TOYOTA RAV4 1996 Service Repair Manual

R10768
SST
R10641
W01227
SST
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−87
1996 RAV4 (RM447U) 1/17/01
(c) Using SST to hold the flange, torque the nut.
SST 09330−00021
Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf)
20. CHECK DRIVE PINION PRELOAD
(a) Using a torque wrench, measure the preload of the back-
lash between the drive pinion and ring gear.
Preload (at starting):
New bearing:
1.0 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing:
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
If preload is larger than the specification, replace the bearing
spacer.
If preload is less than the specification, retorque the nut 13 N·m
(130 kgf·cm, 9 ft·lbf) at a time until the specified preload is
reached.
Torque: 235 N·m (2,400 kgf·cm, 174 ft·lbf) or less
If the maximum torque is exceeded while retighten the nut, re-
place the bearing spacer and repeat the preload procedure. Do
not loosen the pinion nut to reduce the preload.
21. RECHECK TOTAL PRELOAD (See page SA−74)
22. RECHECK RING GEAR BACKLASH
(See page SA−74)
23. RECHECK TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA−79)
24. CHECK COMPANION FLANGE RUNOUT
(See page SA−74)
25. STAKE DRIVE PINION NUT
26. INSTALL SIDE GEAR SHAFT OIL SEALS
(a) Using SST and a hammer, install 2 oil seals until they are
flush with the carrier end surface.
SST 09550−00032, 09950−70010 (09951−07150)
(b) Coat MP grease to the oil seal lip.
27. Torque Sensing LSD:
INSTALL SIDE GEAR SHAFTS

R10664
SST
R10757
Z12363
1 − 2 mm
(0.04 − 0.08 in.) SA−88
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
(a) Install 2 new snap rings to the side gear shafts.
(b) Using SST, install the 2 side gear shafts until it contacts
the pinion shaft.
SST 09520−24010
HINT:
Check that the shaft is fully inserted by confirming the noise it
should make when it is tapped.
28. 2 Pinion Differential:
INSTALL SIDE GEAR SHAFTS
(a) Install the 2 side gear shafts to the differential case.
(b) Install 2 new snap rings to the 2 side gear shafts.
29. INSTALL DIFFERENTIAL CARRIER COVER
(a) Clean contacting surfaces of any residual FIPG material
using gasoline or alcohol.
(b) Apply FIPG to the carrier.
FIPG:
Part No.08826−00090, THREE BOND 1281 or equiva-
lent
HINT:
Install the carrier cover within 3 minutes after applying FIPG.
(c) Torque the 8 bolts.
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)

SA0UN−01
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−89
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−73).
AFTER INSTALLATION, FILL DIFFERENTIAL WITH DIFFERENTIAL OIL (See page SA−69)

SA0UO−04
W04028
Retainer Suspension Cap
Retainer Retainer Cushion
Rear
Shock
Absorber
Bushing
Brake Drum
25 (250, 18)
Cushion Retainer
Retainer
7.8 (80, 69 in.·lbf)
13 (130, 9)
18 (185, 13)
19 (195, 14)
19 (195, 14)
4WD
Lock cap
Cotter Pin
216 (2,200, 59)
80 (820, 59)

 Parking Brake Cable
113 (1,150, 83)
113 (1,150, 83)Upper Suspension Arm
113 (1,150, 83)Camber
Adjust
Cam
Lower Suspension Arm103 (1,050, 76)
Clip 
103 (1,050, 76)
132 (1,350, 98)
To e−adjust Cam
Attachment
Bushing
Rear No.1 Suspension Arm
Attachment Spring Bumper
Upper Insulator
Coil Spring
Shock Absorber
Lower Pivot pin
13 (130, 9)
140 (1,430, 103)
N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part

56 (570, 41)
37 (380, 27)
Rear Drive Shaft4WD: Rear Differential
13 (130, 9)
2WD
Rear Axle Shaft SA−90
− SUSPENSION AND AXLEREAR SHOCK ABSORBER
1996 RAV4 (RM447U)
REAR SHOCK ABSORBER
COMPONENTS

SA0UP−04
R10760
R10777
− SUSPENSION AND AXLEREAR SHOCK ABSORBER
SA−91
1996 RAV4 (RM447U)
REMOVAL
1. JACK UP VEHICLE AND SUPPORT BODY WITH
STANDS
2. REMOVE REAR WHEEL AND SUPPORT NO. 1 SUS-
PENSION WITH JACK
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
3. REMOVE SHOCK ABSORBER
(a) Remove the suspension cap.
(b) Remove the 2 nuts, 2 retainers and cushion.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Insert the wood chip between the No.1 suspension arm
made of cast iron and jack, then support the No.1 suspen-
sion arm with the jack.
(d) Remove the bolt, 2 retainers and shock absorber.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(e) Remove the lower bushing from the shock absorber.

SA0UQ−01
SA0627
SA−92
− SUSPENSION AND AXLEREAR SHOCK ABSORBER
1996 RAV4 (RM447U)
INSPECTION
INSPECT SHOCK ABSORBER
Compress and extend the shock absorber rod and check that
there is no abnormal resistance or unusual operation sounds.
If there is any abnormality, replace the shock absorber with a
new one.
NOTICE:
When discarding the shock absorber, see DISPOSAL on
page SA−93.

SA0UR−01
R10780
− SUSPENSION AND AXLEREAR SHOCK ABSORBER
SA−93
1996 RAV4 (RM447U)
DISPOSAL
1. FULLY EXTEND SHOCK ABSORBER ROD
2. DRILL HOLE TO REMOVE GAS FROM CYLINDER
Using a drill, make a hole near the center of the cylinder as
shown to remove the gas inside.
CAUTION:
The gas coming out is harmless, but be careful of chips
which may fly up when drilling.

SA0US−01
SA−94
− SUSPENSION AND AXLEREAR SHOCK ABSORBER
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−91).

SA0UT−03
W04028
Retainer Suspension Cap
Retainer Retainer Cushion
Rear
Shock
Absorber
Bushing
Brake Drum
25 (250, 18)
Cushion Retainer
Retainer
7.8 (80, 69 in.·lbf)
13 (130, 9)
18 (185, 13)
19 (195, 14)
19 (195, 14)
4WD
Lock cap
Cotter Pin
216 (2,200, 59)
80 (820, 59)

 Parking Brake Cable
113 (1,150, 83)
113 (1,150, 83)Upper Suspension Arm
113 (1,150, 83)Camber
Adjust
Cam
Lower Suspension Arm103 (1,050, 76)
Clip 
103 (1,050, 76)
132 (1,350, 98)
To e−adjust Cam
Attachment
Bushing
Rear No.1 Suspension Arm
Attachment Spring Bumper
Upper Insulator
Coil Spring
Shock Absorber
Lower Pivot pin
13 (130, 9)
140 (1,430, 103)
N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part

56 (570, 41)
37 (380, 27)
Rear Drive Shaft4WD: Rear Differential
13 (130, 9)
2WD
Rear Axle Shaft
− SUSPENSION AND AXLEREAR SUSPENSION ARM AND COIL SPRING
SA−95
1996 RAV4 (RM447U)
REAR SUSPENSION ARM AND COIL SPRING
COMPONENTS

SA0UU−03
R10779
R10764
SST
R10765
SST SA−96
− SUSPENSION AND AXLEREAR SUSPENSION ARM AND COIL SPRING
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE REAR WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. 2WD:
REMOVE AXLE SHAFT (See page SA−52)
3. 4WD:
REMOVE REAR DRIVE SHAFT (See page SA−62)
4. REMOVE BRAKE DRUM
5. REMOVE 2 BRAKE LINE CLAMP BOLTS
Torque:
Bracket: 18 N·m (185 kgf·cm, 13 ft·lbf)
Clamp: 13 N·m (130 kgf·cm, 9 ft·lbf)
6. REMOVE PARKING BRAKE CABLE CLAMP BOLT
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
7. w/ ABS:
REMOVE ABS SPEED SENSOR AND WIRE HARNESS
Torque:
ABS speed sensor: 8 N·m (80 kgf·cm, 69 in.·lbf)
Wire harness: 13 N·m (130 kgf·cm, 9 ft·lbf)
8. REMOVE REAR AXLE HUB WITH BRAKE
(a) Remove the 4 bolts and rear axle hub with brake.
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)
(b) Support it securely.
9. DISCONNECT LOWER SIDE OF SHOCK ABSORBER
(See page SA−91)
10. REMOVE UPPER AND LOWER SUSPENSION ARMS
(a) Remove the 2 clips and 2 nuts.
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
(b) Using SST, disconnect the upper suspension arm.
SST 09628−62011
(c) Using SST, disconnect the lower suspension arm.
SST 09628−62011