TOYOTA RAV4 1996 Service Repair Manual

SA0TY−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 STABILIZER BAR
SA−47
1996 RAV4 (RM447U)
FRONT STABILIZER BAR
COMPONENTS

SA0TZ−02
R10835
R10836
Rear
Paint Line SA−48
− SUSPENSION AND AXLEFRONT STABILIZER BAR
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE FRONT WHEELS
Torque: 103 N·m (1,050 kgf·cm 76 ft·lbf)
2. REMOVE BOTH STABILIZER BAR LINKS
Remove the 4 nuts and 2 stabilizer bar links.
Torque:
3 Door vehicle:
64 N·m (650 kgf·cm, 76 ft·lbf)
5 Door vehicle and all over fender vehicle:
113 N·m (1,150 kgf·cm, 83 ft·lbf)
HINT:
If the ball joint turns together with the nut, use a 5 mm hexagon
wrench to hold the stud.
3. REMOVE STABILIZER BAR
(a) Remove the 4 bolts, 2 brackets and No.1 bushings.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
HINT:
At the time of installation, please refer to the following items.
Install the No.1 bushing to the outside of the paint line.
Install the No.1 bushing to the stabilizer bar so that the
cutout of the bushing faces the rear of the vehicle, as
shown.
(b) Remove the stabilizer bar from the right hand side.
4. REMOVE BOTH CLAMPS AND BOTH BUSHINGS
(a) Using a screwdriver, through out the 2 bushings.
(b) Remove the 2 cushions.

SA0U0−02
R00833
− SUSPENSION AND AXLEFRONT STABILIZER BAR
SA−49
1996 RAV4 (RM447U)
INSPECTION
INSPECT STABILIZER BAR LINK FOR ROTATION CONDI-
TION
(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:
3 Door vehicle:
0.05 − 1.0 N·m (0.5 − 10 kgf·cm, 0.4 − 8.7 in.·lbf)
5 Door vehicle:
0.05 − 2.0 N·m (0.5 − 20 kgf·cm, 0.4 − 17.4 in.·lbf)

SA0U1−01
SA−50
− SUSPENSION AND AXLEFRONT STABILIZER BAR
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−48).

SA0U2−01
F03487
ABS Speed Sensor Connector
Axle Hub with BearingBrake Drum
N·m (kgf·cm, ft·lbf)
51 (520, 38)
: Specified torque
− SUSPENSION AND AXLEREAR AXLE HUB (2WD)
SA−51
1996 RAV4 (RM447U)
REAR AXLE HUB (2WD)
COMPONENTS

SA1YC−02
F03505
R10700
SA−52
− SUSPENSION AND AXLEREAR AXLE HUB (2WD)
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE REAR WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. REMOVE BRAKE DRUM
3. CHECK BEARING BACKLASH AND AXLE HUB DEVI-
ATION
(a) Using a dial indicator near the center of the axle hub and
check the backlash in bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the axle hub with
bearing.
(b) 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
with bearing.
4. w/ ABS:
DISCONNECT ABS SPEED SENSOR
Torque: 8 N·m (80 kgf·cm, 69 in.·lbf)
5. w/ ABS:
REMOVE AXLE SHAFT
(a) Remove the cotter pin and lock cap.
(b) With applying the brakes, remove the nut.
(c) Remove the axle shaft.
Torque: 206 N·m (2,100 kgf·cm, 152 ft·lbf)
6. DISASSEMBLE REAR BRAKE (See page BR−30)
7. DISCONNECT BRAKE LINE
Using SST, disconnect the brake line from the wheel cylinder.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)

R10750
− SUSPENSION AND AXLEREAR AXLE HUB (2WD)
SA−53
1996 RAV4 (RM447U)
8. REMOVE REAR AXLE HUB WITH BACKING PLATE
(a) Remove the 2 bolts and disconnect the parking brake
cable.
Torque: 8 N·m (80 kgf·cm, 69 in.·lbf)
(b) Remove the 4 bolts, spacer (w/o ABS) and rear axle hub.
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)

SA0U4−02
SA−54
− SUSPENSION AND AXLEREAR AXLE HUB (2WD)
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−52).
AFTER INSTALLATION, BLEED BRAKE SYSTEM AND CHECK FOR LEAKS (See page BR−4)

SA0U5−02
F03767
ABS Speed
SensorRear Drive Shaft Rear Differential
Rear Brake Hub Bolt
Brake DrumCotter pin Lock Cap Parking Brake Cable
Bearing
Axle Hub
Pin
56 (570, 41)
15 (155, 11)
80, (820, 59)
206 (2,100, 152)

7.8 (80, 69 in.·lbf)
Backing Plate
N·m (kgf·cm, ft·lbf)
: Specified torque
Non−reusable part

8 (80, 69 in.·lbf)
Brake Line
− SUSPENSION AND AXLEREAR AXLE HUB (4WD)
SA−55
1996 RAV4 (RM447U)
REAR AXLE HUB (4WD)
COMPONENTS

SA0U6−02
R10700
SST
R10750
SA−56
− SUSPENSION AND AXLEREAR AXLE HUB (4WD)
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE REAR WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. REMOVE BRAKE DRUM
3. CHECK BEARING BACKLASH AND AXLE HUB DEVI-
ATION (See page SA−52)
4. REMOVE BOLT AND ABS SPEED SENSOR
Torque: 8 N·m (80 kgf·cm, 69 in.·lbf)
5. REMOVE REAR DRIVE SHAFT (See page SA−62)
6. DISASSEMBLE REAR BRAKE (See page BR−30)
7. DISCONNECT BRAKE LINE
Using SST, disconnect the brake line from the wheel cylinder.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
8. REMOVE REAR AXLE HUB WITH BACKING PLATE
(a) Remove the 2 bolts and disconnect the parking brake
cable.
Torque: 8 N·m (80 kgf·cm, 69 in.·lbf)
(b) Remove the 4 bolts and rear axle hub.
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)