TOYOTA RAV4 1996 Service Repair Manual

DISC BRAKE SPECIFICATIONS
DISC BRAKE SPECIFICATIONS
ABS Actuator Mounting Nuts124 (14)
Brake Bleeder Screws74 (8.3)
Master Cylinder Piston Stopper Bolt89 (10)
Master Cylinder Reservoir Bracket-To-Body Bolt71 (8)
Piston Stopper Bolt89 (10)
Power Brake Unit Mounting Nuts115 (13)
Outer Front Cowl Panel Screws69 (7.8)
Reservoir Bracket Bolt49 (5.5)
ApplicationIn. (mm)
Land Cruiser
Front Disc
Standard Disc Thickness1.260 (32.00)
Minimum Refinish Disc Thickness1.181 (30.00)
Maximum Disc Runout.0028 (.071)
Standard Pad Thickness.453 (11.51)
Minimum Pad Thickness.039 (1.00)
Rear Disc
Standard Disc Thickness.709 (18.00)
Minimum Refinish Disc Thickness.611 (15.52)
Maximum Disc Runout.0040 (.102)
Standard Pad Thickness.472 (12.00)
Minimum Pad Thickness.039 (1.00)
Rear Parking Brake Drum (Disc)
Standard Inside Diameter9.06 (230.1)
Maximum Refinish Diameter9.09 (230.9)
Standard Lining Thickness.157 (4.00)
Minimum Lining Thickness.039 (1.00)
RAV4
Standard Disc Thickness.709 (18.00)
Minimum Refinish Disc Thickness.630 (16.00)
Maximum Disc Runout.0020 (.050)
Standard Pad Thickness.472 (12.00)
Minimum Pad Thickness.039 (1.00)
Sienna
Standard Disc Thickness1.102 (28.00)
Minimum Refinish Disc Thickness1.024 (26.00)
Maximum Disc Runout.0020 (.050)

1999 Toyota RAV4
1999-2000 BRAKES Disc & Drum - Trucks & Vans
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DRUM BRAKE SPECIFICATIONS
DRUM BRAKE SPECIFICATIONS
Standard Pad Thickness.433 (11.00)
Minimum Pad Thickness.039 (1.00)
Tacoma
(2WD)
Standard Disc Thickness.866 (22.00)
Minimum Refinish Disc Thickness.787 (20.00)
Maximum Disc Runout.0028 (.071)
Standard Pad Thickness.472 (12.00)
Minimum Pad Thickness.039 (1.00)
(4WD)
Standard Disc Thickness.866 (22.00)
Minimum Refinish Disc Thickness.787 (20.00)
Maximum Disc Runout.0028 (.071)
Standard Pad Thickness.453 (11.51)
Minimum Pad Thickness.039 (1.00)
Tundra
Standard Disc Thickness.984 (25.00)
Minimum Refinish Disc Thickness.906 (23.00)
Maximum Disc Runout.0028 (.071)
Standard Pad Thickness.374 (9.50)
Minimum Pad Thickness.039 (1.00)
4Runner
Standard Disc Thickness.867 (22.00)
Minimum Refinish Disc Thickness.787 (20.00)
Maximum Disc Runout.0028 (.071)
Standard Pad Thickness.453 (11.51)
Minimum Pad Thickness.039 (1.00)
ApplicationIn. (mm)
RAV4
Standard Diameter9.00 (228.6)
Maximum Refinish Diameter9.079 (230.60)
Standard Lining Thickness.197 (5.00)
Minimum Lining Thickness.039 (1.00)
Brake Shoe Clearance.024 (.60)
Sienna
Standard Diameter9.84 (250.0)
Maximum Refinish Diameter9.92 (252.0)

1999 Toyota RAV4
1999-2000 BRAKES Disc & Drum - Trucks & Vans
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Standard Lining Thickness.236 (6.00)
Minimum Lining Thickness.039 (1.00)
Brake Shoe Clearance.020 (.50)
Tacoma
2WD
Standard Diameter10.00 (254.0)
Maximum Refinish Diameter10.08 (256.0)
Standard Lining Thickness.217 (5.51)
Minimum Lining Thickness.039 (1.00)
Brake Shoe Clearance.024 (.60)
4WD
Standard Diameter11.61 (295.0)
Maximum Refinish Diameter11.69 (297.0)
Standard Lining Thickness.236 (6.00)
Minimum Lining Thickness.039 (1.00)
Brake Shoe Clearance.024 (.60)
Tundra
Standard Diameter11.61 (295.0)
Maximum Refinish Diameter11.69 (297.0)
Standard Lining Thickness.236 (6.00)
Minimum Lining Thickness.039 (1.00)
Brake Shoe Clearance.020 (.50)
4Runner
Standard Diameter11.61 (295.0)
Maximum Refinish Diameter11.69 (297.0)
Standard Lining Thickness.236 (6.00)
Minimum Lining Thickness.039 (1.00)
Brake Shoe Clearance.024 (.60)

1999 Toyota RAV4
1999-2000 BRAKES Disc & Drum - Trucks & Vans
Microsoft
Sunday, November 22, 2009 10:07:29 AMPage 44 © 2005 Mitchell Repair Information Company, LLC.

1999-2000 DRIVE AXLES
Center Differential Lock
DESCRIPTION & OPERATION
CENTER DIFFERENTIAL LOCK SYSTEM
The center differential lock system enables vehicle to have enough traction to move when one of the 4 wheels,
both front wheels or both rear wheels are off the ground or on a slippery surface.
Center differential lock system consists of control switch, differential lock control solenoids, differential lock
actuator, indicator switch, and integration relay. See Fig. 1
.
With control switch off, the center differential lock indicator light on instrument panel is off, along with
vacuum switching valves No. 1 and 2. Vacuum switching valve No. 1 draws vacuum from vacuum tank to
chamber "A" of the vacuum actuator. Vacuum switching valve No. 2 draws atmospheric air to chamber "B".
Under these conditions, the vacuum actuator diaphragm moves the rod, which moves the locking sleeve shift
fork and shaft, which causes the locking sleeve to disengage from the case. See Fig. 2
. During this time, the
center differential warning buzzer will sound. When the locking sleeve is completely disengaged, the warning
buzzer will turn off (free position).

1999 Toyota RAV4
1999-2000 DRIVE AXLES Center Differential Lock

1999 Toyota RAV4
1999-2000 DRIVE AXLES Center Differential Lock
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Fig. 1: Locating Center Differential Lock System Components
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
WARNING BUZZER
The warning buzzer sounds during the time the center differential lock fork moves from lock to free position
(until the center differential lock sleeve is completel
y disengaged from the differential case).

1999 Toyota RAV4
1999-2000 DRIVE AXLES Center Differential Lock
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Sunday, November 22, 2009 10:08:59 AMPage 2 © 2005 Mitchell Repair Information Company, LLC.

Fig. 2: Center Differential Lock System Schematic
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
TROUBLE SHOOTING
CENTER DIFFERENTIAL LOCK SYSTEM
1. Raise vehicle off ground so all 4 wheels can rotate. Apply parking brake and start engine. Turn center
differential lock system on.
2. Depress clutch pedal and shift into 2nd gear. With engine idling, gradually engage the clutch and ensure
engine stalls.
3. With parking brake and engine on, turn center differential lock system off. Depress clutch pedal and shift
into 2nd gear. With engine idling, gradually engage the clutch and ensure front wheels rotate.
CENTER DIFFERENTIAL LOCK INDICATOR LIGHT
Turn ignition on. Ensure indicator light is off with center differential lock system off, and on with system on.
WARNING BUZZER
1. Start en
gine and ensure warning buzzer does not sound when center differential lock switch is turned on.
NOTE: If the buzzer continues to sound, point the wheels straight ahead, accelerate or
decelerate, or drive the vehicle in reverse to stop the buzzer.

1999 Toyota RAV4
1999-2000 DRIVE AXLES Center Differential Lock
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Sunday, November 22, 2009 10:08:59 AMPage 3 © 2005 Mitchell Repair Information Company, LLC.

Change position of vacuum hoses at vacuum switching valves.
2. Turn off center differential lock switch and ensure warning buzzer sounds. Change position of vacuum
hoses at vacuum switching valves once again, and ensure buzzer stops. If buzzer operation is not as
specified, check vacuum hoses.
TESTING
CENTER DIFFERENTIAL LOCK ACTUATOR
Vacuum Tank Chamber
Disconnect vacuum hoses (except No. 1) and plug hose No. 3. See Fig. 3. Apply 20" Hg of vacuum to hose No.
0 and ensure indicator needle remains steady. Actuator may leak 1.7" Hg or less during 15 seconds.
Lock Chamber
Disconnect vacuum hoses No. 1 and 2. Apply 20" Hg of vacuum to hose No. 1 and ensure indicator needle
remains steady. Actuator may leak 1.7" Hg or less during 15 seconds.
Free Chamber
Disconnect all vacuum hoses and plug hose No. 3. Using a "T" fitting, apply 20" Hg of vacuum to hoses No. 0
and 2. Ensure indicator needle remains steady. Actuator may leak 1.7" Hg or less during 15 seconds. NOTE: If actuator operation is not as specified, replace actuator.

1999 Toyota RAV4
1999-2000 DRIVE AXLES Center Differential Lock
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Sunday, November 22, 2009 10:08:59 AMPage 4 © 2005 Mitchell Repair Information Company, LLC.

Fig. 3: Testing Center Differential Lock Actuator
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
CENTER DIFFERENTIAL LOCK CONTROL SWITCH
With switch off, ensure continuity exists between terminals No. 7 and 10. See Fig. 4
. With switch on, ensure
continuity exists between terminals No. 7 and 8. Continuity must exist between switch terminals No. 2 and 3 at
all times (switch illumination circuit). Check bulb or replace switch if continuit
y is not as specified.

1999 Toyota RAV4
1999-2000 DRIVE AXLES Center Differential Lock
Microsoft
Sunday, November 22, 2009 10:08:59 AMPage 5 © 2005 Mitchell Repair Information Company, LLC.

Fig. 4: Testing Center Differential Lock Control Switch
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
CENTER DIFFERENTIAL LOCK INDICATOR LIGHT SWITCH
With switch off (released), ensure no continuity exists between switch terminals No. 1 and No. 2. With switch
on (pushed in), ensure continuity exists between switch terminals No. 1 and No. 2. Replace indicator light
switch if continuity is not as specified.
CENTER DIFFERENTIAL LOCK SOLENOID
Disconnect connector from solenoids No. 1 and No. 2. Check for continuity to each port. Apply battery voltage
to vacuum switching valve terminals and check air flow across passage ports. Disconnect battery voltage and
ensure air flow across passage ports changes. Replace center differential lock solenoid if necessary.
INTEGRATION RELAY
1. Connect positive battery voltage to terminals No. 12 and No. 20. Connect negative battery voltage to
terminal No. 11. See WIRING DIAGRAMS
.
2. Ensure bulb lights up and buzzer sounds for 4-8 seconds. Repeat step 1 . Connect positive battery voltage
to terminal No. 20. Ensure buzzer stops sounding.

1999 Toyota RAV4
1999-2000 DRIVE AXLES Center Differential Lock
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Sunday, November 22, 2009 10:08:59 AMPage 6 © 2005 Mitchell Repair Information Company, LLC.

3. Inspect integration relay circuit. Remove relay from combination meter. Check connectors for damage or
corrosion. Connect voltmeter between relay terminal No. 12 and ground. Turn ignition switch and
differential lock control switch ON. Battery voltage should be present. Turn ignition switch ON and
differential lock control switch OFF. Voltage should not be present.
4. Connect voltmeter between relay terminal No. 20 and ground. Turn ignition switch ON and differential
lock control switch OFF. Battery voltage should be present. Turn ignition off. Voltage should not be
present. If any circuit fails test, replace relay.
WIRING DIAGRAMS

1999 Toyota RAV4
1999-2000 DRIVE AXLES Center Differential Lock
Microsoft
Sunday, November 22, 2009 10:08:59 AMPage 7 © 2005 Mitchell Repair Information Company, LLC.