service TOYOTA RAV4 1996 Service Manual PDF

System
2 - DOME 15 Amp Personal Lights, Open Door Warning Light, Clock
3 - EFI 15 Amp Multiport Fuel Injection System/Sequential Multiport Fuel Injection System
4 - HAZ-HORN 15 Amp Emergency Flashers, Horns
5 - ALT-S 5 Amp Charging system
6 - SPARE 15 Amp Spare fuse
7 - SPARE 7.5 Amp Spare fues
8 - H-LP (LH) 15 Amp Left-Hand Headlight
9 - H-LP (RH) 15 Amp Right-Hand Headlight
10 - DRL 7.5 Amp Daytime Running Light System
11 - H-LP LH-L 10 Amp Left Hand Headlight (Low Beam)
12 - H-LP RH-L 10 Amp Right Hand Headlight (Low Beam)
13 - H-LP LH-H 10 Amp Left Hand Headlight (High Beam)
14 - H-LP RH-H 10 Amp Right Hand Headlight (High Beam)
15 - TAIL 10 Amp Tail Lights, Parking Lights, License Plate Lights, Interior Lights
16 - GAUGE 10 Amp Gauges And Meters, Service Reminder Indicators (Except Discharge And Open
Door Warning Lights), Back-up Lights, Air Conditioning System, Power Windows, Rear Window
Defogger, Center Differential Lock System, Electronically Controlled Automatic Transaxle System
17 - TURN 7.5 Amp Turn Signal Lights
18 - CIG & RAD 15 Amp Cigarette Lighter, Clock, Car Audio System, Power Rear View Mirrors
19 - DEF-I/UP 7.5 Amp Multiport Fuel Injection System/Sequential Multiport Fuel Injection System
20 - IGN 7.5 Amp Multiport Fuel Injection System/Sequential Multiport Fuel Injection System,
Discharge Warning Light
21 - ECU-IG 7.5 Amp Anti-Lock Brake Syste, Electronically Controlled Automatic Transmission
System
22 - WIPER 20 Amp Windshield Wipers And Washer, Rear Window Wiper And Washer
23 - SRS 7.5 Amp SRS Airbag System
24 - OBD 7.5 Amp On-Board Diagnostic System
25 - STOP 10 Amp Stop Lights
26 - A/C 7.5 Amp Air Conditioning System
27 - MAIN No. 1 30 Amp Starting System, Headlights
28 - RDI FAN 30 Amp Electric Cooling Fan
29 - CDS FAN 30 Amp Electric Cooling Fan
30 - POWER 30 Amp Power Windows, Power Door Lock System
31 - DEF 30 Amp Rear Window Defogger
32 - AM 1 40 Amp CIG & RAD, WIPER, GAUGE, ECU-IG, TURN, TAIL, and PANEL fuses
33 - MAIN 80 Amp AM 2, HAZ-HORN, EFI, DOME, RADIO and ALT-S fuses
34 - ALT 100 Amp Tail lights, ABS, RADIO, HTR, AM 1, POWER, STOP and DEF fuses

1999 Toyota RAV4
MAINTENANCE INFORMATION 1997-99 MAINTENANCE Toyota Maintenance Information
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35 - HTR 50 Amp Air Conditioning system
36 - ABS 60 Amp Anti-Lock brake system
Fuse & Circuit Breaker Identificatio - 1998
1 - H-LP (LH) 15 Amp Left-Hand Headlight
2 - H-LP (RH) 15 Amp Right-Hand Headlight
3 - SPARE 10 Amp Spare fuse
4 - SPARE 15 Amp Spare fuse
5 - AM2 5 Amp Multiport Fuel Injection System/Sequential Multiport Fuel Injection System, SRS
Airbag System, Seat Belt Pretensioners, Starting System, Discharge Warning Light
6 - ALT-S 5 Amp Charging system
7 - HAZ 10 Amp Emergency Flashers
8 - EFI 20 Amp (USA) or 15 Amp (Canada)Multiport Fuel Injection System/Sequential Multiport Fuel
Injection System
9 - DOME 15 Amp Personal Lights, Open Door Warning Light, Clock
10 - IGN 20 Amp Charging System
11 - H-LP LH-H 10 Amp Left Hand Headlight (High Beam)
12 - H-LP RH-H 10 Amp Right Hand Headlight (High Beam)
13 - H-LP LH-L 10 Amp Left Hand Headlight (Low Beam)
14 - H-LP RH-L 10 Amp Right Hand Headlight (Low Beam)
15 - SEAT-HTR 10 Amp No Circuit
16 - PWR OUTLET 15 Amp Power Outlet
17 - CIG 15 Amp Cigarette Lighter, Clock, Car Audio System, Power Rear View Mirrors, Electronically
Controlled Automatic Transmission
18 - SRS-SCC 10 Amp SRS Airbag System, Seat Belt Pretensioners
19 - WIPER 20 Amp Windshield Wipers And Washer, Rear Window Wiper And Washer
20 - ECU-IG 10 Amp Electronically Controlled Automatic Transmission System, Rear Window
Defogger, Center Differential Lock System, Electric Moon Roof, Multiport Fuel Injection System,
Electric Cooling Fan, Anti-Lock Brake System, Cruise Control System
21 - TURN & GAUGE 10 Amp Turn Signal Lights, Gauges & Meters, Back-Up Lights, Service
Reminder Indicators, Air Conditioning System, Daytime Running Light System
22 - STOP 10 Amp Stop Lights, High Mounted Stop Light, Electronically Controlled Automatic
Transmission System, Anti-Lock Brake System
23 - TAIL 15 Amp Gauges & Meters, Emergency Flashers, Cigarette Lighter, Center Differential Lock
System, Clock, Rear Window Defogger, Air Conditioning System, Electronically Controlled Automatic
Transmission System, Car Audio System, Tail Lights, License Plate Lights, Parking Lights, Instrument
Panel Light Control, Side Marker Lights
24 - OBD 10 Amp On-Board Diagnosis System
25 - SRS-B 10 Amp SRS Air Bag Warning Light

1999 Toyota RAV4
MAINTENANCE INFORMATION 1997-99 MAINTENANCE Toyota Maintenance Information
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Sunday, November 22, 2009 10:32:42 AMPage 27 © 2005 Mitchell Repair Information Company, LLC.

1999 MANUAL TRANSMISSIONS
Toyota E250 & E250F 5-Speed Overhaul
APPLICATION
TRANSAXLE APPLICATIONS
IDENTIFICATION
Transmission type is identified by ID label located on driver-side door post.
DESCRIPTION
Transaxle design incorporates transmission, center differential, front differential and transfer case (4WD
models). Transmission is shifted by a pair of push-pull cables. These cables provide positive shift feel and
absorb transmission and engine vibrations. The E250F utilizes a full-time transfer case with a limited slip
viscous coupling. Both the E250 and E250F have a center differential, which compensates for difference
between the rotational speed of the front and rear wheels.
ADJUSTMENTS
LUBRICATION
Remove filler plug from side of transmission. Fluid should be level with bottom of filler opening. If fluid is low,
fill until level is correct. Use SAE 75W/90 API GL-4 or GL-5 gear oil for 2WD models, or SAE 75W/90 API
GL-5 gear oil for 4WD models. Capacity is 4.1 qts. (3.9L) for 2WD models, or 5.3 qts. (5.0L) for 4WD models.
ON-VEHICLE SERVICE
AXLE SHAFTS
See appropriate AXLE SHAFTS article in AXLE SHAFTS & TRANSFER CASES.
TROUBLE SHOOTING
See GENERAL TROUBLE SHOOTING article.
Vehicle ApplicationTransaxle Model
RAV4
2WDE250
4WDE250F
NOTE: No adjustments are necessary.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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REMOVAL & INSTALLATION
See appropriate MANUAL TRANSMISSION REMOVAL article in TRANSMISSION SERVICING.
TRANSAXLE DISASSEMBLY
1. Unbolt transfer case from transaxle housing. Using a plastic hammer, remove transfer case from
transaxle. Screw appropriate bolt and washer into differential side gear intermediate shaft. Using slide
hammer type puller, remove shaft. Remove snap ring from shaft.
2. Remove clutch release fork and bearing. Remove back-up light switch. Remove speedometer adapter.
Remove speedometer driven gear or speed sensor, if equipped. Remove gear selecting bellcrank. Remove
shift and select lever lock bolt. Remove control shaft cover. Remove shift and select lever shaft assembly.
See Fig. 1
.
3. Remove case cover. Unstake output shaft lock nut. Lock transmission in 2 gears. Remove output shaft
lock nut. Unlock transmission. See Fig. 2
.
4. Remove No. 3 shift fork set bolt. Remove No. 3 hub sleeve and No. 3 shift fork. Using puller, remove 5th
driven gear. See Fig. 2
. Measure 5th gear clearances. Record for reassembly reference. Using dial
indicator, measure 5th gear thrust clearance. See Fig. 3
and Fig. 4 . Standard clearance should be .004-
.022" (.10-.57 mm). Service limit is .026" (.65 mm). Remount dial indicator to measure lateral movement
(oil clearance) of 5th gear. Standard clearance should be .0004-.002" (.009-.05 mm). Service limit
is .0028" (.070 mm).
5. Remove input shaft snap ring. Using puller, remove No. 3 clutch hub with synchronizer ring and 5th gear.
Remove needle bearing and spacer. Remove 7 Torx (T45) screws and rear bearing retainer. Remove
adjusting shim.
6. Remove input shaft rear bearing snap ring. Remove shift fork shaft snap rings. Remove plug. Remove
seat, spring and detent ball with a magnet. Remove reverse idler gear shaft retaining bolt.
7. Remove transmission housing. Remove output shaft rear bearing outer race. Remove No. 2 oil pipe.
Remove reverse shift arm bracket. Remove reverse idler gear, thrust washer and shaft. Remove all
remaining plugs, seats, springs and detent balls with magnet.
8. To remove No. 1 shift fork shaft, pull up No. 3 shift fork shaft. Using magnetic finger, remove interlock
roller. Remove No. 2 shift fork shaft, shift head and No. 1 shift fork. Pull out No. 3 shift fork shaft along
with the reverse shift fork. Remove No. 2 shift fork. Remove snap rings from shift fork shafts.
9. Remove output and input shaft assemblies. Remove oil pump drive gear. Remove differential case
assembly. Remove oil pipe and oil pump. See Fig. 1
.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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2. Remove snap ring from input shaft. Using bearing splitter or appropriate blocks, support 4th gear, and
press input shaft out of rear bearing and 4th gear. Remove needle bearings, spacer and synchronizer ring.
Remove snap ring. Supporting 3rd gear, press input shaft out of No. 2 hub sleeve. Remove synchronizer
ring, needle bearing and 3rd gear. Remove needle bearing. Press input shaft out of front bearing inner
race. See Fig. 5
.
Inspection
1. Inspect all parts for damage and wear. Replace if necessary. Clean all parts in clean solvent and dry.
Lubricate all parts, and ensure oil passages are free of contamination.
2. Measure input shaft at points "A", "B" and "C". See Fig. 6
. Support input shaft on "V" blocks. Using dial
indicator to measure runout, rotate input shaft 2 complete revolutions. Replace input shaft if runout or any
part of shaft is not within service limit. See INPUT SHAFT JOURNAL DIAMETERS
table.
INPUT SHAFT JOURNAL DIAMETERS
Reassembly
1. Install clutch hub and shifting keys to No. 2 hub sleeve. Ensure key spring end-gaps are not in-line.
2. Apply multipurpose grease to needle bearings. Install bearing in 3rd gear. Place synchronizer ring on 3rd
Service
Limit.016 (.40)
4th Gear Thrust Clearance
Standard.004-.022 (.10-.55)
Service
Limit.024 (.60)
3rd & 4th Gear Lateral Movement
Standard.0004-.002 (.009-.05)
Service
Limit.003 (.07)
NOTE: Input shaft inner bearing race is non-reusable and should be replaced whenever
removed..
Application (1) Minimum Diameter - In. (mm)
"A" Shaft Journal Diameter1.100 (27.95)
"B" Shaft Journal Diameter1.415 (35.95)
"C" Shaft Journal Diameter1.415 (35.95)
Runout Limits.002 (.05)
(1)"A", "B", and "C" refer to measuring points indicated in illustration. See Fig. 6 .
NOTE: Input shaft front inner bearing race is non-reusable and should be replaced
whenever removed.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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Sunday, November 22, 2009 10:48:07 AMPage 7 © 2005 Mitchell Repair Information Company, LLC.

Disassembly
1. For all output shaft clearance specifications, refer to OUTPUT SHAFT CLEARANCE
SPECIFICATIONS table. Using feeler gauge, measure 1st and 2nd gear thrust clearances. Secure output
shaft in soft-jaw vise. Using dial indicator, measure 1st and 2nd gear lateral movement (gear oil
clearance). If clearance exceeds maximum, replace gear, needle bearing and/or shaft.
OUTPUT SHAFT CLEARANCE SPECIFICATIONS
2. Using bearing splitter or blocks, support 4th driven gear, and press output shaft out of rear bearing and
4th driven gear. Remove spacer. Support 2nd gear, and press output shaft out of 3rd driven gear and 2nd
gear. Remove needle bearing, spacer and synchro ring. Remove snap ring. Support 1st gear, and press
output shaft out of No. 1 hub sleeve and 1st gear. Remove synchro ring and needle bearing. See Fig. 7
.
Inspection
1. Inspect all parts for damage and wear. Replace if necessary. Throughly clean all parts in clean solvent,
and dry. Lubricate all parts, and ensure oil passages are free of contamination.
2. Measure output shaft diameter at points "A" and "B". See Fig. 8
. Support output shaft on "V" blocks.
Using a dial indicator to measure runout, rotate output shaft 2 complete revolutions. Replace output shaft
if runout or any part of shaft is not within service limit. See OUTPUT SHAFT JOURNAL
DIAMETERS table.
OUTPUT SHAFT JOURNAL DIAMETERS
ApplicationIn. (mm)
1st Gear Thrust Clearance
Standard.004-.014 (.10-.35)
Service
Limit.016 (.40)
2nd Gear Thrust Clearance
Standard.004-.018 (.10-.45)
Service
Limit.020 (.50)
1st & 2nd Gear Lateral Movement
Standard.0004-.002 (.009-.05)
Service
Limit.003 (.07)
Application (1) Minimum Diameter - In. (mm)
"A" Shaft Journal Diameters1.48 (37.53)
"B" Shaft Journal Diameter1.36 (34.51)
Runout Limits.002 (.06)
(1)"A" and "B" refer to measuring points indicated in illustration. See Fig. 8 .

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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Fig. 8: Measuring Output Shaft Journals
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Reassembly
1. If output shaft rear bearing replacement is necessary, support bearing with bearing splitter or blocks.
Press output shaft out of bearing. To replace, support bearing with Adapter (09316-60010), press shaft
onto bearing. Use 2-jaw puller to remove bearing race from clutch housing. To replace, use driver.
2. Install components in reverse order of disassembly. Install ball, and 1st gear bearing inner race, and align
hole in bearing to shaft. Install No. 1 clutch hub and shifting keys to No. 1 hub sleeve. Install shifting key
springs under shifting keys. Ensure key spring end gaps are not in-line. Apply multipurpose grease to
needle bearings. Install bearing in 1st gear. Place synchronizer ring on gear, and align ring slots with
shifting keys. Press 1st gear and No. 1 hub sleeve onto output shaft. See Fig. 7
. Install 1st gear snap ring.
3. Recheck 1st gear thrust clearance. Clearance should be .004-.014" (.10-.35 mm). Install spacer. Apply
multipurpose grease to needle bearing. Place synchronizer ring on 2nd gear, and align ring slots with
shifting keys. Install 2nd gear. Using press, install 3rd driven gear onto output shaft. Recheck 2nd gear
thrust clearance. Standard clearance should be .004-.018" (.10-.45 mm). Install spacer. Using press, install
4th driven gear on output shaft. Press onto output shaft rear bearing.
OIL PUMP
Disassembly & Inspection
1. Install oil pump drive gear onto drive rotor. Ensure drive rotor turns smoothly. Remove gasket from oil
pump case. Remove bolt, and pull out oil strainer. Hold oil pump cover. Unbolt and remove cover.
Remove spring holder, spring, ball and relief valve seat. See Fig. 9
.
2. Install oil pump drive gear onto drive rotor. Measure clearance between driven rotor and oil pump case.
See Fig. 10
and Fig. 11 . Clearance should be .004-.006" (.10-.16 mm). Service limit is .012" (.30 mm).
Measure tip clearance between drive rotor and driven rotor. See Fig. 10
and Fig. 11 . Standard clearance
should be .003-.006" (.08-.15 mm). Service limit is .012" (.30 mm).
3. Remove oil pump drive gear. Using straightedge and feeler gauge, measure side clearance of both rotors.
Standard clearance should be .001-.003" (.03-.08 mm). Maximum clearance is .006" (.16 mm). Remove
oil pump drive rotor and driven rotor.
Reassembly
Replace "O" ring in oil pump case. Install driven rotor and drive rotor. Install relief valve, ball, spring and
spring holder into oil pump case. Install oil strainer to oil pump case. Tighten oil pump cover bolts to 89 INCH
lbs. (10 N.m). Insert oil pump drive gear onto drive rotor. Ensure drive rotor turns smoothly. Install NEW
gasket onto oil pump case. NOTE: Output shaft inner bearing race is non-reusable and should be replaced.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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1999-2000 MANUAL TRANSMISSION SERVICING
Toyota
APPLICATION
MANUAL TRANSAXLE/TRANSMISSION APPLICATIONS
LUBRICATION
SERVICE INTERVALS
ApplicationTrans. Model
Camry & Solara
2.2LS51 5-Speed
3.0LE153 5-Speed
Celica
1999
2.2LS54 5-Speed
2000
1.8L (1ZZ-FE)C56 5-Speed
1.8L (2ZZ-GE)C60 6-Speed
Corolla 1.8LC59 5-Speed
ECHO 1.5LC150 5-Speed
MR2 1.8LC56 5-Speed
RAV4
2WDE250 5-Speed
4WDE250F 5-Speed
Tacoma
2WD
2.4L & 2.7LW59 5-Speed
3.4LR150 5-Speed
4WD
2.7LW59 5-Speed
3.4LR150F 5-Speed
Tundra
2WDR150 5-Speed
4WDR150F 5-Speed
4Runner
2WD 2.7LW59 5-Speed
4WD
2.7LW59 5-Speed
3.4LR150F 5-Speed

1999 Toyota RAV4
1999-2000 MANUAL TRANSMISSION SERVICING Toyota

1999 Toyota RAV4
1999-2000 MANUAL TRANSMISSION SERVICING Toyota
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Transmission/Transaxle
Check transmission fluid level every 30,000 miles or 24 months. Service interval is not available for vehicles
operated under normal conditions. Under severe conditions such as trailer towing, police, taxi, local delivery
service or operating under dusty conditions, replace transmission fluid every 30,000 miles or 24 months.
Transfer Case
Check transfer case fluid level every 30,000 miles or 24 months. Service interval is not available for vehicles
operated under normal conditions. Under severe conditions such as trailer towing, police, taxi, local delivery
service or operating under dusty conditions, replace transfer case fluid every 30,000 miles or 24 months.
CHECKING FLUID LEVEL
Transmission/Transaxle (All Models)
Remove filler plug from side of transmission/transaxle. Fluid should be level with bottom edge of filler plug
hole. If fluid is low, fill with proper type fluid until fluid is level with filler plug opening. See
RECOMMENDED FLUID
. Reinstall filler plug.
Transfer Case (RAV4, Tacoma, Tundra & 4Runner)
Remove filler plug located on rear of transfer case. Fluid should be level with bottom edge of filler plug hole. If
fluid is low, fill with proper type fluid until fluid is level with filler plug opening. See RECOMMENDED
FLUID . Reinstall filler plug.
RECOMMENDED FLUID
For recommended fluid, see RECOMMENDED FLUID
table. For fluid capacity, see
TRANSAXLE/TRANSMISSION REFILL CAPACITIES
table under FLUID CAPACITIES.
RECOMMENDED FLUID
FLUID CAPACITIES
TRANSAXLE/TRANSMISSION REFILL CAPACITIES
(1)
ApplicationFluid Type
Transaxle/TransmissionSAE 75W-90/API GL-4 Or API GL-5 Gear Oil
Transfer CaseSAE 75W-90/API GL-4 Or API GL-5 Gear Oil
ApplicationQts. (L)
Camry & Solara
2.2L 4-Cylinder2.3 (2.2)
3.0L V64.4 (4.2)
Celica
1999

1999 Toyota RAV4
1999-2000 MANUAL TRANSMISSION SERVICING Toyota
Microsoft
Sunday, November 22, 2009 10:47:31 AMPage 2 © 2005 Mitchell Repair Information Company, LLC.

1999-2000 ACCESSORIES & EQUIPMENT
Power Mirrors
DESCRIPTION & OPERATION
Power mirrors are controlled by a dual control switch assembly, located on driver's door panel, instrument panel
or instrument panel center console. Left/right control switch directs current to desired mirror.
Horizontal/vertical control switch directs current to one of 2 motors located in mirror/motor assembly. Mirror
and motors must be removed and serviced as an assembly.
TROUBLE SHOOTING
BOTH POWER MIRRORS INOPERATIVE
Check fuse for power mirror switch. Check power mirror switch. See POWER MIRROR SWITCH
under
COMPONENT TESTS. Check power mirror motor(s). See POWER MIRROR MOTOR
under
COMPONENT TESTS. Check ground circuit and wiring harness. See WIRING DIAGRAMS
.
LEFT OR RIGHT POWER MIRROR INOPERATIVE
Check power mirror switch. See POWER MIRROR SWITCH
under COMPONENT TESTS. Check power
mirror motor(s). See POWER MIRROR MOTOR
under COMPONENT TESTS. Check ground circuit and
wiring harness. See WIRING DIAGRAMS
.
UP/DOWN OR LEFT/RIGHT FUNCTION INOPERATIVE
Check power mirror motor(s). See POWER MIRROR MOTOR
under COMPONENT TESTS. Check power
mirror switch. See POWER MIRROR SWITCH
under COMPONENT TESTS. Check ground circuit and
wiring harness. See WIRING DIAGRAMS
.
COMPONENT TESTS
POWER MIRROR SWITCH
Remove power mirror switch. Using ohmmeter, check continuity between appropriate mirror switch terminals.
Continuity should exist between specified terminals. See appropriate POWER MIRROR SWITCH
CONTINUITY TEST table. See Fig. 1
-Fig. 21. If switch fails any test, replace switch. NOTE: For additional information on heated mirrors, see REAR WINDOW & MIRROR
DEFOGGERS article.
NOTE: Mirror motor connectors may vary in configuration from vehicle to vehicle of
the same model.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Mirrors

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Mirrors
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