length TOYOTA RAV4 1996 Service User Guide

Fig. 4: Identifying Transmission Oil Pan Drain Plugs (Pickup 4WD With 3.0L V6 & 1995 4Runner 4WD
With V6)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Transmission (All Others)
1. Remove transmission oil pan drain plug from transmission oil pan. Allow fluid to fully drain. If replacing
transmission oil strainer, remove transmission oil pan and gasket.
2. Remove bolts, transmission oil strainer and gasket (if equipped). Thoroughly clean transmission oil pan.
Using NEW gasket (if equipped), install transmission oil strainer. Install and tighten bolts to
specification. See TORQUE SPECIFICATIONS
.
3. Using NEW gasket, install transmission oil pan (if removed). Install and tighten bolts to specification See
TORQUE SPECIFICATIONS
. Fill transmission through dipstick tube to specified capacity using
recommended fluid. See RECOMMENDED FLUID
under LUBRICATION.
4. Ensure vehicle is on a level surface. Apply parking brake. Start engine and apply brakes. Move gearshift
from Park through Low and back to Park.
5. Check fluid level on transmission dipstick. Add proper type fluid so fluid level is at the COOL range
marked on the dipstick. Operate vehicle to normal operating temperature and recheck. See CHECKING
FLUID LEVEL under LUBRICATION.
Transmission Differential (Avalon, Camry, Celica 2.2L 5S-FE, Corolla 1.6L 4A-FE & Tercel 3-Speed)
1. Remove oil filler and drain plugs from differential. See Fig. 1 . Allow fluid to drain. Reinstall drain plug.
2. Fill differential through oil filler plug hole to specified capacity using recommended fluid. See
RECOMMENDED FLUID
under LUBRICATION. Ensure fluid is level with bottom edge of filler plug
hole. Reinstall filler plug.
Transfer Case (Land Cruiser, Pickup, Previa, Tacoma, T100 & 4Runner)
1. Remove filler plug located on rear of transfer case. Remove drain plug from bottom of transfer case.
Allow fluid to drain. Reinstall drain plug.
2. Fill transfer case through oil filler plug hole to specified capacity using recommended fluid. See
RECOMMENDED FLUID
under LUBRICATION. Ensure fluid is level with bottom edge of filler plug
hole. Reinstall filler plug.
Transfer Case (RAV4)
1. Remove drain plug from bottom of transfer case. Allow fluid to drain. Reinstall drain plug. Fill transfer
case through transfer case oil dipstick tube to specified capacity using recommended fluid. See
RECOMMENDED FLUID
under LUBRICATION.
2. Check fluid level on transfer case dipstick. Fluid level should be in the LOW to HIGH range. Add fluid if CAUTION: When removing transmission oil strainer, note bolt size and length
for reassembly reference.

1996 Toyota 4Runner
TRANSMISSION SERVICING - A/T AUTOMATIC TRANSMISSION SERVICING Toyota
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2. Using a press, install bearing assembly on axle shaft. Install NEW snap ring. Press NEW dust cover
against bearing, leaving .039" (1.0 mm) between bearing and dust cover.
3. Using a press, install NEW dust cover onto axle shaft. Right-side (transaxle side) dust cover must be
positioned 3.39-3.43" (86.0-87.0 mm) from end of axle shaft. Wrap splines on axle shaft with tape to
prevent damaging boots during installation. Install NEW boots and NEW boot clamps onto axle shaft.
4. Apply grease supplied with overhaul kit to outboard joint and boot. Install boot and boot clamps onto
outboard joint.
5. Install inboard tripod joint onto axle shaft, with reference mark aligned. Using a hammer and brass drift,
drive on inner race until fully seated on axle shaft. DO NOT allow brass drift to contact cage on inboard
tripod joint during installation.
6. Install NEW snap ring on end of axle shaft. Apply grease supplied with overhaul kit into inboard joint
housing and boot.
7. Install boot on inboard joint cover. Ensure boots are seated in grooves on axle shaft. Adjust axle shaft to
standard axle shaft length. See AXLE SHAFT LENGTH SPECIFICATIONS
. See Fig. 7 . Install and
tighten boot clamps.
Fig. 7: Measuring Axle Shaft Length (Front)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation
1. To install, reverse removal procedure. Before installing axle shafts, install NEW snap ring on end of axle
shaft (except ri
ght side on FWD). Coat axle shaft seals in transaxle with grease. Coat axle shaft splines

1999 Toyota RAV4
1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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and sliding surfaces with Dexron-II. Position snap ring on end of axle shaft, with opening facing
downward.
2. Install axle shaft by lightly tapping axle shaft into transaxle. Ensure axle shaft will move inward and
outward approximately .079-.120" (2.00-3.00 mm), and cannot be pulled from transaxle.
3. To install remaining components, reverse removal procedure. Tighten remaining bolts/nuts to
specification. See TORQUE SPECIFICATIONS
. Fill transaxle with Dexron-II (A/T models), or 75W-
90 gear oil with API GL-3, GL-4 or GL-5 rating (M/T models).
Disassembly (FWD M/T)
1. Remove boot clamps, and slide boots from joints. Paint reference marks on outer race and axle shaft for
reassembly reference. See Fig. 6
.
2. Using a screwdriver, remove snap ring from outer tulip race. Remove outer tulip race from inner joint and
axle shaft. Remove snap ring from end of axle shaft retaining inner joint. Paint reference marks on inner
joint, outer cage and axle shaft for reassembly reference.
3. Remove 6 balls and cage. Using a hammer and brass drift, tap inner joint from axle shaft. Remove inner
snap ring. Remove boots from axle shaft. Using a press, remove dust cover from right-side axle shaft.
Using a press and bearing splitter, remove dust cover from left-side inner joint tulip.
4. Disassemble right-side center axle shaft. Using snap ring pliers or a screwdriver, remove snap ring. Using
a press, remove bearing from axle. Using a screwdriver and hammer, remove outer dust deflector from
axle shaft.
Reassembly
1. Using a press, install NEW dust deflector on outboard end of axle shaft. Install NEW snap ring, then
press center bearing on axle shaft. Press NEW dust cover against bearing. On FWD M/T models,
clearance should be .039" (1.0 mm) between bearing and dust cover. On FWD A/T and AWD models,
clearance should be 3.39-3.43" (86-87 mm) between bearing and dust cover.
2. Using a press, install NEW dust cover on axle shaft. Right-side (transaxle side) dust cover must be
positioned 4.134-4.173" (105.0-106.0 mm) from end of axle shaft. Wrap splines on axle shaft with tape to
prevent damaging boots during installation.
3. Install NEW boots and NEW boot clamps on axle shaft. Install NEW snap ring on axle shaft. Install
inboard joint on axle shaft with small diameter side facing outboard joint. Ensure reference mark on inner
joint and axle shaft are aligned. Install NEW snap ring that retains inner joint on axle shaft.
4. Position outer cage and 6 balls on inner joint, and hold in place with grease. Apply grease supplied with
overhaul kit to inner joint and boot. Install inboard joint tulip (center shaft) on inner joint. Ensure match-
marks are aligned. Install NEW snap ring.
5. Apply grease supplied with overhaul kit into outer joint and boot. Install boot on inner housing and outer
joint. Ensure boots are seated in grooves on axle shaft. Adjust axle shaft to standard axle shaft length. See
AXLE SHAFT LENGTH SPECIFICATIONS
. See Fig. 7 . Install and tighten boot clamps to a
clearance of .047-.157" (1.2-4.0 mm).
Installation
NOTE: Manufacturer does not recommend overhaul of outer joint assembly.

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1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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reassembly reference.
2. Remove outer race from inboard tripod joint and axle shaft. Remove snap ring from end of axle shaft that
retains inboard tripod joint. Paint reference marks on tripod joint and axle shaft for reassembly reference.
3. Using a hammer and brass drift, tap inboard tripod joint from axle shaft. DO NOT tap on roller of tripod
joint during removal. Remove boots from axle shaft. Using a screwdriver and hammer, remove dust
deflector from axle shaft.
Reassembly
1. Using a press, install NEW dust deflector on left side axle shaft. Wrap splines on axle shaft with tape to
prevent damaging boots during installation. Using a punch and hammer, install straight pin onto center
bearing case on right side axle shaft. Press center bearing into bearing case. Install center bearing and
bearing case assembly to inboard joint shaft. Right side dust cover must be positioned so there
is .039" (1.0 mm) between dust cover and bearing assembly.
2. Install NEW boots and NEW boot clamps on axle shaft. Install NEW snap ring on axle shaft. Install
inboard tripod joint on axle shaft, with small diameter side facing outboard joint. Ensure reference mark
on inboard joint and axle shaft are aligned. Install NEW snap ring that retains inboard tripod joint on axle
shaft.
3. Apply grease supplied with overhaul kit to inner joint and boot. Install outer joint tulip on inner joint.
Ensure match-marks are aligned.
4. Apply grease supplied with overhaul kit into outer joint and boot. Install boot on inner housing and outer
joint. Ensure boots are seated in grooves on axle shaft. Adjust axle shaft to standard axle shaft length. See
AXLE SHAFT LENGTH SPECIFICATIONS
. See Fig. 9. Install and tighten boot clamps.

1999 Toyota RAV4
1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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Fig. 9: Measuring Axle Shaft Length (Rear)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation
To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .
After installation, check ABS speed sensor signal and wheel alignment.
Removal RAV4
1. Raise and support vehicle. Remove rear wheels. Drain differential oil into proper container. Remove ABS
speed sensor (if equipped). Remove cotter pin and lock cap. Apply brakes and remove nut.
2. Place match-marks on axle shaft flange and differential flange for installation reference. Remove 4 nuts
and washers. Using a plastic hammer, tap axle shaft from rear hub. Remove rear axle. See Fig. 10
.

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1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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retaining inboard tripod joint. Paint reference marks on tripod joint and axle shaft for reassembly
reference.
3. Using a hammer and brass drift, tap inboard tripod joint from axle shaft. DO NOT tap on roller of tripod
joint during removal. Remove boots from axle shaft. Using a screwdriver and hammer, remove dust
deflector from axle shaft.
Reassembly
1. Using a press, install NEW dust deflector on axle shaft. Wrap splines on axle shaft with tape to prevent
damaging boots during installation.
2. Install NEW boots and NEW boot clamps on axle shaft. Install NEW snap ring on axle shaft. Install
inboard tripod joint on axle shaft, with small diameter side facing outboard joint. Ensure reference mark
on inboard joint and axle shaft are aligned. Install NEW snap ring that retains inboard tripod joint on axle
shaft.
3. Apply grease supplied with overhaul kit to inner joint and boot. Install outer joint tulip on inner joint.
Ensure match-marks are aligned.
4. Apply grease supplied with overhaul kit into outer joint and boot. Install boot on inner housing and outer
joint. Ensure boots are seated in grooves on axle shaft. Adjust axle shaft to standard axle shaft length. See
AXLE SHAFT LENGTH SPECIFICATIONS
. See Fig. 11 . Install and tighten boot clamps.
Fig. 11: Measuring Axle Shaft Length (Rear)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation
To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .
After installation, check ABS speed sensor si
gnal and wheel alignment.

1999 Toyota RAV4
1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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AXLE SHAFT LENGTH SPECIFICATIONS
FRONT AXLE SHAFT LENGTH SPECIFICATIONS (FWD A/T & AWD)
FRONT AXLE SHAFT LENGTH SPECIFICATIONS (FWD M/T)
REAR AXLE SHAFT LENGTH SPECIFICATIONS
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationIn. (mm)
2WD A/T (1)
Left Side21.40-21.80 (543.50-553.50)
Right Side33.05-33.45 (839.60-849.60)
4WD (1)
Left Side19.80-20.197 (503.00-513.00)
Right Side19.93-20.32 (506.22-516.13)
(1)Measure axle shaft length between inner joint flange and outer joint flange. See Fig. 7 .
ApplicationIn. (mm)
2WD M/T (1)
Left Side21.165-21.559 (537.60-547.60)
Right Side32.988-33.382 (837.90-847.90)
(1)Measure axle shaft length between inner joint flange and outer joint flange. See Fig. 7 .
ApplicationIn. (mm)
MR2 (1)
Left Side22.26-22.65 (565.4-570.6)
Right Side31.85-32.25 (809.1-819.1)
RAV4 (2)
Left Side21.590-21.984 (548.39-558.39)
Right Side23.401-23.795 (594.39-604.39)
(1)Measure axle shaft length between inner joint flange and outer joint flange. See Fig. 9 .
(2)Measure axle shaft length between inner joint flange and outer joint flange. See Fig. 11 .
ApplicationFt. Lbs. (N.m)
MR2
ABS Speed Sensor Bolt(1)
Axle Shaft Nut159 (216)
Brake Flex Hose Bracket Bolt21 (29)

1999 Toyota RAV4
1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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applied. See PARKING BRAKE LEVER STROKE SPECIFICATIONS table. Adjust parking brake
if travel is not within specification.
PARKING BRAKE LEVER STROKE SPECIFICATIONS
2. On Land Cruiser, loosen lock nut, and rotate turnbuckle until lever travel is correct. Tighten lock nut.
3. On RAV4, remove rear console box. Loosen lock nut and turn adjusting nut until lever travel is correct.
Tighten lock nut. Install rear console box.
4. On Sienna, release parking brake pedal. Loosen lock nut. Hold equalizer and turn adjusting nut until
pedal travel is correct.
5. On Tacoma (2WD) Tundra (2WD), tighten adjusting nut until travel is correct. Tighten lock nut. Confirm
that rear brakes are not dragging.
6. On Tacoma (4WD) and Tundra (4WD), tighten one of the adjusting nuts of the intermediate lever.
Loosen other nut until travel is correct. Tighten 2 adjusting nuts. Confirm that bell crank stopper screw
comes into contact with backing plate.
7. On 4Runner, remove console box. Loosen adjusting nut until lever travel is correct. Tighten lock nut.
Install console box.
PARKING BRAKE SHOES
Land Cruiser (With Rear Disc Brakes)
Raise and support rear of vehicle. Release parking brake. Remove adjustment hole plug from backing plate.
Turn adjuster until parking brake shoes lock wheel. Back adjuster off 8 notches. Install hole plug.
POWER BRAKE UNIT PUSH ROD
1. Install adjusting gauge on master cylinder with master cylinder gasket in place. Lower adjusting gauge
pin until pin slightly touches master cylinder piston. Perform STEP 1. See Fig. 2
. Turn adjusting gauge
upside down and install on power brake unit.
2. Measure clearance between power brake unit push rod and adjusting gauge pin head. Measured clearance
should be zero on all models except Sienna. On Sienna, clearance should be .014" (.35 mm). Perform
STEP 2. See Fig. 2
. If clearance is not as specified, adjust brake booster push rod length until push rod
li
ghtly touches adjusting gauge pin head.
ApplicationNotches
Land Cruiser4-6
RAV45-8
Sienna3-5
Tacoma12-18
Tundra5-8
4Runner7-9

1999 Toyota RAV4
1999-2000 BRAKES Disc & Drum - Trucks & Vans
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3. Adjust rear pressure by changing length of No. 2 shackle (if necessary). See Fig. 3 . To increase rear
pressure reading, increase distance "A". To decrease rear pressure reading, decrease distance "A".
4. Repeat pressure tests after adjusting shackle length. If rear pressures fail specification after adjustment,
reposition valve body. Raise valve body if rear pressures are too high, lower valve body if rear pressures
are too low.
5. Ensure No. 2 shackle length is within adjustment range. If shackle is removed or replaced, adjust No. 2
shackle to standard length. See NO. 2 SHACKLE LENGTH SPECIFICATIONS
table.
Fig. 3: Measuring LSPV No. 2 Shackle Length (Tacoma Shown; Tundra Similar)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
NO. 2 SHACKLE LENGTH SPECIFICATIONS
2WD1138 (80)640-782 (45-55)
4WD1138 (80)569-711 (40-50)
Tundra1138 (80)670-812 (47-57)
4Runner996 (70)393-563 (28-40)
Application
Standard Length - In.
(mm)Adjustment Range - In.
(mm)
Tacoma

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6. If pressures cannot be adjusted to specification, check valve housing. Position valve body in uppermost
position. Apply brakes and record rear brake pressures. See VALVE BODY ADJUSTMENT
PRESSURE SPECIFICATIONS (TACOMA & TUNDRA) table. If measured value does not meet
specification, replace valve assembly.
VALVE BODY ADJUSTMENT PRESSURE SPECIFICATIONS (TACOMA & TUNDRA)
4Runner
1. For testing purposes, rear axle is loaded to a specified weight. Set total rear axle weight to specified
amount. See LSPV REAR AXLE TEST WEIGHT
table.
2. Attach pressure gauge set to front caliper and rear wheel cylinder. Bleed air from system. See
BLEEDING BRAKE SYSTEM
. Depress brake pedal until front pressure is as specified. See LSPV
PRESSURE SPECIFICATIONS table. Wait 2 seconds and record rear pressure reading.
3. Adjust rear pressure by changing length "A" or "B". See Fig. 4
. To increase rear pressure reading,
decrease distance "A" or "B". To decrease rear pressure reading, increase distance "A" or "B". If valve
cannot be adjusted to specification, replace valve assembly.
2WD3.07 (78)2.83-3.31 (72-84)
4WD4.72 (120)4.49-4.96 (114-126)
Tundra4.72 (120)4.41-5.04 (112-128)
Application
Front Pressure - psi
(kg/cm
2 )
Rear Pressure - psi
(kg/cm
2 )
Tacoma
2WD
1st Reading285 (20)285 (20)
2nd Reading570 (40)327-384 (23-27)
3rd Reading998 (70)412-512 (29-36)
4WD
1st Reading213 (15)213 (15)
2nd Reading570 (40)256-313 (18-22)
3rd Reading998 (70)320-420 (23-30)
Tundra
1st Reading213 (15)213 (15)
2nd Reading569 (40)263-377 (19-27)
3rd Reading1990 (140)682-852 (48-60)
NOTE: DO NOT depress brake pedal more than once or release pedal while
setting pressure on front gauge.
NOTE: To adjust pressure, turning adjusting nut one complete turn (360 degrees) will
change pressure 14 psi (1.0 kg/cm
2 ). If adjusting nut is moved up or

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1999-2000 BRAKES Disc & Drum - Trucks & Vans
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