TOYOTA RAV4 1996 Service Repair Manual

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).

Z12401
SST MX−90
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
(2) Using SST and a spring tension gauge, measure
the driven pinion preload.
SST 09326−20011
HINT:
Turn the driven pinion right and left 2 or 3 times to allow the
bearing to settle.
Preload (at starting):
New bearing
17.7 − 28.4 N (1.8 − 2.9 kgf, 4.0 − 6.4 lbf)
Reused bearing
4.9 − 8.8 N (0.9 − 1.4 kgf, 1.1 − 2.0 lbf)
If the preload exceeds than the specification, re-
place the bearing spacer.
If the preload is less than the specification, retighten
the nut 5−10° gradually a time until the specified
preload is reached.
If the maximum torque is exceeded while retighten-
ing the nut, replace the bearing spacer and repeat
the preload procedure. Do not back off the pinion
nut to reduce the preload.
Torque: 214 N·m (2,184 kgf·cm, 158 ft·lbf) or less
HINT:
Use a torque wrench with a fulcrum length of 50 cm (19.69
in.).
The maximum torque specification for without using SST
is 235 N·m (2,400 kgf·cm, 174 ft·lbf).
(c) Stake the lock nut.
2. ASSEMBLE RING GEAR MOUNTING CASE
(a) Install the transfer ring gear.
(1) Clean the contact surface of the mounting case.
(2) Heat the ring gear to about 100°C (212°F) in boiling
water.
(3) Carefully take the ring gear out of the water.
(4) Clean the contact surface of the ring gear with
cleaning solvent.
(5) Quickly install the ring gear on the mounting case.
HINT:
Align the matchmarks on the mounting case and connect the
ring gear.
(6) Install and torque the 12 bolts.
Torque: 97 N·m (985 kgf·cm, 71 ft·lbf)
(b) Checking the ring gear runout (See page MX−82).

Q06162
SST
Q06163
SST
− MANUAL TRANSAXLETRANSFER (4WD)
MX−91
1996 RAV4 (RM447U)
(c) Install the mounting case left side bearing.
Using SST and a press, install a new left side bearing.
SST 09316−20011
(d) Install the mounting case right side bearing.
Using SST and a press, install a new right side bearing.
SST 09316−20011
3. ADJUST RING GEAR BACKLASH
(a) Install the adjusting shim to the transfer pinion bearing
cage assembly.
HINT:
First install a shim of the same thickness as before.
(b) Install the transfer pinion bearing cage assembly to the
transfer left case.
(c) Install and torque the 6 bolts.
Torque: 39 N·m (400 kgf·cm, 29 kgf·cm)
HINT:
Do not install the O−ring.
(d) Install the ring gear mounting case assembly to the trans-
fer left case.

Q06149
Q06150
SST MX−92
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
(e) Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
(f) Refer to the table below, select a plate washer which will
ensure that the backlash is within the specification. Try to
select a washer of the same size.
HINT:
The backlash will change about 0.02 mm (0.0008 in.) with every
0.03 mm (0.0012 in.) change in shim thickness.
MarkThickness mm (in.)MarkThickness mm (in.)
12.13 (0.0839)132.49 (0.0980)
22.16 (0.0850)142.52 (0.0992)
32.19 (0.0862)152.55 (0.1004)
42.22 (0.0874)162.58 (0.1016)
52.25 (0.0886)172.61 (0.1028)
62.28 (0.0898)182.64 (0.1039)
72.31 (0.0909)192.67 (0.1051)
82.34 (0.0921)202.70 (0.1063)
92.37 (0.0933)212.73 (0.1075)
102.40 (0.0945)222.76 (0.1087)
112.43 (0.0957)232.79 (0.1098)
122.46 (0.0968)242.82 (0.1110)
4. ADJUST TOTAL PRELOAD
(a) Install the transfer right case.
(b) Install and torque the 10 bolts.
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
(c) Adjust the total preload by tightening the differential bear-
ing adjusting nut.
(d) Using SST, tighten the differential bearing adjusting nut.
SST 09318−20010
HINT:
While measuring the preload, tighten the adjusting nut a little at
a time.

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.

Q06135
Q06166
SST
Q06287
SST
Q06168
FIPG
− MANUAL TRANSAXLETRANSFER (4WD)
MX−95
1996 RAV4 (RM447U)
9. INSTALL TRANSFER PINION BEARING CAGE AS-
SEMBLY
(a) Coat the O−ring with gear oil.
(b) Install the O−ring to the transfer pinion bearing cage.
(c) Install the transfer pinion bearing cage with the adjusting
shim (previously selected) to the transfer left case.
(d) Install and torque the 6 bolts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
10. INSTALL RING GEAR MOUNTING CASE ASSEMBLY
11. INSTALL ADJUSTING NUT LOCK PLATE
Using snap ring pliers, install the lock plate so that the projection
from the lock plate fits properly into the groove of the adjusting
nut.
12. INSTALL DIFFERENTIAL SIDE GEAR SHAFT HOLD-
ER
(a) Using SST and a press, install the differential side gear
shaft holder to the transfer right case.
SST 09316−20011
(b) Using snap ring pliers, install the snap ring.
13. INSTALL TRANSFER RIGHT CASE OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09223−15020, 09950−70010 (09951−07150)
(b) Coat the lip of the oil seal with MP grease.
14. INSTALL TRANSFER RIGHT CASE
(a) Apply FIPG to the transfer left case, as shown.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
(b) Apply sealant to the bolt threads.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
(c) Install and torque the 10 bolts.