TOYOTA RAV4 1996 Service Repair Manual

Q01611
Z00201
MX−26
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
3. REPLACE REVERSE RESTRICT PIN
(a) Using a hexagon wrench (6 mm), remove the screw plug.
(b) Using a pin punch and hammer, drive out the slotted
spring pin.
(c) Replace the reverse restrict pin.
(d) Using a pin punch and hammer, drive in the slotted spring
pin.
(e) Apply sealant to the screw plug threads.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
(f) Using a hexagon wrench (6 mm), install and torque the
screw plug.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

MX05X−01
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−27
1996 RAV4 (RM447U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See
page MX−16).
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:
Before reassembly, select a shim by adjusting output
shaft preload.
Coat all of the sliding and rotating surfaces with gear oil
before reassembly.
ADJUST OUTPUT SHAFT PRELOAD
(a) Install the output shaft assembly to the transaxle case.
(b) Install the transmission case to the transaxle case.
HINT:
If necessary, tap on the case with a plastic hammer.
(c) Install and torque the 17 bolts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(d) Install the output shaft rear taper roller bearing outer race.
(e) Install the adjusting shim.
HINT:
When reusing the output shaft bearing, first install a shim of the
same thickness as before. If installing a new taper roller bear-
ing, first select and install a shim of lesser thickness than be-
fore.
(f) Install the rear bearing retainer.
(g) Using a torx wrench (T45), install and torque the 7 torx
screws.
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)
(h) Install a new lock nut to the output shaft.
(i) Turn the output shaft right and left 2 or 3 times to allow the
bearing to settle.

Z12593
MX−28
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
(j) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing
0.8−1.6 N·m (8−16 kgf·cm, 6.9−13.9 in.·lbf)
Reused bearing
0.5−1.0 N·m (5−10 kgf·cm, 4.3−8.7 in.·lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.
(k) The preload will change about 0.4−0.5 N·m (4−5 kgf·cm,
3.5−4.3 in.·lbf) for every 0.05 mm change in adjusting
shim thickness.
MarkThickness mm (in.)MarkThickness mm (in.)
01.30 (0.0512)D1.95 (0.0768)
11.35 (0.0531)E2.00 (0.0787)
21.40 (0.0551)F2.05 (0.0807)
31.45 (0.0571)G2.10 (0.0827)
41.50 (0.0591)H2.15 (0.0846)
51.55 (0.0610)J2.20 (0.0866)
61.60 (0.0630)K2.25 (0.0886)
71.65 (0.0650)L2.30 (0.0906)
81.70 (0.0669)M2.35 (0.0925)
91.75 (0.0689)N2.40 (0.0945)
A1.80 (0.0709)P2.45 (0.0965)
B1.85 (0.0728)Q2.50 (0.0984)
C1.90 (0.0748)−−
(l) Remove the lock nut.
(m) Remove these parts. Removal is in the reverse order of
installation.
Rear bearing retainer
Shim
Transmission case
Output shaft assembly
Output shaft rear bearing outer race

MX028−02
MT0791
Rear Bearing4th GearSpacer
Synchronizer Ring
Snap Ring
Needle Roller Bearing3rd GearNeedle Roller Bearing
 Input Shaft Front Bearing Inner Race
Input Shaft Synchronizer Ring
No.2 Hub Sleeve
No.2 Clutch Hub
Shifting KeySpring
Snap Ring
 Non−reusable part
− MANUAL TRANSAXLEINPUT SHAFT
MX−29
1996 RAV4 (RM447U)
INPUT SHAFT
COMPONENTS

MX029−02
Q06369
3rd Gear
4th Gear
Q00111
Q05165
SST MX−30
− MANUAL TRANSAXLEINPUT SHAFT
1996 RAV4 (RM447U)
DISASSEMBLY
1. MEASURE 3RD AND 4TH GEARS THRUST CLEAR-
ANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
3rd gear: 0.10 − 0.35 mm (0.0039 − 0.0138 in.)
4th gear: 0.10 − 0.55 mm (0.0039 − 0.0217 in.)
Maximum clearance:
3rd gear: 0.40 mm (0.0157 in.)
4th gear: 0.60 mm (0.0236 in.)
2. CHECK 3RD AND 4TH GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between
the gear and shaft.
Standard clearance:
3rd gear: 0.009 − 0.053 mm (0.0004 − 0.0021 in.)
4th gear: 0.009 − 0.051 mm (0.0004 − 0.0020 in.)
Maximum clearance:
3rd and 4th gears: 0.070 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.
3. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.
4. REMOVE REAR BALL BEARING AND 4TH GEAR
Using SST and a press, remove the rear bearing.
SST 09950−00020
5. REMOVE NEEDLE ROLLER BEARING, SPACER AND
SYNCHRONIZER RING
6. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.

Q00115
− MANUAL TRANSAXLEINPUT SHAFT
MX−31
1996 RAV4 (RM447U)
7. REMOVE NO.2 CLUTCH HUB ASSEMBLY, SYNCHRO-
NIZER RING AND 3RD GEAR
Using a press, remove the No.2 hub sleeve, 3rd gear and syn-
chronizer rings.
8. REMOVE NEEDLE ROLLER BEARING

MX02A−02
MT0780
MT0786
WM0064
WM0065
MX−32
− MANUAL TRANSAXLEINPUT SHAFT
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT 3RD GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.
(c) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.7 mm (0.028 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.
2. INSPECT 4TH GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and spline end.
Minimum clearance: 0.8 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.

WM0066
Z19371
BAB
Q00173
− MANUAL TRANSAXLEINPUT SHAFT
MX−33
1996 RAV4 (RM447U)
3. MEASURE NO.2 SHIFT FORK AND HUB SLEEVE
CLEARANCE
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.
4. INSPECT INPUT SHAFT
(a) Check the input shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of the in-
put shaft journal surface.
Minimum outer diameter:
Part A: 27.950 mm (1.1004 in.)
Part B: 35.950 mm (1.4154 in.)
(c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.05 mm (0.0020 in.)

MX02B−04
Q00383
Front
MT0790
Q00183SST
Q00116
MX−34
− MANUAL TRANSAXLEINPUT SHAFT
1996 RAV4 (RM447U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
(a) Install the 3 springs and shifting keys to the clutch hub.
(b) Install the hub sleeve to the clutch hub.
HINT:
Direct identification groove of the hub sleeve to front of the
transmission.
2. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-
SEMBLY TO INPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Assemble the needle roller bearings into the 3rd gear.
(c) Place the synchronizer rings on the gear and align the
ring slots with the shifting keys.
(d) Using SST and a press, install the 3rd gear and No.2 hub
sleeve.
SST 09506−35010
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
H2.30 (0.0906)M2.50 (0.0984)
J2.35 (0.0925)N2.55 (0.1004)
K2.40 (0.0945)P2.60 (0.1024)
L2.45 (0.0965)−−
(b) Using a screwdriver and hammer, tap in the snap ring.

N00494
SST
Q00118
− MANUAL TRANSAXLEINPUT SHAFT
MX−35
1996 RAV4 (RM447U)
4. MEASURE 3RD GEAR THRUST CLEARANCE
(See page MX−30)
5. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE
ROLLER BEARING, 4TH GEAR AND REAR BALL
BEARING
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearings.
(c) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(d) Install the 4th gear.
(e) Using SST and a press, install the rear ball bearing.
SST 09506−35010
6. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
12.35 (0.0925)52.55 (0.1004)
22.40 (0.0945)62.60 (0.1024)
32.45 (0.0965)72.65 (0.1043)
42.50 (0.0984)82.70 (0.1063)
(b) Using a screwdriver and hammer, tap in the snap ring.
7. MEASURE 4TH GEAR THRUST CLEARANCE
(See page MX−30)