TOYOTA RAV4 1996 Service Repair Manual

Fig. 15: Identifying No. 1 Differential Case Measuring Point
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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Sunday, November 22, 2009 10:48:07 AMPage 21 © 2005 Mitchell Repair Information Company, LLC.

Fig. 16: Identifying No. 2 Differential Case Measuring Point
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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Fig. 17: Identifying Front Differential Case Measuring Point
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 18: Measuring Conical Spring Washer Height

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Reassembly (4WD Models)
1. Replace transmission case oil seal and outer bearing race. Adjust bearing race with shims as necessary.
Install adjust shim, tapered outer bearing race, oil baffle and oil seal. On transaxle case side, replace
tapered roller bearing outer race if needed. Install tapered roller bearing to No. 1 differential case side.
Reassemble differential side gear subassembly. Measure backlash of one pinion gear while holding
differential side gear subassembly toward case. Using dial indicator, measure backlash. Ensure backlash
is .002-.008" (.05-.20 mm). See Fig. 19
. If backlash is out of specification, select a thrust washer to
adjust. Thrust washers are available in thicknesses of .031" (.80 mm) to .055" (1.40 mm) in .002" (.05
mm) increments.
2. Reassemble No. 1 differential case. Install No. 2 side gear thrust washer, conical spring washer and
differential side gear subassembly. Install pinions, pinion thrust washers and pinion shafts. Install spacer,
vehicle speed sensor drive gear and snap ring, to front differential case side. Install front differential side
gear thrust washer, and front differential side gear. Install pinion shaft holder, pinions, pinion thrust
washers, No. 2 differential pinion shaft and 2 front differential pinion shafts. Using dial indicator,

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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measure backlash. Ensure backlash is .002-.008" (.05-.20 mm). See Fig. 19. Front differential side gear
thrust washers are available in thicknesses of .039" (1.0 mm) to .049" (1.25 mm) in .002" (.05 mm)
increments. Washers are stamped "B"-"G".
3. Install to No. 2 differential case, No. 2 side gear thrust washer, front differential side gear thrust washer,
front differential side gear and front differential case assembly. Using dial indicator, measure thrust
clearance of front differential side gear. Standard clearance is .007-.010" (.17-.26 mm). See Fig. 20
. If
backlash is out of specification, select appropriate thrust washer to ensure backlash is within
specification. Thrust washers are available in thicknesses of .037" (.95 mm) to .056" (1.40 mm)
in .002" (.05 mm) increments. Washers are stamped "A"-"K". Disassemble No. 2 differential case.
4. Clean contact surface of differential left case. Heat ring gear to approximately 212°F (100°C) in boiling
water. Carefully remove ring gear from water, clean contact surface of ring gear with cleaning solvent.
Quickly install ring gear on differential case, aligning match marks.
5. Check and adjust center differential side gear thrust clearance. Install to front differential case side, front
differential case assembly, front differential side gear, and front differential side gear thrust washer.
Install (temporarily, for reference when checking back lash) a No.2 .039" (1.0 mm) differential side gear
thrust washer. Clean contact surface of No. 2 side gear thrust washer and No. 2 differential case. Apply
plastigage to No. 2 thrust washer. See Fig. 21
. Install No. 2 differential case, and aligning match marks.
Install bolts and tighten to 91 ft. lbs. (124 N.m). Remove bolts and No. 2 differential case. Measure
plastigage at widest point. Standard clearance is .006-.010" (.16-.25 mm). Select No. 2 thrust washer
which will ensure correct backlash specification. Thrust washers are available in thicknesses of .031" (.80
mm) to .055" (1.40 mm) in .002" (.05 mm) increments. Remove No. 2 differential case, No. 2 side gear
thrust washer and temporarily install .039 " (1.0 mm) No. 2 side gear thrust washer.
6. Assemble No. 2 differential case. Install previously selected No. 2 side gear thrust washer, and conical
spring washer to front differential case. Install No. 2 differential case to No. 1 differential case, aligning
match marks. Install and tighten bolt to 91 ft. lbs. (124 N.m).
7. Adjust differential case side bearing preload. Install differential case assembly to transaxle case. Install
transmission case. Tighten bolts to specification. See TORQUE SPECIFICATIONS
. Rotate
differential case assembly right and left 2 or 3 times to allow bearings to settle. Using spring tension
gauge, measure preload. See Fig. 22
. For preload specifications, see PRELOAD SPECIFICATIONS
table. If preload is not within specification, select appropriate adjusting shim. Adjusting shims are
available in thicknesses of .079" (2.0 mm) to .096" (2.45 mm) in .002" (.05 mm) increments. Washers are
stamped "1"-"9", and "A"-"H" measuring from .098" (2.50 mm) to .112" (2.85 mm) in .002" (.05 mm)
increments.
PRELOAD SPECIFICATIONS NOTE: DO NOT mount surface of front differential case, which contacts with
bushing, in vise.
ApplicationLbs. (kg)
Starting Preload (1)
New Bearing7-14 (3.2-6.3)
Used Bearing4-9 (2.0-4.0)
(1)Plus output shaft preload.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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Sunday, November 22, 2009 10:48:07 AMPage 24 © 2005 Mitchell Repair Information Company, LLC.

Fig. 19: Measuring Backlash
NOTE: Total preload will change approximately 1.1 lbs. (.5 kg) for every .002" (.05 mm)
change in adjusting shim thickness.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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Sunday, November 22, 2009 10:48:07 AMPage 25 © 2005 Mitchell Repair Information Company, LLC.

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 20: Measuring Side Gear Thrust Clearance

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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Sunday, November 22, 2009 10:48:07 AMPage 26 © 2005 Mitchell Repair Information Company, LLC.

Fig. 21: Location Of Plastigage
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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Fig. 22: Measuring Differential Side Bearing Preload
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
TRANSAXLE REASSEMBLY
OUTPUT SHAFT BEARING PRELOAD
1. Install oil pump and gasket. Install oil pipe. Install output shaft into clutch housing. Install transmission
housing. Install and tighten bolts to 22 ft. lbs. (29 N.m). Install output shaft rear taper roller bearing outer
race. Install original adjusting shim if output shaft bearing has not been replaced. If new bearing has been
installed, install .002" (.05 mm) thinner adjusting shim. Install bearing retainer. Install rear bearing
retainer, tighten to 31 ft. lbs. (42 N.m).
2. Install lock nut onto output shaft. Rotate output shaft both directions to ensure bearings are seated. Using
torque wrench, measure output shaft starting preload. Starting preload should be 6.9-13.9 INCH lbs. (8-16
N.m) for a new bearing. If bearing has not been replaced, starting preload should be 4.3-8.7 INCH lbs. (5-
10 N.m). If starting preload is not within specification, select alternate adjusting shim. Starting preload
changes about 3.5-4.3 lbs. (4-5 kg) with each increase of shim thickness. Shims are available in .002" (.05
mm) increments. Shims range in thickness from .051" (1.30 mm) to .098" (2.50 mm). Shims are stamped
"0"-"9" and "A"-"Q". Install correct shim. Disassemble transmission.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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REASSEMBLY
1. Assembly is reverse order of disassembly. Remove output shaft. Install oil pump drive gear. Install input
and output shaft assemblies, and shift fork assemblies as single unit. Install shift fork shaft locking balls,
springs, seats and plugs. Install reverse idler gear and shaft. Align referencing marks on idler gear and
clutch housing. Place reverse shift fork pivot into reverse shift arm, and install reverse shift arm bracket to
clutch housing. Install No. 2 oil pipe. Install NEW gasket to oil pipe. See Fig. 1
.
2. Apply Three Bond (1281) sealant to transmission housing. Install transmission housing to clutch housing.
Install reverse idler gear shaft retaining bolt. Install shift shaft locking ball, spring, seat and plug. Install
snap rings onto shift fork shafts.
3. Install output shaft rear bearing outer race. Install correct adjusting shim. Install snap ring onto input shaft
rear bearing. Install rear bearing retainer. Install spacer, needle bearing and 5th gear. Install synchro ring
and key spring to No. 3 clutch hub. Using Installer (09310-17010), install No. 3 clutch hub with
synchronizer ring and key spring. See Fig. 2
.
4. Select a snap ring that will allow minimum axial play and install snap ring onto shaft. Snap rings are
available in thicknesses of .068" (1.75 mm) to .084" (2.15 mm) in .002" (.05 mm) increments. Shims are
stamped "A"-"J". See Fig. 2
.
5. Recheck 5th gear thrust clearance. Standard clearance is .004-.022" (.10-.57 mm). Install 5th driven gear.
Install No. 3 hub sleeve and No. 3 shift fork. Lock transmission in 2 gears. Install and tighten NEW lock
nut to 90 ft. lbs. (123 N.m). Stake lock nut. Unlock transmission.
6. Apply Three Bond (1281) sealant to transmission case cover. Install cover. Install shift and select lever
shaft. Install control shaft cover. Install lock bolt. Install boot onto control shaft oil seal. Ensure boot is
installed in correct direction. Position air bleed of boot downward. Install selecting bellcrank. Install
back-up light switch and speedometer driven gear. Install side gear intermediate shaft. Distance from end
of shaft to clutch housing should be 10.06" (255.5 mm).
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS NOTE: This transmission does not use gaskets between major housings, use
Three Bond (1281) sealant. Assemble housing within 20 minutes after
applying liquid gasket. Allow 30 minutes curing time before filling with oil.
ApplicationFt. Lbs. (N.m)
Back-Up Light Switch30 (40)
Bellcrank Bolt14 (20)
Clutch Release Fork Bolt35 (47)
Differential Case Bolt46 (63)
Differential Ring Gear Bolt91 (123)
Drain & Filler Plug36 (49)
Elbow-To-Transaxle Bolt20 (27)
Oil Cooler Tube-To-Elbow Bolt25 (34)
Oil Pipe Clamp13 (17)

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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Sunday, November 22, 2009 10:48:07 AMPage 29 © 2005 Mitchell Repair Information Company, LLC.

Output Shaft Lock Nut90 (123)
Rear Bearing Retainer Bolt31 (42)
Reverse Idler Shaft Lock Bolt22 (29)
Reverse Shaft Arm Bracket Bolt13 (17)
Selecting Bellcrank Support Set Bolt14 (20)
Selector Shaft Lock Bolt36 (49)
Shift Forks & Head Set Bolts17 (24)
Stiffener Plate-To-Transaxle Bolt27 (37)
Straight Screw Plug18 (25)
Transaxle Case Cover Bolt22 (29)
Transmission Case Cover Bolt22 (29)
Vehicle Speed Sensor Bolt13 (17)
INCH Lbs. (N.m)
Oil Pump-To-Cover Bolt89 (10)
Oil Tube108 (12)
Reverse Restrict Pin Holder115 (13)

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
Microsoft
Sunday, November 22, 2009 10:48:07 AMPage 30 © 2005 Mitchell Repair Information Company, LLC.