remove transaxle TOYOTA RAV4 1996 Service Owners Manual

Q06135
− MANUAL TRANSAXLETRANSFER (4WD)
MX−85
1996 RAV4 (RM447U)
15. REMOVE ADJUSTING NUT LOCK PLATE
Using snap ring pliers, remove the adjusting nut lock plate from
the transfer right case.

Q05709
SST
MX0E0−01
Z12397
SST
Z12546
Q08760
SST SST
Z16232
Socket Wrench MX−86
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
REPLACEMENT
1. REPLACE DRIVEN PINION FRONT BEARING
(a) Using SST and a press, remove the front bearing.
SST 09950−00020
(b) Using SST and a press, install a new front bearing.
SST 09316−60011 (09316−00051)
2. REPLACE FRONT AND REAR BEARING OUTER
RACE
(a) Using a brass bar and hammer, drive out the front and
rear bearing outer race lightly and evenly.
(b) Using SST and a press, install a new front bearing outer
race.
SST 09950−60020 (09951−00780), 09950−70010
(09951−07150)
(c) Using SST and a press, install a new rear bearing outer
race.
SST 09950−60010 (09951−00590), 09950−70010
(09951−07150)
3. REPLACE SHIFT FORK SHAFT OIL SEAL
(a) Using a screwdriver, remove the oil seal from the transfer
right case.
(b) Using a socket wrench and hammer, install a new oil seal.

Z12390
1.5 ± 0.4 mm SST
Z12536
Z12392
SST
Q06138
Q06139
− MANUAL TRANSAXLETRANSFER (4WD)
MX−87
1996 RAV4 (RM447U)
4. REPLACE EXTENSION HOUSING OIL SEAL
(a) Using a screwdriver, remove the oil seal.
(b) Using SST and a hammer, drive in a new oil seal.
SST 09325−20010
Oil seal depth: 1.5 ± 0.4 mm (0.059 ± 0.016 in.)
(c) Coat the lip of oil seal with MP grease.
5. REPLACE SIDE GEAR SHAFT HOLDER BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using a press, remove the bearing from the side gear
shaft holder.
(c) Using SST and a press, install a new bearing.
SST 09316−60011 (09316−00011)
(d) Using a snap ring expander, install the snap ring.
6. REPLACE TRANSFER OIL PIPE
(a) Remove the bolt and oil pipe from the transfer left case.
(b) Using a screwdriver, remove the cushion.
(c) Install a new cushion.
(d) Install the oil pipe.
(e) Install and torque the bolt.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

Z12393
SST
Q06159
SST
Q06177
Q06160
SST MX−88
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
7. Transfer Right Case Side:
REPLACE RING GEAR MOUNTING CASE SIDE BEAR-
ING OUTER RACE
(a) Using SST, turn the bearing adjusting nut, and remove the
outer race and bearing adjusting nut.
SST 09318−20010
(b) Using SST, turn the bearing adjusting nut until it touches
the lip of the case.
SST 09318−20010
(c) Using SST and a press, install a new bearing outer race
until it almost touches the bearing adjusting nut.
SST 09950−60020 (09951−00890), 09950−70010
(09951−07150)
8. Transfer Left Case Side:
REPLACE RING GEAR MOUNTING CASE SIDE BEAR-
ING OUTER RACE
(a) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly.
(b) Remove the plate washer.
(c) Install the plate washer.
HINT:
First install a washer of the same thickness as before.
(d) Using SST and a press, install a new bearing outer race.
SST 09316−60011 (09316−00011, 09316−00061)

MX0C3−02
Z12547
Z12399
SST
Q08203
SST
− MANUAL TRANSAXLETRANSFER (4WD)
MX−89
1996 RAV4 (RM447U)
REASSEMBLY
NOTICE:
When working with FIPG material, you must observe the follow-
ing items.
Using a razor blade and gasket scraper, remove all the old
FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose
material.
Clean both sealing surfaces with a non−residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along
the sealing surface.
Parts must be assembled within 10 minutes of application.
Otherwise, the FIPG material must be removed and reap-
plied.
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. ASSEMBLE TRANSFER PINION BEARING CAGE
(a) Install the transfer pinion bearing cage.
(1) Install a new bearing spacer.
HINT:
Insert the spacer with the smaller diameter facing upwards.
(2) Using SST and a press, install the rear bearing.
HINT:
Press down until the pinion can move slightly up and down.
SST 09316−60011 (09316−00021)
(b) Adjust the driven pinion preload.
(1) Using SST, install and torque a new lock nut.
SST 09326−20011
Torque: 95 N·m (968 kgf·cm, 70 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 38 cm (14.96
in.).
The torque specification for without using SST is 108 N·m
(1,100 kgf·cm, 80 ft·lbf).

Q06164
SST
Q06151
− MANUAL TRANSAXLETRANSFER (4WD)
MX−93
1996 RAV4 (RM447U)
(e) Using SST and a spring tension gauge, measure the total
preload.
SST 09326−20011
Preload (at starting):
New bearing (Driven pinion preload plus)
13 − 14 N (1.3 − 1.4 kgf, 2.9 − 3.1 lbf)
Reused bearing (Driven pinion preload plus)
5 − 9 N (0.5 − 0.9 kgf, 1 − 2 lbf)
HINT:
Turn the output shaft counterclockwise and clockwise several
times.
(f) When the standard value for the total preload exceeds,
remove the transfer right case, and push in the adjusting
nut and outer race. Again adjust the total preload.
5. CHECK RING GEAR BACKLASH
(a) Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
(b) When the backlash exceeds the standard value, select a
different plate washer to the one selected step 4. Again
adjust the backlash and total preload.

Q06165
Z16229
Proper ContactHeel Contact Face Contact
Select an adjusting shim that will bring the
driven pinion closer to the ring gear.
Toe Contact Flank Contact
Select an adjusting shim that will shift the
driven pinion away from the ring gear. MX−94
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
6. CHECK TOOTH CONTACT
(a) Coat 3 or 4 teeth at 4 different positions on the ring gear
with red lead.
(b) Rotate the ring gear, inspect the teeth pattern.
(c) If the teeth are not contacting properly, again select the
proper shim and plate.
MarkThickness mm (in.)MarkThickness mm (in.)
A0.30 (0.0118)F0.45 (0.0177)
B0.33 (0.0130)G0.48 (0.0189)
C0.36 (0.0142)H0.51 (0.0201)
D0.39 (0.0154)J0.54 (0.0213)
E0.42 (0.0165)K0.57 (0.0224)
7. REMOVE RING GEAR MOUNTING CASE ASSEMBLY
(a) Remove the 10 bolts and transfer right case.
(b) Remove the ring gear mounting case assembly.
8. REMOVE TRANSFER PINION BEARING CAGE AS-
SEMBLY
Remove the 6 bolts and transfer pinion bearing cage assembly.

PR02R−01
F03298
Q08983
Matchmarks
Q05852
Q05853
SST
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY
PR−3
1996 RAV4 (RM447U)
REMOVAL
1. LOOSEN CROSS GROOVE JOINT SET BOLT
(a) Depress the brake pedal and hold it.
(b) Using a hexagon wrench, loosen the cross groove joint
set bolts 1/2 turn.
HINT:
Put a piece of cloth, or equivalent, into the inside of the cross
groove joint cover so that the boot does not touch the inside of
the cross groove joint cover.
(c) Loosen the 2 bolts and center support bearing.
2. DISCONNECT PROPELLER SHAFT FROM DIFFER-
ENTIAL
(a) Place matchmarks on both flanges.
(b) Remove the 4 bolts, washers and nuts.
3. REMOVE PROPELLER SHAFT FROM TRANSAXLE
(a) Remove the 2 bolts and center support bearing.
(b) Pull out the propeller shaft yoke from the transaxle.
(c) Insert SST in the transaxle to prevent oil leakage.
SST 09325−20010

R10840
W01206
2WD M/T RH
W01207
2WD A/T RH
W01208
2WD LH and 4WD RH
W01209
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA−21
1996 RAV4 (RM447U)
9. DISCONNECT DRIVE SHAFT FROM AXLE HUB
Using a plastic hammer, disconnect the drive shaft from the axle
hub.
NOTICE:
Be careful not to damage the inner oil seal and ABS speed
sensor rotor.
10. 2WD (M/T) RH:
REMOVE DRIVE SHAFT
NOTICE:
Be careful not to damage the dust cover and oil seal.
(a) Using a screwdriver and hammer, remove the snap ring
from the center bearing bracket.
(b) Remove the bolt from the center bearing bracket.
Torque: 32 N·m (330 kgf·cm, 24 ft·lbf)
(c) Remove the drive shaft with the center drive shaft.
HINT:
If it is hard to remove the bearing, use a brass bar and hammer
and drive flange end of the drive shaft.
(d) Remove the 2 bolts and center bearing bracket.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
11. 2WD (A/T) RH:
REMOVE DRIVE SHAFT
(a) Remove the 2 bolts of the center bearing bracket and pull
out the drive shaft together with the center bearing case
and center drive shaft.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
(b) Remove the center drive shaft with the drive shaft to the
transaxle through the center bearing bracket.
(c) Remove the 3 bolts and center bearing bracket.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
12. 2WD LH:
REMOVE DRIVE SHAFT
(a) Using a brass bar and hammer, remove the drive shaft.
(b) Using a screwdriver, remove the snap ring.
13. 4WD RH:
REMOVE DRIVE SHAFT
(a) Using a brass bar and hammer, remove the drive shaft.
(b) Using a screwdriver, remove the snap ring.
(c) Using a screwdriver, remove the O−ring.
14. 4WD LH:
REMOVE DRIVE SHAFT
(a) Remove the air cleaner.
(b) Remove the transmission case protector.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(c) Using a hub nut wrench or an equivalent, remove the
drive shaft.
(d) Using a screwdriver, remove the snap ring.

SF0RG−02
S01838
2WD
SST
P01630
Ohmmeter
− SFIKNOCK SENSOR
SF−57
1996 RAV4 (RM447U)
INSPECTION
1. 4WD:
REMOVE ENGINE AND TRANSAXLE ASSEMBLY (See
page EM−68)
2. REMOVE KNOCK SENSOR
(a) Disconnect the knock sensor connector.
(b) Using SST, remove the knock sensor.
SST 09816−30010
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
3. INSPECT KNOCK SENSOR
Using an ohmmeter, check that there is no continuity between
the terminal and body.
If there is continuity, replace the sensor.
4. REINSTALL KNOCK SENSOR
Installation is in the reverse order of removal.
5. 4WD:
REINSTALL ENGINE AND TRANSAXLE ASSEMBLY
(See page EM−74)