gently pull out whole trans-
axle.

MX05T−03
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (4WD)
MX−11
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal.
(See page MX−9)
NOTICE:
When working with FIPG material, you must observe the following items.
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non−residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be re-
moved and reapplied.
HINT:
After installation, do the road test.

MX05U−01
Q09032
2WD:
Clutch Release Fork Assembly
with Bearing
Clutch Release Fork SupportControl Lever Housing
Support Bracket
Boot O−Ring
Cover Clutch Release
Line Bracket
Transaxle Case
Transmission
Oil Cooler
Sub−Assembly
Elbow O−RingVehicle Speed Sensor
Transaxle Case Receiver
Transmission Oil
Pipe
Magnet
Transmission
Oil Pipe
 Output Shaft Cover
Tapered Roller Bearing
Outer Race
 Front Oil Seal
Input Shaft Front
Bearing
Transmission Oil Pump
Assembly
Differential Case Assembly
Oil Pump Drive Gear
17 (175, 13)
47 (480, 35)
34 (350, 25)
27 (275, 20)
7.4 (75, 65 in.·lbf)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part Gasket
  MX−12
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
MANUAL TRANSAXLE ASSEMBLY
COMPONENTS

Q09033
Clutch Release
Fork Assembly
with Bearing
Clutch Release Fork Support
Control Lever Housing
Support Bracket
Boot O−Ring
Cover
Clutch Release
Line Bracket
Transaxle Case
Elbow O−RingVehicle Speed Sensor
Transaxle Case Receiver
Transmission Oil
Pipe
Magnet
 Output Shaft Cover
 Tapered Roller Bearing
Outer Race
 Front Oil Seal
 Input Shaft Front
Oil Seal
Transmission Oil Pump
Assembly
Differential Case Assembly
Oil Pump Drive Gear
34 (350, 25)
27 (275, 20)
7.4 (75, 65 in.·lbf)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 Precoated part 4WD:


Transfer Assembly
Transmission
Oil Pipe
17 (175, 13)
17 (175, 13)
69 (700, 51)
69 (700, 51)
39 (400, 29)
47 (480, 35)
Differential Side Gear
Intermediate Shaft
 Snap Ring
69 (700, 51)
Drain Plug
Oil Cooler Line Gasket
 Gasket 
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−13
1996 RAV4 (RM447U)

Q09034

N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 Precoated partTransmission Case Cover Transmission CaseNo.2 Selecting Bellcrank with
Selecting Bellcrank Support Shift and Select Lever
Shaft Assembly
No.1 Oil Receiver Pipe Reverse Restrict
Pin Straight Screw PlugBack−Up Light SwitchNo.3 Shift Fork No.3 Shift Fork ShaftInterlock Roller
Snap RingShift Head
Shift and Select Lever
Shaft Lock BoltNo.2 Shift Fork Shaft Straight Screw Plug Reverse Shift Arm Bracket Assembly
Snap Ring
Reverse Shift Fork
No.1 Shift Fork
No.1 Shift Fork Shaft Seat
Spring
Ball
Slotted Spring
PinSnap RingSnap Ring
No.2 Shift Fork
No.2 Oil Receiver Pipe
Drain Plug Filler Plug
x10 x17


24 (240, 17)
25 (250, 18)
25 (250, 18)
24 (240, 17)
24 (240, 17)
25 (250, 18)
17 (175, 13)
40 (410, 30)
13 (130, 9)49 (500, 36)20 (200, 14)
17 (175, 13)
29 (300, 22)
49 (500, 36)
20 (200, 14)
49 (500, 36)
49 (500, 36)
29 (300, 22)
Breather Plug Gasket  Gasket
 Gasket  Gasket Gasket
 Gasket MX−14
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)

Z17555
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 Precoated partOutput Shaft AssemblyInput Shaft Assembly
 Tapered Roller Bearing
Outer Race
Reverse Idler Gear ShaftReverse Idler Gear
Thrust Washer
Rear Bearing Retainer
Needle Roller Bearing 5th Driven Gear
Synchronizer Pull RingKey Spring
Middle Synchronizer
Ring
Snap Ring Output Shaft
Lock Nut5th Gear
No.3 Clutch Hub
No.3 Hub Sleeve Key Spring Outer Synchronizer RingInner Synchronizer RingSnap Ring
Spacer x7Shim
 Lock Bolt
29 (300, 22)
42 (430, 31)
123 (1,250, 90)
Snap Ring 
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−15
1996 RAV4 (RM447U)