Sensor TOYOTA RAV4 1996 Service Repair Manual

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)

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)

MX05V−02
Q08757
FIPG
Z12375SST
Q09043
255.5 mm MX−16
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
DISASSEMBLY
1. 4WD:
REMOVE TRANSFER ASSEMBLY
(a) Remove the 3 bolts.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(b) Remove the 5 nuts.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(c) Using a plastic hammer, remove the transfer assembly
from the transaxle.
HINT:
At the time of reassembly, please refer to the following item.
Shift into the 4th gear, and install the transfer assembly while
turning the input shaft of the transaxle.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
2. 4WD:
REMOVE DIFFERENTIAL SIDE GEAR INTERMEDI-
ATE SHAFT
(a) Screw in a suitable bolt with a washer into the side gear
intermediate shaft.
(b) Using SST, remove the side gear intermediate shaft.
SST 09910−00015 (09911−00011, 09912−00010)
(c) Remove the snap ring from the differential side gear inter-
mediate shaft.
HINT:
At the time of reassembly, please refer to the following item.
Keeping the intermediate shaft on the differential pinion shaft,
measure the dimension, as shown in the illustration.
Protrusion length: 255.5 mm (10.06 in.)
3. REMOVE RELEASE FORK AND BEARING
4. REMOVE BACK−UP LIGHT SWITCH WITH GASKET
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
5. REMOVE BOLT AND VEHICLE SPEED SENSOR
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
6. REMOVE NO.2 SELECTING BELLCRANK WITH SE-
LECTING BELLCRANK SUPPORT
Remove the 2 bolts and No.2 selecting bellcrank with the se-
lecting bellcrank support.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

MX060−01
Z17560
Transaxle Case Cover
Differential Spider
Differential Pinion
Differential Side Gear
Side Gear Thrust
Washer
Pinion Thrust Washer
 Tapered Roller Bearing
and Outer Race
Differential Right Case
Vehicle Speed Sensor Drive Gear
Differential Left Case
 Tapered Roller Bearing
and Outer Race Ring Gear
Oil Baffle
 Oil Seal x16
Shim  Oil Seal
54 (550, 40)
63 (640, 46)
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part 

x16
 Precoated partStud Bolt
54 (550, 40)
124 (1,260, 91)
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
MX−49
1996 RAV4 (RM447U)
DIFFERENTIAL CASE (2WD)
COMPONENTS

Q05166
SST
MX0DV−01
Z00281
Matchmarks
Z00284
MX−50
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE TAPERED ROLLER BEARING
Using SST, remove the left and right bearings.
SST 09950−40010
2. REMOVE RING GEAR
(a) Place matchmarks on both the differential case and ring
gear.
(b) Remove the 16 bolts.
(c) Using a plastic hammer, tap the ring gear and remove it.
3. DISASSEMBLE DIFFERENTIAL CASE
(a) Place matchmarks on the differential right and left cases.
(b) Using a torx wrench (T50), remove the 16 torx screws.
(c) Using a plastic hammer, tap the differential left case.
(d) Remove the vehicle speed sensor drive gear from the dif-
ferential right case.
(e) Remove the 2 differential side gears, side gear thrust
washers, 4 differential pinions and pinion thrust washers
from the differential left case.

Z00297
Z00298
Z00299
Matchmarks
Z00303
Driven Gear
Side
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
MX−55
1996 RAV4 (RM447U)
(f) Refer to the table below, select the thrust washer which
will ensure that the backlash is within the specification.
Try to select a washer of the same size.
Thickness mm (in.)Thickness mm (in.)
0.80 (0.0315)1.20 (0.0472)
0.90 (0.0354)1.30 (0.0512)
1.00 (0.0394)1.40 (0.0551)
1.10 (0.0433)−
(g) Install the vehicle speed sensor drive gear.
(h) Align the matchmarks on the differential cases.
(i) Using a plastic hammer, carefully tap the differential case
to install it.
(j) Using a torx wrench (T50), install and torque the 16 torx
screws.
Torque: 63 N·m (640 kgf·cm, 46 ft·lbf)
2. INSTALL RING GEAR
(a) Clean the contact surface of the differential case and the
threads of the ring gear and differential case.
(b) Heat the ring gear to about 100°C (212°F) in boiling wa-
ter.
(c) Carefully take the ring gear out of the water.
(d) Clean the contact surface of the ring gear with cleaning
solvent.
(e) Quickly install the ring gear on the differential case.
HINT:
Align the matchmarks on the differential left case and contact
the ring gear.
(f) Temporarily install the 16 bolts.
NOTICE:
The ring gear set bolts should not be tightened until the
ring gear has cooled sufficiently.
(g) After the ring gear has cooled sufficiently, torque the ring
gear set bolts.
Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf)

MX02J−02
Z17561
Tapered Roller Bearing and Outer Race
Snap Ring
Spacer
Vehicle Speed Sensor
Drive Gear
No.1 Differential
Case No.2 Differential Side
Gear Thrust Washer
Differential Side Gear
Subassembly
Differential Pinion Shaft
Differential Pinion Thrust Washer
Differential Pinion
Differential Pinion
Thrust Washer
Differential Pinion
No.2 Front Differential Pinion Shaft
Front Differential Pinion
Shaft Holder
Spacer
Snap Ring Conical Spring
Washer
Pinion Shaft
Holder
No.2 Differential Side
Gear Thrust Washer
Front Differential Case
Front Differential
Pinion Shaft Conical Spring
Washer
No.2 Differential Case
Differential Ring Gear
x16
Oil Baffle Front Differential Side
Gear Thrust Washer
Tapered Roller Bearing and Outer Race
Oil Seal
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable partFront Differential Side Gear
Shim

124 (1,260, 91)
 MX−58
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
DIFFERENTIAL CASE (4WD)
COMPONENTS

Q06218
Q06219
Q07870
SST MX−60
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
(d) Remove these parts from the front differential case:
2 front differential pinion shafts
No.2 front differential pinion shaft
Front differential pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
Front differential side gear
Front differential side gear thrust washer
6. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the spacer and vehicle speed sensor drive gear.
7. DISASSEMBLE NO.1 DIFFERENTIAL CASE
Remove these parts from the No.1 differential case:
4 differential pinion shafts
Pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
Differential side gear subassembly
Conical spring washer
No.2 differential side gear thrust washer
8. No.2 Differential Case Side:
REMOVE TAPERED ROLLER BEARING
Using SST, remove the tapered roller bearing.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00520)