TOYOTA RAV4 1996 Service Repair Manual

Fig. 7: Identifying Output Shaft Components
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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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Sunday, November 22, 2009 10:48:07 AMPage 12 © 2005 Mitchell Repair Information Company, LLC.

Fig. 9: Exploded View Of Oil Pump Assembly
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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Sunday, November 22, 2009 10:48:07 AMPage 13 © 2005 Mitchell Repair Information Company, LLC.

Fig. 10: Measuring Oil Pump Driven Rotor To Case Clearance
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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Sunday, November 22, 2009 10:48:07 AMPage 14 © 2005 Mitchell Repair Information Company, LLC.

Fig. 11: Measuring Oil Pump Drive Rotor Tip To Driven Rotor Clearance
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
SHIFT & SELECT LEVER SHAFT
Disassembly
1. Using pin punch and a hammer, drive out roll pin from No. 2 shift inner lever. Remove snap ring.
Remove No. 2 select spring seat, No. 2 spring and No. 2 shift inner lever. Drive out roll pin from No. 1
shift inner lever. Remove shift interlock plate and No. 1 shift inner lever from shaft. See Fig. 12
.
2. Remove No. 1 compression spring and No. 1 select spring seat. Remove snap ring. Remove control shaft
cover and dust boot. If necessary, replace control shaft cover oil seal. Drive in NEW oil seal to a depth of
0-.020" (0-.51 mm). Apply multipurpose grease to oil seal. See Fig. 12
.
Reassembly
1. Check shift and select lever shaft and components for wear or damage. Replace as needed. Apply
multipurpose grease to shift and select lever shaft. Install boot to control shaft cover. Install shift and
select lever or control shaft to control shaft cover. Install snap ring.
2. Install No. 1 spring seat, No. 1 spring and select inner lever. Drive roll pin into select inner lever. Ensure
No. 1 select spring seat slides smoothly. Install shift interlock plate and No. 1 shift inner lever. Drive roll
pin into shift inner lever. Ensure shift interlock plate turns smoothly. See Fig. 12
.
3. Install No. 2 shift inner lever, No. 2 spring and No. 2 select spring seat. Install snap ring. Drive roll pin
into No. 2 shift inner lever. Ensure No. 2 select sprin
g seat slides smoothly.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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Sunday, November 22, 2009 10:48:07 AMPage 15 © 2005 Mitchell Repair Information Company, LLC.

Fig. 12: Exploded View Of Shift & Select Lever Assembly
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
SHIFT FORK ASSEMBLY
Measure clearance between hub sleeve and shift fork. Maximum clearance is .039" (1.00 mm). If clearance
exceeds specification, replace shift fork or hub sleeve. See Fig. 13
.
SYNCHRO RING & GEAR
Check synchronizer rings for wear or damage. Turn and push ring to check braking action. Measure clearance
between synchronizer ring back and gear spline end. First and 4th gear synchronizer minimum clearance
is .03" (.8 mm). Second and 3rd gear synchronizer minimum clearance is .028" (.7 mm). If clearance is less than
specification, replace s
ynchronizer ring. See Fig. 13.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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Sunday, November 22, 2009 10:48:07 AMPage 16 © 2005 Mitchell Repair Information Company, LLC.

Fig. 13: Measuring Synchronizer Ring & Shift Fork Clearances
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
DIFFERENTIAL
Disassembly (2WD Models)
1. Separate differential housings. Press tapered roller bearings from both cases. Match mark differential case
and ring gear. Remove ring gear. Match mark differential case halves. Separate case halves. Remove
speed sensor drive gear from right case.
2. Remove 2 differential side gears, side gear thrust washers, 4 pinions and pinion thrust washers from left
case. On transmission side of housing, remove oil seal and baffle. Drive out bearing race. Remove
existing shim. Install NEW shim of lesser thickness. Press in NEW bearing race. Install oil baffle. Drive
in NEW oil seal.
3. On transaxle side of housing, remove 4 bolts and 3 nuts, and tap case cover loose. Drive oil seal from
cover. Remove bearing outer race. Using press and driver, install NEW bearing race. Drive in NEW oil
seal. Coat seal lips with multipurpose grease. Coat case cover with Three Bond (1281) sealant. Apply
sealant to bolt threads, and install and tighten bolts.
Reassembly (2WD Models)
1. Coat all sliding and rotating surfaces with gear oil before reassembly. Install thrust washer to side gear.
Install 4 pinions and thrust washers to spider. Install side gear and spider with 4 pinions onto differential
left case. Install dial indicator to pinion gear and measure backlash while pushing pinions and spider to
left side. Standard backlash should be .002-.008" (.05-.20 mm).
NOTE: Measure differential bearing preload prior to transmission disassembly.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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2. Push side gear and pinions to right side of case. Measure side gear backlash. Select thrust washer which
will ensure backlash is within limits. Thrust washers are available in thicknesses of .031" (.80 mm)
to .055" (1.40 mm), in .004" (.10 mm) increments.
3. Install vehicle speed sensor drive gear. Align match marks on differential cases and carefully tap together.
Install and tighten attaching screws. Clean contact surface of differential case and threads of ring gear.
Heat ring gear in water to 212°F (100°C). Quickly clean ring gear contact surface with solvent, then
install on differential case.
4. Allow ring gear to cool. Tighten ring gear bolts to 91 ft. lbs. (124 N.m). Press NEW bearings onto
differential cases. Adjust output shaft bearing preload. See OUTPUT SHAFT BEARING PRELOAD

under TRANSAXLE REASSEMBLY. Install differential case assembly into transaxle case half. Install
output shaft assembly. Install transmission case half. Tighten bolts.
5. Install output shaft bearing outer race. Install shim. Install rear bearing retainer, and tighten bolts. Install
NEW lock nut onto output shaft. Rotate output shaft 2-3 times to set bearings. Install torque wrench, and
measure side bearing preload. If preload is not 1.6-3.0 INCH lbs. (1.8-3.5 kg) for NEW bearings, or 1.0-.9
INCH lbs. (1.1-2.2 kg) for used bearings, select appropriate adjusting shim. Adjusting shims are available
in thicknesses of .079" (2.0 mm) to .112" (2.85 mm) in .002" (.05 mm) increments. Shims are stamped
"1"-"9", and "A"-"H".
Disassembly (4WD Models)
1. Remove No. 2 differential case. Match mark differential case and ring gear. Remove ring gear. Remove
No. 2 differential side gear thrust washer and conical spring washer. See Fig. 14
.
2. Remove front differential case assembly. Remove front differential side gear and thrust washer. Remove
snap ring and spacer.
Remove front differential pinion shafts, No. 2 front pinion shaft, shaft holder, pinions, pinion thrust
washers, front differential side gear and front differential thrust washer. Remove snap ring, spacer and
vehicle speed sensor drive gear. Remove tapered roller bearing.
3. From No. 1 differential case, remove pinion shafts, shaft holder, pinions and thrust washers, differential
side gear subassembly, conical spring washer and side gear thrust washer. Remove tapered roller bearing.
See Fig. 14
. NOTE: Total preload will change approximately 1.7 lbs. (1 kg) for every .002" (.05
mm) change in adjusting shim thickness.
NOTE: Wrap vinyl tape around case to prevent damage.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
Microsoft
Sunday, November 22, 2009 10:48:07 AMPage 18 © 2005 Mitchell Repair Information Company, LLC.

Fig. 14: Exploded View Of Differential Assemblies (4WD Shown; 2WD Is Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Measurements (4WD Models)
For differential measurement specifications, see DIFFERENTIAL CASE SPECIFICATIONS table. Using a
dial bore
gauge, measure inner diameters of No. 1 differential case and No. 2 differential case. Measure outer

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
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Sunday, November 22, 2009 10:48:07 AMPage 19 © 2005 Mitchell Repair Information Company, LLC.

diameters of No. 2 differential case. Measure height of conical spring washer. See Fig. 15 -Fig. 18.
DIFFERENTIAL CASE SPECIFICATIONS
ApplicationIn. (mm)
No. 1 Differential Case (1)
"A" Standard Diameter4.095-4.096 (104.0-104.03)
"A" Maximum Diameter4.097 (104.06)
No. 2 Differential Case (1)
"B" Standard Diameter3.819-3.820 (97.00-97.04)
"B" Maximum Diameter3.821 (97.06)
Front Differential Case (1)
"C" Standard Diameter4.092-4.093 (103.93-103.96)
"C" Minimum Diameter4.089 (103.85)
"D" Standard Diameter3.816-3.818 (96.93-96.96)
"D" Minimum Diameter3.813 (96.85)
Conical Spring Washer
No. 1 Case Washer
Standard Height.067-.075 (1.70-1.90)
Minimum Height.063 (1.60)
No. 2 Case Washer
Standard Height.102-.110 (2.60-2.80)
Minimum Height.098 (2.50)
(1)"A", "B", "C" and "D" refer to measuring points indicated in illustration. See Fig. 18 .

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
Microsoft
Sunday, November 22, 2009 10:48:07 AMPage 20 © 2005 Mitchell Repair Information Company, LLC.