TOYOTA RAV4 1996 Service Repair Manual

R05752
SST
R11852
Weight
R04211
Tires
(3 or more)Inner Diam.
Width RS−16
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 RAV4 (RM447U)
(d) Install the SST.
CAUTION:
Place the disc wheel on level ground.
(1) Connect the SST connector to the steering wheel
pad connector.
SST 09082−00700, 09082−00760
NOTICE:
To avoid damaging the SST connector and wire harness,
do not lock the secondary lock of the twin lock. Also, pro-
vide some slack for the SST wire harness inside the disc
wheel.
(2) Move the SST to at least 10 m (33 ft) away from the
steering wheel pad tied down on the disc wheel.
(e) Cover the steering wheel pad with cardboard box or tires.
Covering method using cardboard box:
Cover the steering wheel pad with the cardboard
box and weight the cardboard box down in 4 places
with at least 190 N (20 kg, 44 lb).
Size of cardboard box:
Must exceed the following dimensions:
x= 460 mm (18.11 in.)
When dimension y of the cardboard box exceeds the
diameter of the disc wheel with tire to which the steer-
ing wheel pad is tied −
x= 460 mm (18.11 in.) + width of tire
y= 650 mm (25.59 in.)
NOTICE:
If a cardboard box smaller than the specified size is used,
the cardboard box will be broken by the shock of the airbag
deployment.
Covering method using tires:
Place at least 3 tires without disc wheel on top of the
disc wheel with tire to which the steering wheel pad
is tied.
Tire size: Must exceed the following dimensions−
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Do not use tires with disc wheels.

H03208
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS−17
1996 RAV4 (RM447U)
NOTICE:
The tires may be marked by the airbag deployment, so use
redundant tires.
(f) Deploy the airbag.
(1) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the battery negative
(−) terminal.
(2) Confirm that no one is within 10 m (33 ft) area
around the disc wheel to which the steering wheel
pad is tied.
(3) Press the SST activation switch and deploy the air-
bag.
HINT:
The airbag deploys simultaneously as the LED of the SST ac-
tivation switch lights up.
(g) Dispose of the steering wheel pad (with airbag).
CAUTION:
The steering wheel pad is very hot when the airbag is
deployed, so leave it alone for at least 30 minutes af-
ter deployment.
Use gloves and safety glasses when handling a steer-
ing wheel pad with deployed airbag.
Always wash your hands with water after completing
the operation.
Do not apply water, etc. to a steering wheel pad with
deployed airbag.
(1) Remove the steering wheel pad from the disc
wheel.
(2) Place the steering wheel pad in a vinyl bag, tie the
end tightly and dispose of it in the same way as oth-
er general parts.

RS031−08
RS−18
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 RAV4 (RM447U)
REPLACEMENT
REPLACEMENT REQUIREMENTS
In the following cases, replace the steering wheel pad, steering wheel or spiral cable.
CaseReplacing part
If the airbag has been deployed.Steering wheel pad
If the steering wheel pad has been found to be faulty in troubleshooting.Steering wheel pad
If the spiral cable has been found to be faulty in troubleshooting.Spiral cable
If the steering wheel pad has been found to be faulty during checking items.
(See page RS−9)Steering wheel pad
If the steering wheel has been found to be faulty during checking items.
(See page RS−9)Steering wheel
If the spiral cable has been found to be faulty during checking items.
(See page RS−9)Spiral cable
If the steering wheel pad has been dropped.Steering wheel pad
CAUTION:
For replacement of the steering wheel pad, see page SR−12 and SR−19, and be sure to follow the
correct procedure.

RS032−10
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS−19
1996 RAV4 (RM447U)
INSTALLATION
(See page SR−19)

SA0T5−01
− SUSPENSION AND AXLETROUBLESHOOTING
SA−1
1996 RAV4 (RM447U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below th help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Wander/pulls
1. Tires (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Steering linkage (Loosen or worn)
4. Hub bearings (Loosen or worn)
5. Steering gear (Out of adjustment or broken)
6. Suspension parts (Worn out)SA−2
SA−4
−
SA−10
SA−52
SA−56
−
−
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn out)−
SA−32
SA−95
SA−35
SA−92
Sways/pitches
1. Tires (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn out)SA−2
SA−49
SA−35
SA−92
Front wheel shimmy
1. Tires (Worn or improperly inflated)
2. Wheels (Out of balance)
3. Shock absorber (Worn out)
4. Wheel alignment (Incorrect)
5. Ball joints (Worn)
6. Hub bearings (Loosen or worn)
7. Steering linkage (Loosen or worn)
8. Steering gear (Out of adjustment or broken)SA−2
SA−2
SA−35
SA−2
SA−45
SA−10
−
−
Abnormal tire wear
1. Tires (Improperly inflated)
2. Wheel alignment (Incorrect)
3. Suspension parts (Worn out)
4. Shock absorber (Worn out)SA−2
SA−4
−
SA−35
SA−92
Noise in rear differential
1. Oil level (Low or wrong grade)
2. Excessive backlash between pinion and ring gear
3. Ring, pinion or side gears (Worn or chipped)
4. Pinion shaft bearing (Worn)
5. Side bearing (Worn)
6. Differential bearing (Loosen or worn)SA−69
SA−79
SA−79
SA−79
SA−79
SA−79
Oil leak from rear differential
1. Oil level (Too high or wrong grade)
2. Drive pinion oil seal (Worn or damaged)
3. Side gear oil seal (Worn or damaged)
4. Companion flange (Loose or damaged)
5. Side gear shaft (Damaged)SA−69
SA−79
SA−79
SA−74
SA−79

SA0T6−02
R03031
R14869
R07928
SA−2
− SUSPENSION AND AXLETIRE AND WHEEL
1996 RAV4 (RM447U)
TIRE AND WHEEL
INSPECTION
1. INSPECT TIRE
(a) Check the tires for wear and proper inflation pressure.
Cold tire inflation pressure
Tire sizeFront
kPa (kgf/cm2
or bar, psi)
Rear
kPa (kgf/cm2 or bar, psi)
3 Door vehicle
215/70R16 99S180 (1.8, 26)180 (1.8, 26)
5 Door vehicle
215/70R16 99S190 (1.9, 28)180 (1.8, 26)
(b) Check the tire runout.
Tire runout: 1.0 mm (0.039 in.) or less
2. ROTATING TIRES
HINT:
See the illustration for where to rotate each tire.
3. INSPECT WHEEL BALANCE
(a) Check and adjust the Off−the−car balance.
(b) If necessary, check and adjust the On−the−car−balance.
Imbalance after adjustment: 13.0 g (0.029 lb) or less

R10657
− SUSPENSION AND AXLETIRE AND WHEEL
SA−3
1996 RAV4 (RM447U)
4. CHECK WHEEL BEARING LOOSENESS
(a) Check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
(b) Check the axle hub deviation.
Maximum: 0.07 mm (0.0028 in.)
5. CHECK FRONT SUSPENSION FOR LOOSENESS
6. CHECK STEERING LINKAGE FOR LOOSENESS
7. CHECK BALL JOINT FOR LOOSENESS
8. CHECK SHOCK ABSORBER WORKS PROPERLY
Check for oil leak
Check mounting bushings for wear
Check bounce for front and rear of the vehicle

R10734R10735
F02020
Front:
Rear:SA0T7−05
Z03382
SA3213
A
CB
FrontD SA−4
− SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
1996 RAV4 (RM447U)
FRONT WHEEL ALIGNMENT
INSPECTION
1. MEASURE VEHICLE HEIGHT
Tire sizeFront*1
mm (in.)Rear*2
mm (in.)
215/70R16 (2WD)227 (8.94)353 (13.90)
215/70R16 (4WD)227 (8.94)360 (14.17)
*1: Front measuring point:
Measure from the ground to the center of the lower suspension
arm front mounting bolt.
*
2: Rear measuring point:
Measure from the ground to the center of the body side No.1
suspension arm mounting bolt.
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to the specification.
If the vehicle height is not to specification, try to adjust it by
pushing down on or lifting the body.
2. INSTALL CAMBER−CASTER−KINGPIN GAUGE
ONTO VEHICLE OR POSITION VEHICLE ON WHEEL
ALIGNMENT TESTER
Follow the specific instructions of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
Tire size: 215/70R16
2WD4WD
Camber
Left−right error−0°20’ ± 45’
(−0.33°± 0.75°)
45’ (0.75°) or less−0°15’± 45’
(−0.25° ± 0.75°)
45’ (0.75°) or less
Caster
Left−right error1°25’ ± 45’
(1.42° ± 0.75°)
45’ (0.75°) or less1°20 ± 45’
(1.33° ± 0.75°)
45’ (0.75°) or less
Steering axis inclination
Left−right error11°00’ ± 45’
(11° ± 0.75°)
45’ (0.75°) or less10°45’ ± 45’
(10.75° ± 0.75°)
45’ (0.75°) or less
If the caster and steering axis inclination are not within the spec-
ification, after the camber has correctly adjusted, recheck the
suspension parts for damaged and/or worn out parts.
4. INSPECT TOE−IN
To e−in
(total)A + B: 0° ± 0’10’ (0° ± 0.17°)
C D: 0 ± 2 mm (0 ± 0.08 in.)
If the toe−in is not within the specification, adjust it by the tie rod
end.

R10850
W01204
F01195
Bolt
Set Bolt Adjusting Bolt
1 Dot 2 Dots 3 Dots
30’
45’
1°15’
1°30’
Adjusting
ValueOD=13.9 mmOD=13.3 mm OD=12.4 mm
Original
15’
1°00’
− SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
SA−5
1996 RAV4 (RM447U)
5. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe−in.
(a) Remove the front wheels.
(b) Remove the 2 nuts on the lower side of the shock absorb-
er.
(c) Coat the threads of the nuts with engine oil.
(d) Temporarily install the 2 nuts.
(e) Adjust the camber by pushing or pulling the lower side of
the shock adjustment is required.
(f) Tighten the 2nuts.
Torque: 158 N·m (1,610 kgf·cm, 117 ft.lbf)
(g) Install the front wheels.
Torque: 103 N·m (1,050 kgf·cm, 76 ft.lbf)
(h) Check the camber.
HINT:
Try to adjust the camber to the center value.
Adjusting value for the set bolts is 6’ − 30’ (0.1° − 0.5°).
If the camber is not within the specification, using the table be-
low, estimate for how much additional camber adjustment will
be required, and select the camber adjusting bolt.

W01205
1
2
R10746
R10747
SA0028
AB
FrontA B
A: Inside
B: Outside SA−6
− SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
1996 RAV4 (RM447U)
(i) Follow the above mentioned steps again. Between the
step (b) and (c), exchange 1 or 2 selected bolts.
HINT:
When exchanging the 2 bolts, exchange 1 bolt for each time.
6. ADJUST TOE−IN
(a) Remove the boot clamps.
(b) Loosen the tie rod end lock nuts.
(c) Turn the left and right rack ends an equal amount to adjust
the toe−in.
HINT:
Try to adjust the toe−in to the center value.
Make sure that the length of the left and right rack ends
is the same.
Tie rod end length difference:
1.5 mm (0.059 in.) or less
(d) Torque the tie rod end lock nuts.
Torque: 56 N·m (570 kgf·cm, 41 ft·lbf)
(e) Place the boot on the seat and install the clamp.
HINT:
Make sure that the boots are not twisted.
7. INSPECT WHEEL ANGLE
Turn the steering wheel fully, and measure the turning angle.
Inside wheel33°15’ ± 2.0° (33.25° ± 2.0°)
Outside wheel: Reference28°05’ (28.08°)
If the wheel angles differ from the standard specification, adjust
the toe−in.