TOYOTA RAV4 1996 Service Repair Manual

SA0TP−01
R10846
SST
Vinyl Tape
R10826
R10825
SST
R10848
MP Grease
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA−37
1996 RAV4 (RM447U)
REASSEMBLY
1. INSTALL LOWER INSULATOR ONTO SHOCK AB-
SORBER
2. INSTALL SPRING BUMPER TO PISTON ROD
3. INSTALL COIL SPRING AND SUSPENSION SUPPORT
(a) 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:
Do not use an impact wrench. It will damage the SST.
(b) Install the coil spring to the shock absorber.
HINT:
Fit the lower end of the coil spring into the gap of lower spring
seat of the shock absorber.
(c) Align the tab of spring upper seat with the tabs of the up-
per insulator.
(d) Install the spring upper seat with upper insulator to the
shock absorber with the ’OUT’ mark facing the outside of
the vehicle.
(e) Install the dust seal and suspension support.
(f) Using SST to hold the spring upper seat, install a new nut.
SST 09729−22031
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)
(g) Remove the SST.
(h) Pack MP grease into the suspension support.
(i) Install the cap.

SA0TQ−01
SA−38
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−33).
AFTER INSTALLATION, CHECK FRONT WHEEL ALIGNMENT (See page SA−4)

SA0TR−03
Z19330
23 Door vehicle
Stabilizer Bar LinkStabilizer
BarPower Steering Gear Assembly
Bracket
No.1
Bushing
Bushing
Clamp
(A/T Only)
Front Suspension
Crossmember
Center MemberLower Suspension
Arm Bracket
Cushion
Retainer
Lower Suspension Arm
LH Engine Cover
29 (300, 22)
29 (300, 22)
113 (1,150, 83)
8.3 (85, 74 in.·lbf)
112 (1,140, 82)
172 (1,750, 126)
206 (2,100, 152)
127 (1,300, 94)
137 (1,400, 101)
28 (290, 21)

N·m (kgf·cm, ft·lbf)
Non−reusable part: Specified torque
X7
Clamp 137 (1,400, 101)
64 (650, 47)
113 (1,150, 83)5 Door vehicle
− SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
SA−39
1996 RAV4 (RM447U)
FRONT LOWER SUSPENSION ARM
COMPONENTS

SA0TS−03
R10828
A
A B
R10829
W01708
SA−40
− SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. A/T LH:
REMOVE LH ENGINE UNDER COVER
3. EXCEPT A/T LH:
DISCONNECT STABILIZER BAR LINK FROM LOWER
SUSPENSION ARM (See page SA−48)
4. A/T LH:
REMOVE STABILIZER BAR (See page SA−48)
5. DISCONNECT LOWER SUSPENSION ARM FROM
LOWER BALL JOINT
Remove the bolt and 2 nuts.
Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf)
6. DISCONNECT LOWER SUSPENSION ARM BRACKET
Remove the nut and 2 bolts.
Torque:
Bolt A: 137 N·m (1,400 kgf·cm, 101 ft·lbf)
Nut B: 28 N·m (290 kgf·cm, 21 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
After stabilizing the suspension, torque the bolts and nut.
7. EXCEPT A/T LH:
REMOVE LOWER SUSPENSION ARM
Remove the bolt and lower suspension arm.
Torque: 172 N·m (1,750 kgf·cm, 126 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
After stabilizing the suspension, torque the bolt.
8. A/T LH:
REMOVE LOWER SUSPENSION ARM
(a) Remove the 2 center member set nuts and disconnect the
center member.
Torque: 112 N·m (1,140 kgf·cm, 82 ft·lbf)

R10831
R10832
R10833
R10834
− SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
SA−41
1996 RAV4 (RM447U)
(b) Remove the 2 power steering gear assembly set bolts
and nuts.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
(c) Remove the exhaust pipe No.1 support bracket from the
front exhaust pipe.
(d) Remove the bolt and clamp.
Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf)
(e) Support the front suspension crossmember with a jack.
(f) Remove the 2 bolts and front suspension crossmember
with the lower suspension arms.
Torque: 206 N·m (2,100 kgf·cm, 152 ft·lbf)
(g) Remove the bolt and lower suspension arm.
Torque: 172 N·m (1,750 kgf·cm, 126 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
After stabilizing the suspension, torque the bolt.
9. REMOVE LOWER SUSPENSION ARM BRACKET
Remove the bolt, lower suspension arm bracket and cushion
retainer.
Torque: 137 N·m (1,400 kgf·cm, 101 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
After stabilizing the suspension, torque the bolt.

SA0TT−01
SA−42
− SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−40).
AFTER INSTALLATION CHECK FRONT WHEEL ALIGNMENT (See page SA−4)

SA0TU−02
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
− SUSPENSION AND AXLEFRONT LOWER BALL JOINT
SA−43
1996 RAV4 (RM447U)
FRONT LOWER BALL JOINT
COMPONENTS

SA0TV−01
R10677
SST
SA−44
− SUSPENSION AND AXLEFRONT LOWER BALL JOINT
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE STEERING KNUCKLE WITH AXLE HUB
(See page SA−10)
2. REMOVE LOWER BALL JOINT
(a) Using a screwdriver, remove the dust deflector.
(b) Remove the cotter pin and nut.
(c) Using SST, remove the lower ball joint.
SST 09628−62011

SA0TW−03
N00208
− SUSPENSION AND AXLEFRONT LOWER BALL JOINT
SA−45
1996 RAV4 (RM447U)
INSPECTION
INSPECT BALL JOINT FOR ROTATION CONDITION
(a) As shown in the illustration, flip the ball joint stud back and
forth 5 times, before installing the nut.
(b) Using a torque wrench, turn the nut continuously one turn
each 2 − 4 seconds and take the torque reading on the 5th
turn.
Turning torque:
1.0 − 4.4 N·m (10 − 45 kgf·cm, 8.7 − 39 in.·lbf)

R10771
SST
SST
SST
SA0TX−03
SA−46
− SUSPENSION AND AXLEFRONT LOWER BALL JOINT
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL NEW 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.
2. INSTALL LOWER BALL JOINT
(a) Install the lower ball joint and tighten the nut.
Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf)
(b) Install a new cotter pin.
3. INSTALL STEERING KNUCKLE WITH AXLE HUB
4. CHECK ABS SPEED SENSOR SIGNAL (See page
DI−257)