check oil TOYOTA RAV4 1996 Service Repair Manual

1. Insert column hole cover No. 2. Align match marks on column assembly and No. 2 "U" joint assembly.
Install bolt to connect No. 2 "U" joint assembly.
2. Install column assembly with No. 2 "U" joint assembly. Install 4 steering column set nuts. Connect
connectors. On models equipped with A/T, connect transmission control cable assembly to shift lever
assembly.
3. Align match marks on No. 2 "U" joint assembly and No. 2 intermediate shaft assembly. Align match
marks on control valve shaft and No. 2 intermediate shaft assembly. Install "A" and "B" bolts.
4. Install brake pedal return spring and No. 2 heater to register duct. Install lower finish panel with 4 bolts.
Connect hood lock release lever with 2 screws. Install spiral cable. See SPIRAL CABLE
under
ADJUSTMENTS. Install combination switch with 3 screws. Connect air bag and connectors.
5. Install lower and upper column covers with 3 screws. Ensure tires are in straight-ahead position. Turn
cable counterclockwise until there is resistance. Rotate cable clockwise 2.5 turns to align mark.
6. To install steering wheel, align match marks on wheel and main shaft. Install wheel set nut. Connect
connector. Install steering wheel pad. Connect air bag connector. Install wheel pad when Torx screw is
set in screw case. Using a Torx socket wrench, torque 2 screws to 78 INCH lbs. (8.8 N.m). Install 2
steering wheel lower No. 2 covers. Check steering wheel center point.
7. Tighten all bolts to specifications. See TORQUE SPECIFICATIONS
. Ensure spiral cable is properly
installed and adjusted. See SPIRAL CABLE
under ADJUSTMENTS.
Removal & Installation (4Runner)
1. Disconnect negative battery cable. Remove steering wheel. See STEERING WHEEL & AIR BAG .
Remove upper and lower column covers. See Fig. 4
. Remove left-side lower finish panel. Remove starter
switch bezel. Remove No. 2 heater to register duct from under steering column.
2. Remove combination switch with spiral cable. Remove spiral cable. Remove brake pedal return spring.
Mark intermediate shaft No. 2, "U" joints No. 2 and control valve for installation reference. Remove
intermediate shaft No. 2 and bolts. Remove column hole cover and column hole cover No. 2 set bolt.
3. Remove steering column assembly with "U" joint No. 2. Disconnect "U" joint No. 2. To install, reverse
removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS
.
OVERHAUL
STEERING COLUMN
Disassembly (Land Cruiser)
1. Remove No. 2 lower cover. Mark shaft assembly and main shaft assembly for reassembly reference.
Remove intermediate shaft assembly. See Fig. 6
. Remove transponder key coil with key cylinder lamp
assembly. Remove key cylinder lamp assembly.

1999 Toyota RAV4
1999-2000 STEERING Steering Columns - Tilt Wheel - Trucks & Vans
Microsoft
Sunday, November 22, 2009 10:34:02 AMPage 12 © 2005 Mitchell Repair Information Company, LLC.

nut.
Disassembly (Transfer Right Case Retainer)
Using a screwdriver, remove oil seal. Remove snap ring. Remove side gear shaft holder with a plastic hammer.
Remove snap ring. Using an arbor press, remove holder bearing. Remove oil seal. See Fig. 4
.
Fig. 4: Exploded View Of Transfer Right Case Retainer

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Reassembly
Using press, install holder bearing. Install snap ring. Install side gear shaft holder. Install snap ring. Coat oil seal
lip with grease. Install left side oil seal. Install right side oil seal.
Disassembly (Transfer Right Case)
Check oil pump operation. Oil pump should turn smoothly with oil pump driven gear. Remove 3 bolts and oil
pump driven gear stopper. Remove oil pump cover, drive rotor and driven rotor. Remove relief valve and
spring. See Fig. 5
.

1999 Toyota RAV4
1999 TRANSFER CASES Toyota A-540H Overhaul
Microsoft
Sunday, November 22, 2009 10:49:16 AMPage 7 © 2005 Mitchell Repair Information Company, LLC.

6. Remove right case. Remove ring gear mounting case and center differential case. Remove driven pinion
bearing cage assembly. Using Oil Seal Puller (09308-00010), remove outer race and plate washer.
7. Using Bearing Replacer (09316-60010), install NEW oil seal. Oil seal depth is .12" (3 mm). Coat lip of
oil seal with grease. Install plate washer. Using Bearing Replacer (09316-60010) and an arbor press,
install left case bearing outer race.
8. Coat "O" ring with gear oil and install on driven pinion bearing cage assembly. Install driven pinion
bearing cage with adjusting shim to transfer left case. Install 6 bolts. Tighten bolts to 29 ft. lbs. (39 N.m).
Install ring gear mounting case and center differential case.
9. Install NEW apply gasket to left case. Coat "O" ring with gear oil. Install "O" ring to oil pump strainer.
Install strainer to right case. Install bolts. Tighten to 48 INCH lbs. (5.4 N.m) Install oil pump driven gear.
Apply Sealant (Three Bond 1281) to left case. Install right case as soon as seal packing is applied. Install
right case to left case. Install 10 bolts. Tighten to 32 ft. lbs. (44 N.m). Check total preload as shown in
step 3 .
10. Install lock plate so projection from lock plate fits properly into groove of adjusting nut. When lock plate
cannot be installed, tighten adjusting nut smallest amount possible. Coat NEW "O" ring with gear oil.
Install "O" ring on lock bolt. Install and tighten lock nut to 62 INCH lbs. (7 N.m).
11. Apply Sealant (Three Bond 1281) to left case. Install inspection hole cover as soon as seal packing is
applied. Install hole cover to transfer left case. Install 3 bolts. Tighten to 12 ft. lbs. (16 N.m).
12. Coat NEW "O" ring with gear oil. Install "O" ring and NEW apply gasket. Install right case retainer to
transfer right case. Install 5 bolts. Tighten bolts to 21 ft. lbs. (29 N.m).
13. Install NEW oil seal in extension housing. Coat lip of oil seal with grease. Install NEW "O" ring in
extension housing. Install extension housing to driven pinion bearing cage. Install 4 bolts. Tighten to 18
ft. lbs. (25 N.m). Using a hammer, install dust deflector (if equipped). Install dynamic damper. Tighten to
18 ft. lbs. (25 N.m).
14. Install NEW "O" ring on speed sensor. Install speed sensor to transfer left case. Tighten to 48 INCH lbs.
(5.4 N.m). Install transfer mode selector lever, rod and lever guide (if equipped). Tighten 2 lever bolts to
96 INCH lbs. (11 N.m). Tighten guide bolt to 48 INCH lbs. (5.4 N.m).
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
Case-To-Case Bolts33 (44)
Differential Switch30 (40)
Drain Plug29 (39)
Dynamic Damper Bolts18 (25)
Extension Housing Bolts18 (25)
Inspection Cover Bolts12 (16)
Pinion Bearing Cage Bolts29 (39)
Shift Fork Bolt12 (16)

1999 Toyota RAV4
1999 TRANSFER CASES Toyota A-540H Overhaul
Microsoft
Sunday, November 22, 2009 10:49:16 AMPage 19 © 2005 Mitchell Repair Information Company, LLC.