TOYOTA RAV4 1996 Service Repair Manual

MX−76
− MANUAL TRANSAXLEDIFFERENTIAL LOCKING SYSTEM (4WD)
1996 RAV4 (RM447U)
(c) Diaphragm (Free Side):
Inspect the transfer vacuum tank.
(1) Disconnect the solenoid hose No.0, No.1, No.2 and
No.3 from the solenoid.
(2) Fill in the No.3 hose with a plug.
(3) Check that the indicator needle remains steady
when a vacuum of 500 mmHg (19.685 in.Hg) are
applied to the hose No.0 and No.2.
Standard:
Indicator falls 45 mmHg (1.772 in.Hg) or less during 15
seconds.
NOTICE:
Apply vacuum simultaneously to the hose No.0 and hose
No.2.
(4) Reinstall the removed hoses to the solenoid.
NOTICE:
Check that the hose No.0, No.1, No.2 and No.3 are securely
installed to the solenoid.

MX065−01
D01958
Shift Lever Knob
Side Trim Cover
Side Trim Cover
Shift Control Cable Grommet Retainer
Shift Lever Assembly Select Control Cable
N·m (kgf·cm, ft·lbf) : Specified torqueWasherClip
Washer GrommetRetainerConsole Box Boot
12 (120, 9)
4.9 (50, 43 in.·lbf)
4.9 (50, 43 in.·lbf)
Clip Clip
Clip
Clip
ClipWasher
Bracket
− MANUAL TRANSAXLESHIFT LEVER AND CONTROL CABLE
MX−77
1996 RAV4 (RM447U)
SHIFT LEVER AND CONTROL CABLE
COMPONENTS

MX066−01
Z17562
Oil Cooler Clamp
Cushion
Oil Cooler Assembly
Oil Cooler Line Clamp
 O−Ring
Union
LH Engine Under Cover
 Non−reusable partOil Cooler No.2 Line
Painted Mark Line Clamp
Oil Cooler No.1 Line
: Specified torque
N·m (kgf·cm, ft·lbf)Bumper Cover RH Engine Under Cover
17 (175, 13)
34 (350, 25)
4.9 (50, 43 in.·lbf)
29 (300, 22)34 (350, 25)
6.4 (65, 56 in.·lbf)
 O−Ring
Elbow
26 (270, 20)
6.4 (65, 56 in.·lbf)
ClampCushion
6.4 (65, 56 in.·lbf)6.4 (65, 56 in.·lbf)CushionClamp
 
Line Clamp
34 (350, 25)
MX−78
− MANUAL TRANSAXLEOIL COOLER (4WD)
1996 RAV4 (RM447U)
OIL COOLER (4WD)
COMPONENTS

MX0C1−01
Q09037
Adjusting Shim
Transfer Oil PipeExtension Housing
x6
Dust Deflector
Transfer Pinion Bearing
Cage Assembly
Differential Lock
Indicator Switch Cushion
Differential Bearing
Adjusting Nut
Ring Gear Mounting
Case Assembly
Bearing Outer Race
Plate Washer
Transfer Left Case
Drain Plug Snap Ring
Shift Fork Shaft
Differential
Side Gear
Shaft Holder
Side Gear Shaft
Holder Bearing
Snap Ring
Adjusting Nut Lock Plate
N·m (kgf·cm, ft·lbf): Specified torque
Non−reusable part
Precoated part 
x10Transfer Right CaseDifferential Lock
Sleeve Differential Lock
Shift Fork Plug
Transfer Inspection
Hole Cover O−Ring

Plug
Oil Seal Dust BootGasket
 Oil Seal
44 (450, 33)


39 (400, 29)

16 (160, 12)
Gasket

39 (400, 29)
Gasket 
25 (250, 18)
40 (410, 30)16 (160, 12)

25 (260, 19)
Dynamic Damper
25 (260, 19)
 Bearing
Outer Race 
13 (130, 9)
O−Ring 
39 (400, 29)Oil Seal

− MANUAL TRANSAXLETRANSFER (4WD)
MX−79
1996 RAV4 (RM447U)
TRANSFER (4WD)
COMPONENTS

Z17563
Transfer Driven PinionDriven Pinion Front Bearing
and Outer RaceTransfer Pinion Bearing Cage
Driven Pinion Rear Bearing
and Outer Race
 Lock Nut
Transfer Pinion Bearing Spacer
 Non−reusable part


See page MX−89
MX−80
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)

Z17564
Left Side Bearing
Right Side Bearing
Ring Gear Mounting Case
Transfer Ring Gear
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable partx12
 
97 (985, 71)
− MANUAL TRANSAXLETRANSFER (4WD)
MX−81
1996 RAV4 (RM447U)

MX0DZ−01
Q06131
Q06157
SST
Q06158
MX−82
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE DUST BOOT
2. REMOVE DYNAMIC DAMPER
Remove the 4 bolts and dynamic damper.
3. REMOVE EXTENSION HOUSING
(a) Remove the 4 bolts, tap the extension housing with a
plastic hammer and remove it.
(b) Remove the O−ring from the extension housing.
4. REMOVE PLUG AND DIFFERENTIAL LOCK INDICA-
TOR SWITCH
(a) Using a hexagon wrench (6 mm), remove the plug.
(b) Using a hexagon wrench (10 mm), remove the plug and
gasket.
(c) Remove the differential lock indicator switch and gasket.
5. REMOVE TRANSFER RIGHT CASE OIL SEAL
Using a screwdriver and hammer, remove the oil seal.
6. CHECK PRELOAD
(a) Using SST and a spring tension gauge, measure the driv-
en pinion preload of the backlash between the driven pin-
ion and ring gear.
SST 09326−20011
Preload (at starting):
9−14 N (0.9−1.4 kgf, 2−3 lbf)
(b) Using SST and a spring tension gauge, measure the total
preload.
SST 09326−20011
Total preload (at starting):
Driven pinion preload plus
5−9 N (0.5−0.9 kgf, 1−2 lbf)
7. REMOVE TRANSFER INSPECTION HOLE COVER
(a) Remove the 3 bolts.
(b) Using a screwdriver and hammer, remove the transfer in-
spection hole cover.
8. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13−0.18 mm (0.0051−0.0071 in.)
9. CHECK TOOTH CONTACT (See page MX−89)

Z12395
SST
Z12545
Q06133
Q06142
SST
− MANUAL TRANSAXLETRANSFER (4WD)
MX−83
1996 RAV4 (RM447U)
10. REMOVE TRANSFER PINION BEARING CAGE AS-
SEMBLY
(a) Remove the 6 bolts, tap the transfer pinion bearing cage
assembly with a plastic hammer and remove it.
(b) Remove the O−ring and 2 adjusting shims from the trans-
fer pinion bearing cage.
(c) Remove the lock nut.
(1) Unstake the lock nut.
(2) Using SST, remove the lock nut.
SST 09326−20011
(d) Remove the transfer driven pinion.
Using a press, remove the transfer driven pinion, rear
bearing and spacer.
11. REMOVE DIFFERENTIAL LOCK SHIFT FORK, LOCK
SLEEVE AND SHIFT FORK SHAFT
Remove the bolt, shift fork, shift fork shaft and lock sleeve.
12. REMOVE TRANSFER RIGHT CASE
Remove the 10 bolts, tap the transfer right case with a plastic
hammer and remove it.
13. REMOVE RING GEAR MOUNTING CASE ASSEMBLY
(a) Remove the mounting case right side bearing.
Using SST, remove the right side bearing.
SST 09950−40010, 09950−60010 (09951−00500)

Q06143
SST
Q06144
Q06161
Q06148
Q06134
SST MX−84
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
(b) Remove the mounting case left side bearing.
Using SST, remove the left side bearing.
SST 09950−40010, 09950−60010 (09951−00500)
(c) Check the ring gear runout.
Using a dial indicator, check the ring gear runout.
Maximum runout: 0.1 mm (0.004 in.)
(d) Remove the transfer ring gear.
(1) Place matchmarks on both the ring gear mounting
case and transfer ring gear.
(2) Remove the 12 bolts.
(3) Using a pin punch and hammer, tap out the transfer
ring gear.
14. REMOVE DIFFERENTIAL SIDE GEAR SHAFT HOLD-
ER
(a) Using snap ring pliers, remove the snap ring from the
transfer right case.
(b) Using SST and a press, remove the differential side gear
shaft holder.
SST 09527−17011

Q06135
− MANUAL TRANSAXLETRANSFER (4WD)
MX−85
1996 RAV4 (RM447U)
15. REMOVE ADJUSTING NUT LOCK PLATE
Using snap ring pliers, remove the adjusting nut lock plate from
the transfer right case.