TOYOTA RAV4 1996 Service Repair Manual

Fig. 3: Adjusting Dimension Between Rear Side Of Center Bearing Housing & Rear Side Of Bracket
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REAR DRIVE AXLES
1. Raise and support vehicle. Remove rear wheel. Remove ABS sensor. Remove cotter pin and lock cap.
Depress and hold brake pedal and remove hub nut.
2. Place reference marks on rear drive axle and differential side gear shaft. Remove 4 nuts and washers.
Disconnect rear drive axle from differential side gear shaft. Remove drive axle from axle carrier.
3. To install, reverse removal procedure. Check operation of axle and ABS sensor.
COMPANION FLANGE & OIL SEAL
Removal
Remove drive shaft. See DRIVE SHAFT . Using a chisel and hammer, unstake companion flange nut. Remove
nut. Using puller, remove companion flange, oil seal and oil slinger. Discard oil seal. Using puller, remove front
bearing and spacer. Discard bearing and spacer.
Installation
1. Install NEW bearing and spacer. Install oil slinger and NEW oil seal. Drive NEW oil seal .08" (2.0 mm)
below differential case surface. Apply grease to oil seal lip. To complete installation, reverse removal

1999 Toyota RAV4
1999-2000 DRIVE AXLES Differentials, Axle Shafts & Drive Shafts -- Rear Integral Housing -- RAV4
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procedure.
2. Apply gear oil to NEW companion flange nut threads. Torque nut to specification. See TORQUE
SPECIFICATIONS . Adjust drive pinion preload. See AXLE ASSEMBLY SPECIFICATIONS . Fill
differential. See LUBRICATION
.
DIFFERENTIAL ASSEMBLY
Removal & Installation
1. Remove drive shaft. See DRIVE SHAFT . Remove rear drive axles. See AWD, FWD & RWD AXLE
SHAFTS - MR2 & RAV4 article in DRIVE AXLES.
2. Support differential with jack. Remove 2 rear mounting bolts. Remove 2 front mounting bolts. Remove
differential. Remove rear mount cushion from differential.
3. To install, reverse removal procedure. Fill differential.
OVERHAUL
REAR DRIVE AXLE
Disassembly
1. Check drive axle to ensure there is no play in outboard joint. Ensure inboard joint slides smoothly in
thrust direction and that there is no excessive play in radial direction. Check boots for damage.
2. With screwdriver, remove inboard and outboard boot clamps. Paint reference marks on inboard joint tulip
and drive axle (DO NOT use punch marks). Remove inboard joint tulip from drive axle.
3. Remove snap ring from tripod. Paint reference marks on end of drive axle and tulip. With brass bar and
hammer, remove tripod from drive axle. Use care not to tap roller.
4. Slide out both boots and 4 clamps. DO NOT disassemble outboard joint. With screwdriver and hammer,
remove No. 2 dust deflector.
Reassembly
1. Use press and adapters to install NEW No. 2 dust deflector. See Fig. 4 . Wrap tape around spline of drive
axle. Temporarily install NEW outboard and inboard joint boots.
2. Place beveled side of tripod axial spline toward outboard joint. Align reference marks. With brass bar and
hammer, tap tripod onto drive axle. Install NEW snap ring.
3. Pack inboard joint and boot with grease. Align reference marks and install inboard joint tulip to drive
axle.
4. Pack outboard joint and boot with grease. Ensure both boots and on shaft groove and that boots are not
stretched or compressed when drive axle assembly is at standard length. See Fig. 5
. See DRIVE AXLE
STANDARD LENGTH table. Install 4 NEW boot clamps. Bend clamp band and lock in place.

1999 Toyota RAV4
1999-2000 DRIVE AXLES Differentials, Axle Shafts & Drive Shafts -- Rear Integral Housing -- RAV4
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Fig. 4: Installing No. 2 Dust Deflector On Rear Drive Axle
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 5: Showing Standard Length Measurement Of Rear Drive Axle

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

1999 Toyota RAV4
1999-2000 DRIVE AXLES Differentials, Axle Shafts & Drive Shafts -- Rear Integral Housing -- RAV4
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DRIVE AXLE STANDARD LENGTH
DIFFERENTIAL ASSEMBLY
Disassembly
1. Remove differential carrier cover. Using dial indicator, check companion flange vertical and lateral
runout. Runout should not exceed .0039" (.099 mm). See Fig. 6
.
Fig. 6: Checking Companion Flange Vertical & Lateral Runout

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2. Using INCH-lb. torque wrench installed on drive pinion nut, measure drive pinion rotating torque. This
will determine drive pinion bearing preload for reassembly reference. Drive pinion rotating torque should
be within specification. See AXLE ASSEMBLY SPECIFICATIONStable.
ApplicationIn. (mm)
Left Axle23.401-23.795 (594.38-604.39)
Right Axle23.401-23.795 (594.38-604.39)

1999 Toyota RAV4
1999-2000 DRIVE AXLES Differentials, Axle Shafts & Drive Shafts -- Rear Integral Housing -- RAV4
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3. Using dial indicator, check ring gear runout at backside of ring gear while rotating ring gear. See Fig. 7 .
Replace ring gear if ring gear runout exceeds .0028" (.071 mm).
4. Using dial indicator, check ring gear backlash while rotating ring gear back and forth, and holding drive
pinion from rotating. See Fig. 7
. Check ring gear backlash at 3 different areas on ring gear. Ring gear
backlash should be .0051-.0071" (.129-.180 mm). If not, adjust side bearing preload or replace
components as necessary.
5. On all differentials check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article
in GENERAL INFORMATION.
6. On models equipped with conventional rear differential, use dial indicator to check side gear backlash
while holding one side gear against differential case. See Fig. 7
. Side gear backlash should be .0020-
.0079" (.050-.201 mm). If side gear backlash is not within specification, different thickness thrust washers
must be installed on side
gears.

1999 Toyota RAV4
1999-2000 DRIVE AXLES Differentials, Axle Shafts & Drive Shafts -- Rear Integral Housing -- RAV4
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Fig. 7: Checking Typical Ring Gear Runout, Ring Gear Backlash & Side Gear Backlash
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 DRIVE AXLES Differentials, Axle Shafts & Drive Shafts -- Rear Integral Housing -- RAV4
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Fig. 8: Exploded View Of Rear Differential Assembly
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
7. Measure total assembled preload required to rotate drive pinion and ring gear for reassembly reference.
Total assembled preload should be within specification. See AXLE ASSEMBLY SPECIFICATIONS

table.
8. Remove companion flange and oil seal from differential carrier. See COMPANION FLANGE & OIL
SEAL under REMOVAL & INSTALLATION. Remove oil slinger from front bearing. Remove spacer
from drive pinion.
9. On LSD models, use special puller to remove both side gear shafts from differential. With screwdriver,
remove snap rings from both shafts. On conventional rear differential, use needle nose pliers to remove
snap rings from inside differential carrier to remove side gear shafts. Remove shafts.

1999 Toyota RAV4
1999-2000 DRIVE AXLES Differentials, Axle Shafts & Drive Shafts -- Rear Integral Housing -- RAV4
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10. Place reference marks on differential carrier and bearing caps. Remove both bearing caps. See Fig. 8 .
11. Using side bearing replacer and a hammer, remove 2 side bearing plate washers. Measure and record
thickness of plate washers. Remove differential case. Mark location of side bearing outer races for
reassembly reference. Remove side bearing outer races from carrier.
12. Remove drive pinion from differential carrier. Press front bearing from drive pinion (if necessary). Using
hammer and brass drift, remove bearing races from differential carrier.
13. Place reference marks on ring gear and differential case. Unstake and remove ring gear bolts. Using soft-
face hammer, tap ring gear from differential case. Using puller, remove side bearings from differential
case (if necessary).
14. If disassembling differential case on models equipped with conventional rear differential, drive straight
pin from ring gear bolt side of differential case. Remove pinion shaft, side gears, pinion gears and thrust
washers. On all models, remove dust cover from side gear shafts (if necessary).
Reassembly
1. Press NEW dust cover on side gear shafts (if removed). Install side gears and thrust washers. Install
pinion gears, thrust washers and pinion shaft in differential case. Ensure hole in pinion shaft aligns with
hole for straight pin in differential case.
2. Check side gear backlash with dial indicator. See Fig. 7
. Ensure side gear backlash is within .0020-
.0079" (.050-.201 mm).
3. If side gear backlash is not within specification, install different thickness thrust washers on side gears
and recheck side gear backlash.
4. Once correct side gear backlash is obtained, install straight pin in differential case. Using hammer and
punch, stake differential case at straight pin area.
5. On all models, heat ring gear in boiling water. Remove ring gear from water and allow moisture to
evaporate. Install ring gear on differential case with reference marks aligned. Temporarily install ring
gear bolts to ensure correct alignment of ring gear. Allow ring gear to cool.
6. Once ring gear has cooled, install and tighten ring gear bolts in a crisscross pattern to specification. See
TORQUE SPECIFICATIONS
. Stake ring gear bolt plates.
7. Using press, press side bearings on differential case (if removed). Install differential case into carrier.
Install 2 plate washers to remove all play in bearings. Install bearing caps. Using a dial indicator, measure
ring gear runout. runout should be .0028" (.071 mm).
8. Remove bearing caps, plate washers and differential carrier. Press outer races into front and rear of NOTE: On models with Limited Slip Differential (LSD), manufacturer does not
recommend disassembly of differential case.
NOTE: Steps 1-4 only apply to conventional rear differential models.
CAUTION: Ring gear bolts MUST NOT be tightened to specification until ring
gear has cooled.

1999 Toyota RAV4
1999-2000 DRIVE AXLES Differentials, Axle Shafts & Drive Shafts -- Rear Integral Housing -- RAV4
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differential carrier. Install original washer onto drive pinion. Press rear bearing onto drive pinion.
9. Install drive pinion into carrier and install front drive pinion bearing. Check and adjust gear tooth contact
pattern. Assemble and install pinion spacer, oil slinger and NEW oil seal.
10. Press companion flange onto drive pinion. Coat threads of flange nut with grease. Adjusting drive pinion
preload by tightening nut, in increments, while holding flange. Tighten nut to reach starting preload of
8.7-13.9 INCH lbs. (1.0-1.6 N.m) if a NEW front bearing was installed, or 4.3-6.9 INCH lbs. (.5-.8 N.m)
if original bearing was installed.
11. Install differential case with ring gear and outer bearing races in differential carrier.
12. Install plate washer on ring gear back side only. Using a plastic hammer, tap on ring gear to snug down
washer and bearing. Using dial indicator, check ring gear backlash while rotating ring gear back and
forth, and holding drive pinion from rotating. See Fig. 7
.
13. Check ring gear backlash at 3 different areas on ring gear and record ring gear backlash. Ring gear
backlash should be .0051" (.129 mm).
14. If ring gear backlash is not within specifications, select ring gear back side plate washer to bring backlash
within specification. Select ring gear teeth side washer thick enough to eliminate any clearance between
outer race and differential case.
15. Remove teeth side plate washer and differential case. Install ring gear back side plate washer. Place outer
plate washer onto differential case, together with outer race. Install differential case with outer race into
carrier. Tap ring gear with plastic hammer to snug down washer and bearing.
16. With a dial indicator, re-measure ring gear backlash. It should be .0051-.0071" (.13-.18 mm). If not,
increase or decrease thickness of washers on both sides of ring gear by equal amount. Clearance should
exist between plate washer and case when backlash is within specification.
17. When ring gear backlash is properly adjusted, remove teeth side plate washer. With micrometer, measure
thickness of plate washer. Install NEW washer that is .0024-.0035" (.060-.088 mm) thicker than plate
washer removed. Washer should press into position about 2/3 way by hand. Use brass bar and hammer to
fully seat plate washer.
18. Align reference marks on bearing caps and carrier. Install bearing caps and tighten bolts to specification.
See TORQUE SPECIFICATIONS
. Ensure ring gear backlash is within specified range. If not, increase
or decrease thickness of washers on both sides of ring gear by equal amount.
19. Using INCH-lb. torque wrench installed on drive pinion nut, measure total assembled preload required to
rotate drive pinion and ring gear. Total assembled preload should equal amount of starting preload plus
2.6-4.3 INCH lbs. (.3-.5 N.m).
20. Check gear tooth contact pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL
INFORMATION. If gear tooth contact pattern is incorrect, install different thickness adjusting washer
located in differential carrier, behind race for front bearin
g. Recheck gear tooth contact pattern. Adjusting CAUTION: When tightening drive pinion nut, DO NOT overtighten nut, as spacer
is not installed on drive pinion. Drive pinion nut must be tightened
until correct drive pinion rotating torque is obtained.
NOTE: Backlash will change about .0008" (.020 mm) for every .0012" (.030 mm)
change in plate washer thickness.

1999 Toyota RAV4
1999-2000 DRIVE AXLES Differentials, Axle Shafts & Drive Shafts -- Rear Integral Housing -- RAV4
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washers are available in various thicknesses.
21. Remove companion flange and front bearing. Install NEW spacer on drive pinion. Install NEW front
bearing. Install oil slinger on drive pinion. Install drive pinion in differential carrier.
22. Apply grease to lip of NEW oil seal for drive pinion. Install oil seal in differential carrier until surface of
oil seal is .079" (2.01 mm) below surface of differential carrier.
23. Press companion flange onto drive pinion. Coat threads on drive pinion and NEW drive pinion nut with
gear oil. Install drive pinion nut. Hold companion flange and tighten nut to 80 ft. lbs. (108 N.m).
24. Measure preload of backlash between drive pinion and ring gear. Starting preload should be 8.7-13.9
INCH lbs. (1.0-1.6 N.m) with a NEW front bearing, or 4.3-6.9 INCH lbs. (.5-.8 N.m) with a reused
bearing.
25. If drive pinion starting preload exceeds specified range, replace bearing spacer and repeat procedure. If
starting preload is less than specified range, tighten drive pinion nut, in small increments, until specified
preload is reached. DO NOT exceed 174 ft. lbs. (236 N.m) torque on drive pinion nut. If torque is
exceeded, replace spacer and repeat procedure. DO NOT back off nut if torque is exceeded.
26. Once correct starting preload is obtained, recheck total preload, ring gear backlash, tooth contact pattern
between ring gear and drive pinion, and companion flange runout. When okay, stake drive pinion nut.
Install NEW side gear oil seals until flush with carrier end surface.
27. On models equipped with LSD, install NEW snap ring on end of side gear shafts. Coat snap rings with
grease. Using slide hammer, install side gear shafts until pinion shaft is contacted.
28. On models equipped with conventional rear differential, install side gear shafts. Install 2 NEW snap rings
into the inside of differential.
29. Clean carrier and cover contact surfaces. Apply sealant on differential carrier cover and install. Install and
tighten bolts to specification. See TORQUE SPECIFICATIONS
.
AXLE ASSEMBLY SPECIFICATIONS
AXLE ASSEMBLY SPECIFICATIONS CAUTION: When tightening drive pinion nut, DO NOT overtighten nut. Drive
pinion nut must be tightened until correct drive pinion rotating torque
is obtained.
ApplicationSpecification
Drive Pinion Rotating Torque
New Bearings8.7-13.9 INCH lbs. (1.0-1.6 N.m)
Used Bearings4.3-6.9 INCH lbs. (.5-.8 N.m)
Ring Gear Backlash.0051-.0071" (.129-.180 mm)
Ring Gear Runout.0028" (.071 mm)
Side Gear Backlash.0020-.0079" (.050-.201 mm)
Total Assembled Preload (1) 2.6-4.3 INCH lbs. (.3-.5 N.m)
(1)Add this amount to drive pinion rotating torque to obtain total preload.

1999 Toyota RAV4
1999-2000 DRIVE AXLES Differentials, Axle Shafts & Drive Shafts -- Rear Integral Housing -- RAV4
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