TOYOTA RAV4 1996 Service Repair Manual

W01994
Vinyl Tape
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA−27
1996 RAV4 (RM447U)
(e) Temporarily the install new outboard and inboard joint
boots and new boot clamps.
HINT:
Before installing the 2 boots, wrap vinyl tape around the spline
of the drive shaft to prevent damaging the boots.
(1) Place 2 new clamps on a new outboard joint boot
and install the boot to the drive shaft.
(2) Temporarily install a new inboard joint boot to the
drive shaft.
(f) Assembly the inboard joint.
(1) Using a snap ring expander, install a new snap ring.
(2) Install the cage to the drive shaft.
NOTICE:
The side with smaller diameter must face outboard.
(3) Align the matchmarks placed before disassembly.
(4) Using a brass bar and hammer, tap in the inner race
to the drive shaft.
NOTICE:
Be careful not to damage the inner race.
(5) Using a snap ring expander, install a new snap ring.
(g) Install the boot to outboard joint.
Before assembling the boot, pack the outboard joint and
boot with grease in the boot kit.
HINT:
Use the grease supplied in the boot kit.
Grease capacity (Color = Black):
115 − 135 g (4.1 − 4.8 oz.)
(h) Install the inboard joint tulip (or center drive shaft) to front
drive shaft.
(1) Pack the inboard joint and boot with grease in the
boot kit.
HINT:
Use the grease supplied in the boot kit.
Grease capacity (Color = Yellow ocher):
115 − 135 g (4.1 − 4.8 oz.)
(2) Align the matchmarks placed before removal, and
install the cage to the inner race.
(3) Install the 6 balls.
HINT:
Apply grease onto the balls to keep them from falling.
(4) Align the matchmarks placed before assembly, and
install the inboard joint tulip or center drive shaft to
the drive shaft.
(5) Install a new snap ring.
(6) Temporarily install the boot to the inboard joint tulip.
(i) Assemble the boot clamps to both boots.
(1) Make sure that the 2 boots are on the shaft groove.

W01213
RH
LH
R10353
SST
F01439
w/o ABS w/ ABS
SST
SA1453
W00880
SST SA−28
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 RAV4 (RM447U)
(2) Make sure that the 2 boots are not stretched or con-
tracted when the drive shaft is at standard length.
Drive shaft standard length:
RH842.9 ± 5.0 mm (33.185 ± 0.197 in.)
LH542.6 ± 5.0 mm (21.362 ± 0.197 in.)
(3) Place 2 new boot clamps to the inboard joint boot.
(4) Bend the band and lock it with a screwdriver.
(5) Secure the 2 clamps onto the boot.
(6) Place SST onto the clamps.
SST 09521−24010
(7) Tighten the SST so that the clamps.
NOTICE:
Do not overtighten the SST.
(8) Using SST, adjust the clearance of the clamps.
SST 09240−00020
Clearance: 1.9 mm (0.075 in.)
2. 2WD A/T and 4WD:
REASSEMBLE DRIVE SHAFT
(a) Install the No.2 dust deflector.
Using SST and a press, install a new No.2 dust deflector.
SST 09309−36010, 09316−20011
(b) 2WD RH:
Assemble the center drive shaft.
(1) Using a pin punch and hammer, install the straight
pin into the bearing case.
(2) Using SST and a press, install a new bearing into
the bearing case.
SST 09950−60010 (09951−00580),
09950−70010 (09951−07150)
(3) Using a screwdriver, install a new snap ring.

SA1456
SST
FA1971
SST 1.0 mm
(0.039 in.)
FA1889
86 − 87 mm
(3.39 − 3.43 in.)
SA1459
RA1310
Vinyl Tape
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA−29
1996 RAV4 (RM447U)
(4) Using SST and a press, install the bearing with the
bearing case assembly to the center drive shaft.
SST 09710−30021 (09710−03141)
(5) Using a snap ring expander, install a new snap ring.
(6) Using SST, an extension bar and press, install a
new dust cover.
SST 09506−35010
HINT:
The clearance between the dust cover and bearing should be
kept in the ranges shown in the illustration.
(c) 2WD RH:
Install the dust cover.
Using a steel plate and press, install a new dust cover until
the distance from the tip of the center drive shaft to the
dust cover reaches the specification, as shown in the il-
lustration.
(d) 2WD LH and 4WD:
Install the dust cover.
Using a press, install a new dust cover.
(e) Temporarily install the new outboard and inboard joint
boots.
HINT:
Before installing the 2 boots, wrap vinyl tape around the spline
of the drive shaft to prevent damaging the boots.
(1) Temporarily install a new outboard joint boot to the
drive shaft.
(2) Temporarily install a new inboard joint boot to the
drive shaft.
(f) Install the tripod.

W01214
2WD A/T RH
Others SA−30
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 RAV4 (RM447U)
(1) Place the beveled side of the tripod axial spline to-
ward the outboard joint.
(2) Align the matchmarks placed before removal.
(3) Using a brass bar and hammer, tap in the tripod to
the drive shaft.
NOTICE:
Do not tap the roller.
(4) Using a snap ring expander, install a new snap ring.
(g) Install the boot to outboard joint.
Before assembling the boot, pack the outboard joint and
boot with grease in the boot kit.
HINT:
Use the grease supplied in the boot kit.
Grease capacity (Color = Black):
120 − 130 g (4.2 − 4.6 oz.)
(h) Install the inboard joint tulip or center drive shaft to front
drive shaft.
(1) Pack the inboard joint and boot with grease in the
boot kit.
HINT:
Use the grease supplied in the boot kit.
Grease capacity (Color = Yellow ocher):
180 − 190 g (6.3 − 6.7 oz.)
(2) Align the matchmarks placed before removal, and
install the inboard joint tulip on center drive shaft to
the drive shaft.
(3) Temporarily install the boot to the inboard joint tulip.
(i) Assemble the boot clamps to both boots.
(1) Make sure that the 2 boots are on the shaft groove.
(2) Make sure that the 2 boots are not stretched or con-
tracted when the drive shaft is at standard length.
Drive shaft standard length:
2WD A/T RH844.6 ± 5.0 mm (33.252 ± 0.197 in.)
2WD A/T LH548.5 ± 5.0 mm (21.594 ± 0.197 in.)
4WD RH511.2 ± 5.0 mm (20.126 ± 0.197 in.)
4WD LH508.0 ± 5.0 mm (20.000 ± 0.197 in.)
(3) Place 4 new boot clamps to the 2 boots.
(4) Bend the band and lock it with a screwdriver.

SA0TJ−07
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA−31
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order removal (See page SA−20).
AFTER INSTALLATION, CHECK ABS SPEED SENSOR SIGNAL (See page DI−257) AND FRONT
WHEEL ALIGNMENT (See page SA−4)
HINT:
Coat the oil seal lip with MP grease.
Except 2WD RH:
Before installing the drive shaft, set the snap ring opening side facing downward.
Except 2WD RH:
Whether or not the drive shaft is making contact with the pinion shaft can be known by sound or feeling
when driving it in.
Except 2WD RH:
After installation, check that there is 2 − 3 mm (0.08 − 0.12 in.) of play in axial direction.
Except 2WD RH:
After installation, check that the drive shaft can not be pulled out by hand.

SA0TK−03
Z19329
Suspension
Support
No.2
CapSpring Upper Seat
Spring
Bumper
Lower
Insulator
Shock Absorber Coil Spring Upper
Insulator
ABS Speed
Sensor Suspension
Support
Dust Seal Shock Absorber
with Coil Spring
Front Drive Shaft
Flexible Hose
Tie Rod End
Cotter Pin
Disc
Cotter Pin
Lock Cap
Lower Ball JointCotter Pin
Brake Caliper
Lower Suspension Arm80 (820, 59)
47 (475, 34)
5 (55, 48 in.·lbf)
158 (1,610, 117)
107 (1,090, 79)
127 (1,300, 94)
49 (500, 36)
216 (2,200, 159)
127 (1,300, 94)
19 (192, 14)
8 (80, 69 in.·lbf)
Dust Deflector
 

 
N·m (kgf·cm, ft·lbf): Specified torque
Non−reusable part
SA−32
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 RAV4 (RM447U)
FRONT SHOCK ABSORBER
COMPONENTS

SA0TL−03
R10850
R10823
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA−33
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. DISCONNECT FLEXIBLE HOSE AND ABS SPEED
SENSOR WIRE HARNESS (w/ ABS) FROM SHOCK
ABSORBER
Remove the 2 bolts and disconnect the flexible hose and ABS
speed sensor wire harness.
Torque:
Flexible hose: 19 N·m (192 kgf·cm, 14 ft·lbf)
ABS wire harness: 5 N·m (55 kgf·cm, 48 in.·lbf)
3. DISCONNECT SHOCK ABSORBER FROM STEERING
KNUCKLE
Torque: 158 N·m (1,610 kgf·cm, 117 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Coat the nut’s threads with engine oil.
4. REMOVE SHOCK ABSORBER WITH COIL SPRING
Remove the 3 nuts, suspension support No.2 and shock ab-
sorber with the coil spring.
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)

SA0TM−01
R10824
SST Vinyl
Tape
R10825
SST SA−34
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 RAV4 (RM447U)
DISASSEMBLY
REMOVE COIL SPRING
(a) Install 2 nuts and a bolt to the bracket at the lower portion
of the shock absorber and secure it in a vise.
(b) Using SST, compress the coil spring.
SST 09727−30021
HINT:
To prevent the coil spring from damaging, wind vinyl tape on the
coil spring.
NOTICE:
When holding the shock absorber with the coil spring
removed, do not hold it by the spring lower seat. Also,
do not knock the spring lower seat.
Do not use an impact wrench. It will damage the SST.
(c) Remove the cap.
(d) Using SST to hold the spring upper seat, remove the nut.
SST 09729−22031
(e) Remove these parts from the shock absorber:
Suspension support
Dust seal
Spring upper seat
Upper insulator and coil spring
Spring bumper and lower insulator

SA0TN−01
N00203
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA−35
1996 RAV4 (RM447U)
INSPECTION
INSPECT SHOCK ABSORBER
Compress and extend the shock absorber rod and check that
there is no abnormal resistance or unusual operation sounds.
If there is any abnormality, replace the shock absorber with a
new one.
NOTICE:
When discarding the shock absorber, see DISPOSAL on
page SA−36.

SA0TO−01
N00204
SA−36
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 RAV4 (RM447U)
DISPOSAL
1. FULLY EXTEND SHOCK ABSORBER ROD
2. DRILL HOLE TO REMOVE GAS FROM CYLINDER
Using a drill, make a hole between the lines, as shown.
CAUTION:
The gas coming out is harmless, but be careful of chips
which may fly up when drilling.