TOYOTA RAV4 1996 Service Repair Manual

Q06410
SST
SST
Q00036
Z00309
MX−56
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
1996 RAV4 (RM447U)
3. INSTALL TAPERED ROLLER BEARING
Using SST and a press, install new left and right bearings onto
the differential case.
SST 09316−20011, 09316−60011 (09316−00011)
HINT:
Press the bearing on the ring side first.
4. ADJUST OUTPUT SHAFT ASSEMBLY PRELOAD
(See page MX−27)
5. INSTALL DIFFERENTIAL CASE ASSEMBLY TO
TRANSAXLE CASE
6. INSTALL OUTPUT SHAFT ASSEMBLY
Lift up the differential case and install the output shaft assem-
bly.
7. INSTALL TRANSMISSION CASE
(a) Install the transmission case.
HINT:
If necessary, tap on the case with a plastic hammer.
(b) Install and torque the 17 bolts.
Torque: 29 N·m (300 kgf·cm 22 ft·lbf)
8. INSTALL OUTPUT SHAFT REAR TAPERED ROLLER
BEARING OUTER RACE
Using a plastic hammer, drive in the outer race.
9. INSTALL SHIM (See page MX−27)
HINT:
Install the previously selected shim.
10. INSTALL REAR BEARING RETAINER
Using a torx wrench (T45), install and torque the 7 torx screws.
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)
11. ADJUST DIFFERENTIAL CASE SIDE BEARING PRE-
LOAD
(a) Install a new lock nut to the output shaft.
(b) Turn the output shaft right and left 2 or 3 times to allow the
bearings to settle.
(c) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing (Output shaft preload plus)
0.2 − 0.3 N·m (1.8 − 3.5 kgf·cm, 1.6 − 3.0 in.·lbf)
Reused bearing (Output shaft preload plus)
0.1 − 0.2 N·m (1.1 − 2.2 kgf·cm, 1.0 − 1.9 in.·lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.

− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
MX−57
1996 RAV4 (RM447U)
HINT:
The total preload will change by about 0.1 − 0.2 N·m (1 − 2
kgf·cm, 0.9 − 1.7 in.·lbf) with each 0.05 mm change in adjusting
shim thickness.
MarkThickness mm (in.)MarkThickness mm (in.)
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
12. REMOVE REAR BEARING RETAINER
Using a torx wrench (T45), remove the 7 torx screws and rear
bearing retainer.
13. REMOVE SHIM
14. REMOVE TRANSMISSION CASE
(a) Remove the 17 bolts.
(b) Using a plastic hammer, tap the transmission case.
15. REMOVE OUTPUT SHAFT ASSEMBLY
16. REMOVE DIFFERENTIAL CASE ASSEMBLY

MX02J−02
Z17561
Tapered Roller Bearing and Outer Race
Snap Ring
Spacer
Vehicle Speed Sensor
Drive Gear
No.1 Differential
Case No.2 Differential Side
Gear Thrust Washer
Differential Side Gear
Subassembly
Differential Pinion Shaft
Differential Pinion Thrust Washer
Differential Pinion
Differential Pinion
Thrust Washer
Differential Pinion
No.2 Front Differential Pinion Shaft
Front Differential Pinion
Shaft Holder
Spacer
Snap Ring Conical Spring
Washer
Pinion Shaft
Holder
No.2 Differential Side
Gear Thrust Washer
Front Differential Case
Front Differential
Pinion Shaft Conical Spring
Washer
No.2 Differential Case
Differential Ring Gear
x16
Oil Baffle Front Differential Side
Gear Thrust Washer
Tapered Roller Bearing and Outer Race
Oil Seal
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable partFront Differential Side Gear
Shim

124 (1,260, 91)
 MX−58
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
DIFFERENTIAL CASE (4WD)
COMPONENTS

MX02K−03
Z12377
Matchmarks
Z12483
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−59
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE NO.2 DIFFERENTIAL CASE
(a) Remove the 16 bolts.
(b) Remove the No.2 differential case upward.
2. REMOVE DIFFERENTIAL RING GEAR
(a) Place matchmarks on both the differential case and ring
gear.
(b) Using a plastic hammer, tap out the ring gear.
3. REMOVE NO.2 DIFFERENTIAL SIDE GEAR THRUST
WASHER AND CONICAL SPRING WASHER
4. REMOVE FRONT DIFFERENTIAL CASE ASSEMBLY
5. DISASSEMBLE FRONT DIFFERENTIAL CASE
(a) Remove the front differential side gear together with the
thrust washer from the front differential case.
(b) Remove the front differential side gear thrust washer from
the side gear.
(c) Using a snap ring expander, remove the snap ring and
spacer.
HINT:
Before removing the shaft snap ring, wrap vinyl tape around the
case to prevent from damage.

Q06218
Q06219
Q07870
SST MX−60
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
(d) Remove these parts from the front differential case:
2 front differential pinion shafts
No.2 front differential pinion shaft
Front differential pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
Front differential side gear
Front differential side gear thrust washer
6. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the spacer and vehicle speed sensor drive gear.
7. DISASSEMBLE NO.1 DIFFERENTIAL CASE
Remove these parts from the No.1 differential case:
4 differential pinion shafts
Pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
Differential side gear subassembly
Conical spring washer
No.2 differential side gear thrust washer
8. No.2 Differential Case Side:
REMOVE TAPERED ROLLER BEARING
Using SST, remove the tapered roller bearing.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00520)

Q07895
SST
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−61
1996 RAV4 (RM447U)
9. No.1 Differential Case Side:
REMOVE TAPERED ROLLER BEARING
Using SST, remove the tapered roller bearing.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00450)

MX0DX−01
Q06209
A
B
Case No.1 Differential
Case No.2 Differential
Q06210
A B
Z12920
MX−62
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
INSPECTION
1. MEASURE NO.1 AND NO.2 DIFFERENTIAL CASES
Using a cylinder gauge, measure the inner diameter of the No.1
and No.2 differential cases bushing.
Standard diameter:
A: 104.000−104.035 mm (4.0945−4.0959 in.)
B: 97.000−97.035 mm (3.8189−3.8203 in.)
Maximum diameter:
A: 104.060 mm (4.0969 in.)
B: 97.060 mm (3.8213 in.)
2. MEASURE FRONT DIFFERENTIAL CASE
Using a micrometer, measure the outer diameter of the front dif-
ferential case.
Standard diameter:
A: 103.929−103.964 mm (4.0917−4.0931 in.)
B: 96.929−96.964 mm (3.8161−3.8175 in.)
Minimum diameter:
A: 103.850 mm (4.0887 in.)
B: 96.850 mm (3.8130 in.)
3. MEASURE CONICAL SPRING WASHER
Using calipers, measure the height of the conical spring wash-
er.
Standard height:
No.2 differential case side
2.60−2.80 mm (0.102−0.110 in.)
No.1 differential case side
1.70−1.90 mm (0.067−0.075 in.)
Minimum height:
No.2 differential case side
2.50 mm (0.098 in.)
No.1 differential case side
1.60 mm (0.063 in.)

Z12494
MX0DY−01
Z12381
SST
Z12496
Q06288
SST
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−63
1996 RAV4 (RM447U)
REPLACEMENT
1. Transmission Case Side:
REPLACE OIL SEAL AND TAPERED ROLLER BEAR-
ING OUTER RACE
(a) Using a screwdriver, remove the oil seal.
(b) Remove the transmission oil baffle.
(c) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly.
(d) Remove the adjust shim.
(e) Install the adjust shim.
(See page MX−65)
HINT:
First select and install a shim of less thickness than before.
(f) Using SST and a press, install the tapered roller bearing
outer race.
SST 09316−60011 (09316−00011, 09316−00041)
(g) Install the transmission oil baffle.
HINT:
Install the transmission oil baffle projection into the case side
cutout.
(h) Using SST, drive in a new oil seal.
SST 09223−15020, 09950−70010 (09951−07150)
(i) Coat the lip of the oil seal with MP grease.

Z12497
Z12383
SST MX−64
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
2. Transaxle Case Side:
REPLACE TAPERED ROLLER BEARING OUTER
RACE
(a) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly through the cutout portion on the
transaxle case.
(b) Using SST and a press, install the tapered roller bearing
outer race.
SST 09316−60011 (09316−00011, 09316−00041)

Q06211
SST
MX02M−03
Q06212
SST
Q06224
Thrust Washer
Thickness
1.0 mm (0.039 in.)
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−65
1996 RAV4 (RM447U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. No.1 Differential Case Side:
INSTALL TAPERED ROLLER BEARING
Using SST, install a new tapered roller bearing.
SST 09316−20011
2. No.2 Differential Case Side:
INSTALL TAPERED ROLLER BEARING
Using SST, install a new tapered roller bearing.
SST 09316−20011
3. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE
GEAR BACKLASH (DIFFERENTIAL SIDE GEAR SUB-
ASSEMBLY SIDE)
(a) Install these parts to the No.1 differential case:
No.2 differential side gear thrust washer
Temporarily install a 1.0 mm (0.039 in.) thick thrust
washer
Differential side gear subassembly
Pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
4 differential pinion shafts