TOYOTA RAV4 1996 Service Repair Manual

SA0T8−05
SA3213
AB
D
Front
C
W01763
− SUSPENSION AND AXLEREAR WHEEL ALIGNMENT
SA−7
1996 RAV4 (RM447U)
REAR WHEEL ALIGNMENT
INSPECTION
1. MEASURE VEHICLE HEIGHT (See page SA−4)
NOTICE:
Before inspect the wheel alignment, adjust the vehicle
height to specification.
2. INSTALL CAMBER−CASTER−KINGPIN GAUGE OR
ONTO WHEEL ALIGNMENT TESTER
Follow the specifications of the equipment manufacturer.
3. INSPECT CAMBER
2WD4WD
Camber
Left−right error−1°20’ ± 45’
(1.33° ± 0.75°)
45’ (0.75°) or less−1°05’ ± 45’
(1.08° ± 0.75°)
45’ (0.75°) or less
If the camber is not within the specification, adjust it by the cam-
ber adjust cam.
4. INSPECT TOE−IN
2WD
To e−in
(total)A + B: 0°20’ ± 0’10’ (0.33° ± 0.17°)
C − D: 4 ± 2 mm (0.16 ± 0.08 in.)
4WD
To e−in
(total)A + B: 0°15’ ± 0’10’ (0.25° ± 0.17°)
C − D: 3 ± 2 mm (0.12 ± 0.08 in.)
If the toe−in is not within the specification, adjust it by the toe−
adjust cam.
If the toe−in is not within the specification, adjust it by the toe−
adjust cam.
5. ADJUST CAMBER
(a) Loosen the camber adjust cam lock bolt.
(b) Turn the camber adjust cam to adjust camber.
HINT:
Try to adjust the camber to the center value.
The camber will change about 16’ (0.27°) with each grad-
uation of the cam.
(c) Torque the lock bolt.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)

R10782
W01761
SA−8
− SUSPENSION AND AXLEREAR WHEEL ALIGNMENT
1996 RAV4 (RM447U)
6. ADJUST TOE−IN
(a) Measure the distance between each wheel disc and cor-
ner of the cam bracket, then confirm that both are the
same.
Left−right difference: 1 mm (0.04 in.) or less
If the left−right difference is larger than 1 mm (0.04 in.), adjust
it by following the procedures below.
(b) Loosen the toe−adjust cam lock bolt.
(c) Turn the toe−adjust cam an equal amount to adjust toe−
in.
HINT:
Try it adjust the tie−in to the center value.
The toe−in will change about 2.5 mm (0.10 in.) with each
graduation of the cam (both side).
(d) Torque the lock bolts.
Torque: 132 N·m (1,350 kgf·cm, 97 ft·lbf)

SA0T9−03
Z19327
49
ABS Speed Sensor158 (1,610, 117)
49 (500, 36)
8.3 (85, 74 in.·lbf)
127 (1,300, 94)
107 (1,090, 79)
Steering Knuckle
with Axle Hub
Axle Hub Snap Ring Oil Seal
Lower Ball JointSteering Knuckle Front Shock Absorber
Lower
Suspension
Arm
Lock CapCotter Pin 
5 (55, 48 in.·lbf)
Front Drive Shaft
Tie Rod End
Hub Bolt
Disc Cotter Pin

Brake Caliper
Dust Deflector 
Dust Cover 
Bearing 
Cotter Pin 
Oil Seal  N·m (kgf·cm, ft·lbf)
Non−reusable part: Specified torque

216 (2,200, 159)
127 (1,300, 94)

8 (80, 69 in.·lbf)
− SUSPENSION AND AXLEFRONT AXLE HUB
SA−9
1996 RAV4 (RM447U)
FRONT AXLE HUB
COMPONENTS

SA0TA−03
R10657
R10655
SA−10
− SUSPENSION AND AXLEFRONT AXLE HUB
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050kgf·cm, 76 ft·lbf)
2. CHECK BEARING BACKLASH AND AXLE HUB DEVI-
ATION
(a) Remove the 2 bolts and brake caliper from the steering
knuckle.
(b) Support the brake caliper securely.
(c) Remove the disc.
(d) Using a dial indicator near the center of the axle hub and
check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the bearing.
(e) Using a dial indicator, check the deviation at the surface
of the axle hub outside the hub bolt.
Maximum: 0.07 mm (0.0028 in.)
If the deviation exceeds the maximum, replace the axle hub and
bearing.
3. REMOVE DRIVE SHAFT LOCK NUT
(a) Install the disc and brake caliper.
Torque: 107 N·m (1,090 kgf·cm, 79 ft·lbf)
(b) Remove the cotter pin and lock cap.
(c) With applying the brakes, remove the nut.
Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf)
(d) Remove the brake caliper and disc.
4. w/ ABS:
REMOVE ABS SPEED SENSOR AND WIRE HARNESS
FROM STEERING KNUCKLE
Remove the 2 bolts, ABS speed sensor and wire harness.
Torque:
ABS speed sensor x Steering knuckle:
8 N·m (80 kgf·cm, 69 in.·lbf)
ABS speed sensor wire x Steering knuckle:
5 N·m (55 kgf·cm, 48 in.·lbf)
5. LOOSEN 2 NUTS ON LOWER SIDE ON SHOCK AB-
SORBER
Torque: 158 N·m (1,610 kgf·cm, 117 ft·lbf)
HINT:
Do not remove the 2 nuts and bolts.
6. D I S C O N N E C T T I E R O D E N D F R O M S T E E R I N G
KNUCKLE
(a) Remove the cotter pin and nut.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)

R10678
SST
− SUSPENSION AND AXLEFRONT AXLE HUB
SA−11
1996 RAV4 (RM447U)
(b) Using SST, disconnect the tie rod end from the steering
knuckle.
SST 09610−20012
7. DISCONNECT LOWER BALL JOINT FROM LOWER
ARM
Remove the bolt and 2 nuts.
Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf)
8. REMOVE STEERING KNUCKLE WITH AXLE HUB
HINT:
At the time of installation, please refer to the following item.
Coat the threads of the nut’s with engine oil.
NOTICE:
Be careful not to damage the oil seal, boot and ABS speed
sensor rotor.

SA0TB−01
R10677
SST
R10676
SST
R10675
SST
SST
F01922
SST
SA−12
− SUSPENSION AND AXLEFRONT AXLE HUB
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE DUST DEFLECTOR
Using a screwdriver, remove the dust deflector.
2. REMOVE LOWER BALL JOINT
(a) Remove the cotter pin and nut.
(b) Using SST, remove the lower ball joint.
SST 09628−62011
3. REMOVE AXLE HUB
(a) Using SST, remove the axle hub.
SST 09520−00031
(b) Using SST, remove the inner race (outside) from the axle
hub.
SST 09950−40010 (09951−04020, 09952−04010,
09953−04020, 09954−04010, 09955−04060,
09957−04010, 09958−04010),
09950−60010 (09951−00370)
4. REMOVE DUST COVER
Remove the 4 bolts and dust cover.
5. REMOVE OIL SEALS
(a) Using SST, remove the inner oil seal.
SST 09308−00010

F01923
SST
R10731
SST
SST
− SUSPENSION AND AXLEFRONT AXLE HUB
SA−13
1996 RAV4 (RM447U)
(b) Using SST, remove the outer oil seal.
SST 09308−00010
6. REMOVE BEARING FROM STEERING KNUCKLE
(a) Using snap ring pliers, remove the snap ring.
(b) Place the inner race on the outside of the bearing.
(c) Using SST and a press, remove the bearing.
SST 09527−17011, 09950−60010 (09951−00540),
09950−70010 (09951−07150)

SA0TC−02
R10732
SST
R10737
SST
SST
W01224
SST
SST
R10736
SST
SST
R10771
SST
SST SST SA−14
− SUSPENSION AND AXLEFRONT AXLE HUB
1996 RAV4 (RM447U)
REASSEMBLY
1. INSTALL BEARING
(a) Using SST and press, install a new bearing to the steering
knuckle.
SST 09608−32010, 09950−70010 (09951−07150)
(b) Using snap ring pliers, install a new snap ring.
2. INSTALL DUST COVER
Install the dust cover with the 4 bolts.
Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf)
3. INSTALL NEW OUTER OIL SEAL
(a) Using SST and a hammer, install a new outer oil seal.
SST 09608−32010, 09950−70010 (09951−07150)
(b) Apply MP grease to the oil seal lip.
4. INSTALL FRONT AXLE HUB
Using SST and a press, install the axle hub.
SST 09527−17011, 09950−60010 (09951−00370),
09950−70010 (09951−07150)
5. INSTALL NEW INNER OIL SEAL
(a) Using SST and a hammer, install a new inner oil seal.
SST 09608−32010, 09950−70010 (09951−07150)
(b) Apply MP grease to the oil seal lip.
6. INSTALL DUST DEFLECTOR
Using SST and a hammer, install a new dust deflector.
SST 09316−20011, 09608−32010, 09950−70010
(09951−07150)
HINT:
Align the holes for the ABS speed sensor in the dust deflector
and steering knuckle.

− SUSPENSION AND AXLEFRONT AXLE HUB
SA−15
1996 RAV4 (RM447U)
7. INSTALL LOWER BALL JOINT
(a) Install the lower ball joint and torque the nut.
Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf)
(b) Install a new cotter pin.

SA0TD−04
SA−16
− SUSPENSION AND AXLEFRONT AXLE HUB
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−10).
AFTER INSTALLATION, CHECK ABS SPEED SENSOR SIGNAL (See page DI−257) AND FRONT
WHEEL ALIGNMENT (See page SA−4)