TOYOTA RAV4 1996 Service Repair Manual

MX05V−02
Q08757
FIPG
Z12375SST
Q09043
255.5 mm MX−16
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
DISASSEMBLY
1. 4WD:
REMOVE TRANSFER ASSEMBLY
(a) Remove the 3 bolts.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(b) Remove the 5 nuts.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(c) Using a plastic hammer, remove the transfer assembly
from the transaxle.
HINT:
At the time of reassembly, please refer to the following item.
Shift into the 4th gear, and install the transfer assembly while
turning the input shaft of the transaxle.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
2. 4WD:
REMOVE DIFFERENTIAL SIDE GEAR INTERMEDI-
ATE SHAFT
(a) Screw in a suitable bolt with a washer into the side gear
intermediate shaft.
(b) Using SST, remove the side gear intermediate shaft.
SST 09910−00015 (09911−00011, 09912−00010)
(c) Remove the snap ring from the differential side gear inter-
mediate shaft.
HINT:
At the time of reassembly, please refer to the following item.
Keeping the intermediate shaft on the differential pinion shaft,
measure the dimension, as shown in the illustration.
Protrusion length: 255.5 mm (10.06 in.)
3. REMOVE RELEASE FORK AND BEARING
4. REMOVE BACK−UP LIGHT SWITCH WITH GASKET
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
5. REMOVE BOLT AND VEHICLE SPEED SENSOR
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
6. REMOVE NO.2 SELECTING BELLCRANK WITH SE-
LECTING BELLCRANK SUPPORT
Remove the 2 bolts and No.2 selecting bellcrank with the se-
lecting bellcrank support.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

Q05816
FIPG
Q00449
Q05849
SST
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−17
1996 RAV4 (RM447U)
7. REMOVE SHIFT AND SELECT LEVER SHAFT LOCK
BOLT WITH GASKET
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
8. REMOVE SHIFT AND SELECT LEVER SHAFT AS-
SEMBLY WITH GASKET
Remove the 4 bolts, shift and select lever shaft assembly and
gasket.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
9. REMOVE TRANSMISSION CASE COVER
Remove the 10 bolts and transmission case cover.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
10. REMOVE BREATHER PLUG WITH GASKET
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
11. REMOVE OUTPUT SHAFT LOCK NUT
(a) Unstake the lock nut.
(b) Engage the gear double meshing.
(c) Remove the lock nut.
Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf)
(d) Disengage the gear double meshing.
12. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
(a) Remove the No.3 shift fork set bolt.
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
(b) Remove the No.3 hub sleeve and No.3 shift fork.
13. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950−30010

Z01304
Z01306
Q00299
Z01308
SST MX−18
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
14. MEASURE 5TH GEAR THRUST CLEARANCE AND
RADIAL CLEARANCE
(a) Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.10−0.57 mm (0.0039−0.0224 in.)
Maximum clearance:
0.65 mm (0.0256 in.)
(b) Using a dial indicator, measure the radial clearance.
Standard clearance:
0.009−0.050 mm (0.0004−0.0020 in.)
Maximum clearance:
0.070 mm (0.0028 in.)
15. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
At the time of the reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
a1.75 (0.0689)f2.00 (0.0787)
b1.80 (0.0709)g2.05 (0.0807)
c1.85 (0.0729)h2.10 (0.0827)
d1.90 (0.0748)j2.15 (0.0847)
e1.95 (0.0768)−−
(b) Using SST, remove the No.3 clutch hub with the synchro-
nizer ring and 5th gear.
SST 09950−30010
16. REMOVE NEEDLE ROLLER BEARING AND SPACER
17. REMOVE REAR BEARING RETAINER
Using a torx socket wrench (T45), remove the 7 torx screws and
rear bearing retainer.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)

Q06190
Q01615
Q00056
Q05815
FIPG
MT0669
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−19
1996 RAV4 (RM447U)
18. REMOVE SNAP RING
(a) Using a snap ring expander, remove the input shaft rear
bearing snap ring.
(b) Using 2 screwdrivers and a hammer, remove the 2 snap
rings.
19. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING
AND LOCKING BALL
(a) Using a hexagon wrench (6 mm), remove the plug.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Using a magnetic finger, remove the seat, spring and
locking ball.
20. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
21. REMOVE TRANSMISSION CASE
Remove the 17 bolts and tap the case with a plastic hammer.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
22. REMOVE SHIM
HINT:
At the time of reassembly, please refer to the following item.
Install the previously selected shim by adjusting output shaft
preload.
(See page MX−27)

MT0693
SST
Q06375
Z17557
Matchmarks
Q01614
Q08124
MX−20
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
23. REMOVE OUTPUT SHAFT REAR TAPER ROLLER
BEARING OUTER RACE
Using SST and a hammer, remove the output shaft rear taper
roller bearing outer race.
SST 09316−60011 (09316−00011)
24. REMOVE TRANSMISSION OIL PIPE
(a) Remove the gasket from the oil pipe.
(b) Remove the 2 bolts and oil pipe.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
25. REMOVE REVERSE SHIFT ARM BRACKET AS-
SEMBLY
Remove the bolt and pull off the reverse shift arm and bracket.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
26. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft, remove the reverse idler gear and thrust
washer.
HINT:
At the time of reassembly, please refer to the following item.
Align the matchmarks, as shown.
27. REMOVE STRAIGHT SCREW PLUG, LOCKING BALL
AND SPRING
(a) Using a hexagon wrench (6 mm), remove the 2 plugs.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Using a magnetic finger, remove the 2 seats, springs and
balls.
28. REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD
SET BOLT
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
29. REMOVE NO.1 SHIFT FORK SHAFT
Pull up the No.3 shift fork shaft, remove the No.1 shift fork shaft.
HINT:
At the time of reassembly, please refer to the following item.
When it is difficult to push the fork shaft through the reverse shift
fork, pull up the No.3 shift fork shaft.

Q08125
Q08126
Z00182
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−21
1996 RAV4 (RM447U)
30. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from the re-
verse shift fork.
31. REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD
AND NO.1 SHIFT FORK
(a) Pull out the No.2 shift fork shaft.
(b) Remove the shift head and No.1 shift fork.
32. REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE
SHIFT FORK AND NO.2 SHIFT FORK
(a) Pull out the No.3 shift fork shaft with the reverse shift fork.
(b) Remove the No.2 shift fork.
33. REMOVE SNAP RING
(a) Using 2 screwdrivers and a hammer, remove the snap
ring and reverse shift fork from the No.3 shift fork shaft.
(b) Using 2 screwdrivers and a hammer, remove the 3 snap
rings from the No.1, No.2 and No.3 shift fork shafts.
34. REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY
(a) Leaning the output shaft to the differential side, remove
the input shaft assembly.
(b) Lift up the differential case assembly, remove the output
shaft assembly.
35. REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Remove the oil pump drive gear.
(b) Remove the differential case assembly.
36. REMOVE MAGNET FROM TRANSAXLE CASE
37. REMOVE TRANSMISSION OIL PUMP ASSEMBLY
AND OIL PIPE
(a) Remove the 2 bolts and oil pipe.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
(b) Remove the 2 bolts and oil pump assembly.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)

MT0781
MX−22
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
38. REMOVE NO.5 SYNCHRONIZER RING WITH KEY
SPRING FROM NO.3 CLUTCH HUB
(a) Remove the No.5 synchronizer ring with the key spring
from the No.3 clutch hub.
(b) Using a screwdriver, remove the snap ring.
HINT:
Wrap vinyl tape on the screwdriver to prevent damaging the
synchronizer ring.
(c) Remove the synchronizer rings.

MX0DT−01
MT0782
WM0066
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−23
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT NO.5 SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
middle No.5 synchronizer ring in one direction while push-
ing it to the outer No.5 synchronizer ring. Check that the
ring locks.
If it does not lock, replace the synchronizer ring.
2. MEASURE SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.

Z00192
SST
MX0DU−01
Z00194
SST
Q08014
SST
Q05164
SST
Q00141
SST MX−24
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
REPLACEMENT
1. REPLACE INPUT SHAFT BEARING AND OIL SEAL
(a) Remove the 3 bolts and transaxle case receiver.
(b) Using SST, pull out the bearing.
SST 09612−65014
(c) Using a screwdriver, remove the oil seal.
(d) Using SST, drive in a new oil seal.
SST 09608−00081, 09950−70010 (09951−07150)
(e) Coat the lip of seal with MP grease.
(f) Using SST, drive in a new bearing.
SST 09950−60010 (09951−00580), 09950−70010
(09951−07150)
(g) Install the transaxle case receiver.
(h) Install and torque the 3 bolts.
Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf)
(i) Using SST and a press, remove the inner race.
SST 09950−00020
(j) Using SST and a press, install a new input shaft front
bearing inner race.
SST 09316−60011 (09316−00021)

Q00338
SST
Z00197
Q06368
SST
SST
Q00245
SSTSocket Wrench
Z00199SST
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−25
1996 RAV4 (RM447U)
2. REPLACE OUTPUT SHAFT FRONT BEARING OUTER
RACE AND OUTPUT SHAFT FRONT COVER
(a) Using SST, pull out the output shaft front bearing outer
race.
SST 09308−00010
(b) Remove the output shaft cover.
(c) Install a new output shaft cover.
HINT:
Install the output shaft cover projection into the case side
groove.
(d) Using SST and a hammer, drive in a new output shaft front
bearing outer race.
SST 09316−60011 (09316−00011, 09316−00021)
(e) Using SST and a socket wrench, remove the output shaft
front bearing.
SST 09950−00020, 09950−00030
(f) Using SST and a press, install a new output shaft front
bearing.
SST 09316−60011 (09316−00071)