TOYOTA RAV4 1996 Service Repair Manual

Q06192
Q06220
Q06193
MX−66
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
(b) Using a dial indicator, measure the backlash of one pinion
gear while holding the differential side gear sub assembly
toward the case.
Standard backlash: 0.05−0.20 mm (0.0020−0.0079 in.)
HINT:
Push the pinion gear of the right side of the differential case.
If the backlash is out of the specification, refer to the table below
and select a thrust washer which will ensure that the backlash
is within the specification.
MarkThickness mm (in.)MarkThickness mm (in.)
−0.80 (0.0315)−1.15 (0.0453)
−0.85 (0.0335)−1.20 (0.0472)
−0.90 (0.0354)−1.25 (0.0492)
−0.95 (0.0374)−1.30 (0.0512)
−1.00 (0.0394)−1.35 (0.0531)
−1.05 (0.0413)−1.40 (0.0551)
−1.10 (0.0433)−−
(c) Disassemble the No.1 differential case.
4. ASSEMBLE NO.1 DIFFERENTIAL CASE
Install these parts to the No.1 differential case:
No.2 side gear thrust washer (previously selected)
Conical spring washer
Differential side gear subassembly
Pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
4 differential pinion shafts
HINT:
Ensure that the conical spring washer is installed correctly.
5. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR
(a) Install the vehicle speed sensor drive gear and spacer.
(b) Using a snap ring expander, install the snap ring.

Q06218
Q06194
Q06195
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−67
1996 RAV4 (RM447U)
6. CHECK AND ADJUST FRONT SIDE GEAR BACK-
LASH (FRONT DIFFERENTIAL CASE SIDE)
(a) Install these parts to the front differential case:
Front differential side gear thrust washer
Front differential side gear
Front differential pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
No.2 front differential pinion shaft
2 front differential pinion shafts
(b) Using a dial indicator, measure the backlash of one pinion
gear while holding the front differential side gear toward
the case.
Standard backlash: 0.05−0.20 mm (0.0020−0.0079 in.)
NOTICE:
Do not mount the surface of front differential case which
contacts with bushing in a vise.
If the backlash is out of the specification, refer to the table below
and select a thrust washer which will ensure that the backlash
is within the specification.
MarkThickness mm (in.)
B1.00 (0.0394)
C1.05 (0.0413)
D1.10 (0.0433)
E1.15 (0.0453)
F1.20 (0.0472)
G1.25 (0.0492)
7. INSTALL SNAP RING
(a) Install the spacer.
(b) Using a snap ring expander, install the shaft snap ring, as
shown.
HINT:
Before installing the shaft snap ring, wrap vinyl tape around the
case to avoid damaging the case.

Q06221
Q06196
MX−68
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
8. CHECK AND ADJUST FRONT DIFFERENTIAL SIDE
GEAR THRUST CLEARANCE (NO.2 DIFFERENTIAL
CASE SIDE)
(a) Install these parts to the No.2 differential case:
No.2 differential side gear thrust washer
Front differential side gear thrust washer
Front differential side gear
Front differential case assembly
HINT:
Engage the front differential side gear and pinion gear of the
front differential case.
(b) Using a dial indicator, measure the thrust clearance of the
front differential side gear while holding the front differen-
tial case on the No.2 differential case side.
Standard clearance: 0.17−0.26 mm (0.007−0.010 in.)
HINT:
Turning the side gear a bit, check the maximum value of the
thrust clearance.
If the backlash is out of the specification, refer to the table below
and select a thrust washer which will ensure that the backlash
is within the specification.
MarkThickness mm (in.)MarkThickness mm (in.)
A0.95 (0.0374)F1.20 (0.0472)
B1.00 (0.0394)G1.25 (0.0492)
C1.05 (0.0413)H1.30 (0.0512)
D1.10 (0.0433)J1.35 (0.0531)
E1.15 (0.0453)K1.40 (0.0551)
(c) Disassemble the No.2 differential case.
9. INSTALL RING GEAR
(a) Clean the contact surface of the differential left case.
(b) Heat the ring gear to about 100°C (212°F) in boiling wa-
ter.
(c) Carefully take the ring gear out of the water.
(d) Clean the contact surface of the ring gear with cleaning
solvent.
(e) Quickly install the ring gear on the differential case.
HINT:
Align the matchmarks on the No.2 differential case and connect
the ring gear.

Q06225
Thrust Washer
Thickness
1.0 mm (0.039 in.)
Q06213
Plastigage
Plastigage
Q06214Matchmarks
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−69
1996 RAV4 (RM447U)
10. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE
GEAR THRUST CLEARANCE (FRONT DIFFERENTIAL
CASE SIDE)
(a) Install these parts:
Front differential case assembly
Front differential side gear
Front differential side gear thrust washer
Temporarily install a 1.0 mm (0.039 in.) thick
No.2 differential side gear thrust washer
No.2 differential side gear thrust washer
HINT:
Engage the front differential side gear and pinion gear of
the No.1 differential case.
The temporarily installed a 1.0 mm (0.039 in.) thick No.2
side gear thrust washer is used for reference when check-
ing backlash.
(b) Clean the contact surface of the No.2 side gear thrust
washer and No.2 differential case.
(c) Apply plastigage on the No.2 side gear thrust washer, as
shown.
HINT:
Apply the plastigage on the No.2 side gear thrust washer in the
4 positions directly above the pinion shafts in the No.1 differen-
tial case’s position.
(d) Install the No.2 differential case downward.
HINT:
Align the matchmarks on the No.1 differential case and contact
the No.2 differential case.
(e) Install and torque the 16 bolts.
Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf)
(f) Remove the 16 bolts and No.2 differential case upward.

Q06273
Q06274
Q06214Matchmarks MX−70
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
(g) Measure the Plastigage at its widest point.
Standard clearance: 0.16−0.25 mm (0.006−0.010 in.)
(h) Refer to the table below, select the No.2 thrust washer
which will ensure that the backlash is within the specifica-
tion. Try to select a washer of the same size.
MarkThickness mm (in.)MarkThickness mm (in.)
−0.80 (0.0315)−1.15 (0.0453)
−0.85 (0.0335)−1.20 (0.0472)
−0.90 (0.0354)−1.25 (0.0492)
−0.95 (0.0374)−1.30 (0.0512)
−1.00 (0.0394)−1.35 (0.0531)
−1.05 (0.0413)−1.40 (0.0551)
−1.10 (0.0433)−−
(i) Remove the No.2 differential case, No.2 side gear thrust
washer and (temporarily install) a 1.0 mm (0.039 in.) thick
No.2 side gear thrust washer.
11. ASSEMBLE NO.2 DIFFERENTIAL CASE
(a) Install the No.2 side gear thrust washer (previously se-
lected) and conical spring washer to the front differential
case.
HINT:
Be careful not to mistake the direction of the conical spring
washer.
(b) Install the No.2 differential case to the No.1 differential
case.
HINT:
Align the matchmarks on the No.2 differential case and connect
the No.1 differential case.
(c) Install and torque the 16 bolts.
Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf)
12. ADJUST DIFFERENTIAL CASE SIDE BEARING PRE-
LOAD
(a) Install the differential case assembly to the transaxle
case.
(b) Install the transmission case.
HINT:
If necessary, tap on the transmission case with a plastic ham-
mer.
(c) Install and torque the 17 bolts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

Q06275
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−71
1996 RAV4 (RM447U)
(d) Turn the differential case assembly right and left 2 or 3
times to allow the bearings to settle.
(e) Using a spring tension gauge, measure the preload.
Preload (at starting):
New bearing (Output shaft preload plus)
31−61 N (3.2−6.3 kgf, 7−14 lbf)
Reused bearing (Output shaft preload plus)
20−39 N (2.0−4.0 kgf, 4−9 lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.
HINT:
The total preload will change about 5.1 N (0.5 kgf, 1.1 lbf) for
every 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)
(f) Remove the 17 bolts, tap the transmission case with a
plastic hammer and remove it.
(g) Remove the differential case assembly.

MX063−02
Q10401
Differential Lock Control Switch
Solenoid Hose No.0
Differential Lock
Control Solenoid
Differential Lock ActuatorDifferential Lock Indicator
SwitchIntegration Relay
Solenoid Hose No.1
Solenoid Hose No.2
Solenoid Hose No.3 MX−72
− MANUAL TRANSAXLEDIFFERENTIAL LOCKING SYSTEM (4WD)
1996 RAV4 (RM447U)
DIFFERENTIAL LOCKING SYSTEM (4WD)
LOCATION

MX0C0−02
Q06152
− MANUAL TRANSAXLEDIFFERENTIAL LOCKING SYSTEM (4WD)
MX−73
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT CENTER DIFFERENTIAL LOCK SYSTEM
(a) Inspect the differential lock operation.
(1) Use a lift or jack stand to lift up the vehicle so that
all 4 tires can rotate.
(2) Apply the parking brake and start the engine.
(3) Set the center differential lock switch to ON.
(4) Depress the clutch pedal and shift into the 2nd gear.
(5) With the engine idling, gradually engage the clutch
and check that the engine stops.
(6) With the parking brake and engine ON, turn the cen-
ter differential lock switch OFF.
(7) Depress the clutch pedal and shift into the 2nd gear.
(8) With the engine idling, gradually engage the clutch
and check that the front wheels rotate.
HINT:
This inspection must be done when the engine is idling.
(b) Inspect the center differential lock indicator operation.
(1) Turn the ignition switch ON.
(2) Check that when the differential lock switch is
turned ON and OFF, the differential lock indicator
lamp lights up and goes off, respectively.
(c) Inspect the center differential lock warning buzzer opera-
tion.
(1) Start the engine and check that the differential lock
warning buzzer does not sound when the center dif-
ferential lock switch is turned ON.
(2) Interchange the solenoid hose No.1 and solenoid
hose No.2 between the differential lock control sole-
noid No.1 and No.2 and the differential lock actua-
tor. And check that the differential lock warning
buzzer sounds when the differential lock switch is
turned OFF.
(3) Return the solenoid hose No.1 and solenoid hose
No.2 to their original location, and check that the dif-
ferential lock warning buzzer stops.
HINT:
Do the inspection with the vehicle stopped.
After finishing the inspection, inspect the differential lock
control solenoid hoses.

Z13341
Q06243
Q06242
BE2682
MX−74
− MANUAL TRANSAXLEDIFFERENTIAL LOCKING SYSTEM (4WD)
1996 RAV4 (RM447U)
2. INSPECT DIFFERENTIAL LOCK CONTROL COM-
PONENTS
(a) Inspect the differential lock control switch continuity.
Switch PositionTester ConnectionSpecified Condition
OFF (Free)7−10Continuity
ON (Lock)7−8Continuity
Illumination circuit2−3Continuity
If continuity is not as specified, check the bulb or replace the
switch.
(b) Inspect the differential lock warning buzzer.
(1) Remove the combination meter, then remove the
differential lock warning buzzer.
(2) Taking care to match the polarity of the buzzer, ap-
ply battery positive voltage to the terminals of the
buzzer and check that the buzzer sounds.
(c) Inspect the differential lock indicator switch continuity.
Switch PositionTester ConnectionSpecified Condition
Free1 − 2No continuity
Push1 − 2Continuity
If continuity is not as specified, replace the switch.

− MANUAL TRANSAXLEDIFFERENTIAL LOCKING SYSTEM (4WD)
MX−75
1996 RAV4 (RM447U)
3. INSPECT DIFFERENTIAL LOCK CONTROL SOLE-
NOID
Inspect the differential lock control solenoid.
(1) Disconnect the connector from the solenoid No.1
and No.2.
(2) Check continuity to each port when battery positive
voltage is applied and not applied to the connector
terminals of the solenoid No.1 and No.2.
Solenoid No.1
ConditionPort
Battery positive voltageE1 − Air
No voltageG − E1
Solenoid No.2
ConditionPort
Battery positive voltageF − E2
No voltageE2 − Air
4. INSPECT TRANSFER VACUUM ACTUATOR
(a) Vacuum Tank:
Inspect the transfer vacuum tank.
(1) Disconnect the solenoid hose No.0, No.2 and No.3
from the solenoid.
(2) Fill in the No.3 hose with a plug.
(3) Check that the indicator needle remains steady
when a vacuum of 500 mmHg (19.685 in.Hg) is ap-
plied to the hose No.0.
Standard:
Indicator falls 45 mmHg (1.772 in.Hg) or less during 15
seconds.
(b) Diaphragm (Lock Side):
Inspect the transfer vacuum tank.
(1) Disconnect the solenoid hose No.1 and No.2 from
the solenoid.
(2) Check that the indicator needle remains steady
when a vacuum of 500 mmHg (19.685 in.Hg) is ap-
plied to the hose No.1.
Standard:
Indicator falls 45 mmHg (1.772 in.Hg) or less during 15
seconds.