TOYOTA RAV4 1996 Service Repair Manual

SA0U7−01
R10738
SST
SST
R10739
SSTSST
− SUSPENSION AND AXLEREAR AXLE HUB (4WD)
SA−57
1996 RAV4 (RM447U)
DISASSEMBLY
REMOVE AXLE HUB FROM BEARING
(a) Using SST, remove the axle hub from the bearing.
SST 09950−60010 (09951−00370),
09950−40010 (09951−04020, 09952−04010,
09953−04020, 09954−04010, 09955−04060,
09957−04010, 09958−04010)
(b) Using SST, remove the inner race (outside) from the axle
hub.
SST 09950−60010 (09951−00370),
09950−40010 (09951−04020, 09952−04010,
09953−04020, 09954−04010, 09955−04060,
09957−04010, 09958−04010)

SA0U8−01
R10740
SST
SST SA−58
− SUSPENSION AND AXLEREAR AXLE HUB (4WD)
1996 RAV4 (RM447U)
REASSEMBLY
INSTALL AXLE HUB TO NEW BEARING
Using SST and a press, install the axle hub to a new bearing.
SST 09527−17011, 09550−60010 (09951−00530)
HINT:
Before install the bearing, place the backing plate on the axle
hub.

SA0U9−01
− SUSPENSION AND AXLEREAR AXLE HUB (4WD)
SA−59
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−56).
AFTER INSTALLATION, BLEED BRAKE SYSTEM (See page BR−4) AND CHECK FOR LEAKS

SA0UA−01
R10741
SST
R10751
SA−60
− SUSPENSION AND AXLEREAR WHEEL HUB BOLT
1996 RAV4 (RM447U)
REAR WHEEL HUB BOLT
REPLACEMENT
1. REMOVE REAR WHEEL
2. REMOVE BRAKE DRUM
3. REMOVE HUB BOLT
Using SST, remove the hub bolt.
SST 09628−10011
4. INSTALL HUB BOLT
Install a washer and nut to the hub bolt, as shown in the illustra-
tion, and install the hub bolt by tightening the nut.
5. INSTALL BRAKE DRUM
6. INSTALL REAR WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)

SA0UB−06
Z19331
Rear Drive Shaft
ABS Speed Sensor
Lock CapCotter pin
Inboard Joint Tulip
Snap Ring
Boot Clamp
Outboard Joint Boot
Inboard Joint Boot Tripod
Outboard Joint with Drive Shaft
Dust Deflector 
Boot Clamp 
Boot Clamp 
56 (570, 41)
8 (80, 69 in.·lbf)
206 (2,100, 152)


 

N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part

− SUSPENSION AND AXLEREAR DRIVE SHAFT
SA−61
1996 RAV4 (RM447U)
REAR DRIVE SHAFT
COMPONENTS

R10041
SST
SA0UC−03
R10773Matchmarks SA−62
− SUSPENSION AND AXLEREAR DRIVE SHAFT
1996 RAV4 (RM447U)
REMOVAL
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
hicle with the drive shaft bearing removed. Therefore,
if it is absolutely necessary to place the vehicle
weight on the hub bearing, first support it with SST.
SST 09608−16042 (09608−02021, 09608−02041)
w/ ABS:
After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage the sensor rotor
serrations on the drive shaft.
1. REMOVE REAR WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. w/ ABS:
REMOVE BOLT AND ABS SPEED SENSOR
Torque: 7.8 N·m (80 kgf·cm, 69 ft·lbf)
3. REMOVE DRIVE SHAFT LOCK NUT
(a) Remove the cotter pin and lock cap.
(b) With depressing the brakes, remove the nut.
Torque: 206 N·m (2,100 kgf·cm, 152 ft·lbf)
4. REMOVE DRIVE SHAFT
(a) Place matchmarks on the drive shaft and differential side
gear shaft.
(b) Remove the 4 nuts and washers, and disconnect the
drive shaft from the differential side gear shaft.
Torque: 56 N·m (570 kgf·cm, 41 ft·lbf)
(c) Remove the drive shaft from the axle carrier.

SA0UD−01
Z12871
Z12368
Matchmarks
N00194
Matchmarks
− SUSPENSION AND AXLEREAR DRIVE SHAFT
SA−63
1996 RAV4 (RM447U)
DISASSEMBLY
1. CHECK DRIVE SHAFT
(a) Check to see that there is no play in the outboard joint.
(b) Check to see that the inboard joint slides smoothly in the
thrust direction.
(c) Check to see that there is no noticeable play in the radial
direction of the inboard joint.
(d) Check for damage to the boots.
2. REMOVE INBOARD AND OUTBOARD JOINT BOOT
CLAMPS
Using a screwdriver, remove the 4 boot clamps.
3. REMOVE INBOARD JOINT TULIP
(a) Place matchmarks on the inboard joint tulip and drive
shaft.
NOTICE:
Do not punch the marks.
(b) Remove the inboard joint tulip from the drive shaft.
4. REMOVE TRIPOD
(a) Using a snap ring expander, remove the snap ring.
(b) Place matchmarks on the shaft and tripod.
NOTICE:
Do not punch the marks.
(c) Using a brass bar and hammer, remove the tripod from
the drive shaft.
NOTICE:
Do not tap the roller.
5. REMOVE INBOARD AND OUTBOARD JOINT BOOTS
AND CLAMPS
Slide out the 2 boots and 4 clamps.
NOTICE:
Do not disassemble the outboard joint.

R11387
w/o ABS w/ ABS SA−64
− SUSPENSION AND AXLEREAR DRIVE SHAFT
1996 RAV4 (RM447U)
6. REMOVE NO.2 DUST DEFLECTOR
Using a screwdriver and hammer, remove the No.2 dust deflec-
tor.

SA0UE−05
F01439
w/o ABS w/ ABS
SST
RA1310
Vinyl Tape
− SUSPENSION AND AXLEREAR DRIVE SHAFT
SA−65
1996 RAV4 (RM447U)
REASSEMBLY
1. INSTALL NEW NO.2 DUST DEFLECTOR
Using SST and a press, install a new No.2 dust deflector.
SST 09309−36010, 09316−20011
NOTICE:
Be careful not to damage the ABS speed sensor rotor.
2. TEMPORARILY INSTALL NEW OUTBOARD AND IN-
BOARD JOINT BOOTS
HINT:
Before installing the 2 boots, wrap vinyl tape around the spline
of the drive shaft to prevent damaging the boots.
(a) Temporarily install a new outboard joint boot to the drive
shaft.
(b) Temporarily install a new inboard joint boot to the drive
shaft.
3. INSTALL TRIPOD
(a) Place the beveled side of the tripod axial spline toward the
outboard joint.
(b) Align the matchmarks placed before removal.
(c) Using a brass bar and hammer, tap in the tripod to the
drive shaft.
NOTICE:
Do not tap the roller.
(d) Using a snap ring expander, install a new snap ring.
4. INSTALL INBOARD JOINT TULIP
(a) 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.)
(b) Align the matchmarks placed before removal, and install
the inboard joint tulip to the drive shaft.
5. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
(a) Before assembling the boot, pack the outboard joint and
boot with grease in the boot kit.
Use the grease supplied in the boot kit.
Grease capacity (Color = Black):
100 − 110 g (3.5 − 3.9 oz.)
(b) Make sure that the 2 boots are on the shaft groove.

Z13445
SA−66
− SUSPENSION AND AXLEREAR DRIVE SHAFT
1996 RAV4 (RM447U)
(c) Make sure that the 2 boots are not stretched or contracted
when the drive shaft is at standard length.
Standard length:
RH599.4 ± 5.0 mm (23.598 ± 0.197 in.)
LH553.4 ± 5.0 mm (21.787 ± 0.197 in.)
(d) Place 4 new boot clamps to the 2 boots.
(e) Bend the band and lock it with a screwdriver.