shift TOYOTA RAV4 1996 Service Repair Manual

148
CRUISE CONTROL
CURRENT IS APPLIED AT ALL TIMES THROUGH THE STOP FUSE TO TERMINAL 2 OF THE STOP LIGHT SW, AND ALSO THROUGH
THE DOME FUSE TO TERMINAL 15 OF THE CRUISE CONTROL ECU.
WITH THE IGNITION SW TURNED TO ON, CURRENT FLOWS THROUGH THE GAUGE FUSE TO TERMINAL 8 OF THE COMBINATION
METER AND THE CURRENT THROUGH THE DOME FUSE FLOWS TO TERMINAL 15 OF THE CRUISE CONTROL ECU.
WHEN THE IGNITION SW IS ON AND THE CRUISE CONTROL MAIN SW IS TURNED ON, A SIGNAL IS INPUT FROM TERMINAL 5 OF THE
CRUISE CONTROL SW TO TERMINAL 19 OF THE CRUISE CONTROL ECU. AS A RESULT, THE CRUISE CONTROL ECU FUNCTIONS
AND THE CURRENT FLOWS FROM THE ECU-IG FUSE TO TERMINAL 14 OF THE CRUISE CONTROL ECU TO TERMINAL 13 OF THE
CRUISE CONTROL ECU " GROUND, AND THE CRUISE CONTROL SYSTEM IS IN A CONDITION READY FOR OPERATION.
AT THE SAME TIME, THE CURRENT THROUGH THE GAUGE FUSE FLOWS TO TERMINAL 8 OF THE CRUISE CONTROL INDICATOR
LIGHT "TERMINAL 6 "TERMINAL 7 OF THE CRUISE CONTROL ECU "TERMINAL 13 "GROUND, CAUSING THE CRUISE
CONTROL INDICATOR LIGHT TO LIGHT UP, INDICATING THAT THE CRUISE CONTROL IS READY FOR OPERATION.
1. SET OPERATION
WHEN THE CRUISE CONTROL MAIN SW IS TURNED ON AND THE SET SW IS PUSHED WITH THE VEHICLE SPEED WITHIN THE SET
LIMIT (APPROX. 40 KM/H, 25 MPH TO 200 KM/H, 124 MPH), A SIGNAL IS INPUT TO TERMINAL 18 OF THE CRUISE CONTROL ECU AND
THE VEHICLE SPEED AT THE TIME THE SET SW IS RELEASED IS MEMORIZED IN THE ECU AS THE SET SPEED.
2. SET SPEED CONTROL
DURNING CRUISE CONTROL DRIVING, THE ECU COMPARES THE SET SPEED MEMORIZED IN THE ECU WITH THE ACTUAL VEHICLE
SPEED INPUT INTO TERMINAL 20 OF THE CRUISE CONTROL ECU FROM THE SPEED SENSOR, AND CONTROLS THE CRUISE
CONTROL ACTUATOR TO MAINTAIN THE SET SPEED.
WHEN THE ACTUAL SPEED IS LOWER THAN THE SET SPEED, THE ECU CAUSES THE CURRENT TO THE CRUISE CONTROL
ACTUATOR TO FLOW FROM TERMINAL 12 OF THE CRUISE CONTROL ECU "TERMINAL 6 OF THE CRUISE CONTROL ACTUATOR "
TERMINAL 7 "TERMINAL 11 OF THE CRUISE CONTROL ECU. AS A RESULT, THE MOTOR IN THE CRUISE CONTROL ACTUATOR IS
ROTATED TO OPEN THE THROTTLE VALVE AND THE THROTTLE CABLE IS PULLED TO INCREASE THE VEHICLE SPEED. WHEN THE
ACTUAL DRIVING SPEED IS HIGHER THAN THE SET SPEED, THE CURRENT TO THE CRUISE CONTROL ACTUATOR FLOWS FROM
TERMINAL 11 OF THE ECU "TERMINAL 7 OF THE CRUISE CONTROL ACTUATOR "TERMINAL 6 "TERMINAL 12 OF THE CRUISE
CONTROL ECU.
THIS CAUSES THE MOTOR IN THE CRUISE CONTROL ACTUATOR TO ROTATE TO CLOSE THE THROTTLE VALVE AND RETURN THE
THROTTLE CABLE TO DECREASE THE VEHICLE SPEED.
3. COAST CONTROL
DURING THE CRUISE CONTROL DRIVING, WHILE THE COAST SW IS ON, THE CRUISE CONTROL ACTUATOR RETURNS THE
THROTTLE CABLE TO CLOSE THE THROTTLE VALVE AND DECREASE THE DRIVING SPEED. THE VEHICLE SPEED WHEN THE COAST
SW IS TURNED OFF IS MEMORIZED AND THE VEHICLE CONTINUES AT THE NEW SET SPEED.
4. ACCEL CONTROL
DURING CRUISE CONTROL DRIVING, WHILE THE ACCEL SW IS TURNED ON, THE CRUISE CONTROL ACTUATOR PULLS THE
THROTTLE CABLE TO OPEN THE THROTTLE VALVE AND INCREASE THE DRIVING SPEED.
THE VEHICLE SPEED WHEN THE ACCEL SW IS TURNED OFF IS MEMORIZED AND THE VEHICLE CONTINUES AT THE NEW SET
SPEED.
5. RESUME CONTROL
UNLESS THE VEHICLE SPEED FALLS BELOW THE MINIMUM SPEED LIMIT (APPROX. 40 KM/H, 25 MPH) AFTER CANCELING THE SET
SPEED BY THE CANCEL SW, PUSHING THE RESUME SW WILL CAUSE THE VEHICLE TO RESUME THE SPEED SET BEFORE
CANCELLATION.
6. MANUAL CANCEL MECHANISM
IF ANY OF THE FOLLOWING OPERATIONS OCCURS DURING CRUISE CONTROL OPERATION, THE MAGNETIC CLUTCH OF THE
ACTUATOR TURNS OFF AND THE MOTOR ROTATES TO CLOSE THE THROTTLE VALVE AND THE CRUISE CONTROL IS RELEASED.
*PLACING THE SHIFT LEVER EXCEPT Dº POSITION (PARK/NEUTRAL POSITION SW EXCEPT Dº POSITION). SIGNAL IS NOT INPUT
TO TERMINAL 2 OF THE ECUº
*DEPRESSING THE BRAKE PEDAL (STOP LIGHT SW ON). SIGNAL INPUT TO TERMINAL 16 OF THE ECUº
*PUSHING THE CANCEL SW (CANCEL SW ON). SIGNAL INPUT TO TERMINAL 18 OF THE ECUº
SYSTEM OUTLINE

149
7. AUTO CANCEL FUNCTION
A) IF ANY OF THE FOLLOWING OPERATING CONDITIONS OCCURS DURING CRUISE CONTROL OPERATION, THE SET SPEED IS
ERASED, CURRENT FLOW TO THE MAGNETIC CLUTCH IS STOPPED AND THE CRUISE CONTROL IS RELEASED. (MAIN SW TURNS
OFF).
WHEN THIS OCCURS, THE IGNITION SW MUST BE TURNED OFF ONCE BEFORE THE MAIN SW WILL TURN ON.
*WHEN CURRENT CONTINUED TO FLOW TO THE MOTOR INSIDE THE ACTUATOR IN THE THROTTLE VALVE OPENº DIRECTION.
*THE MOTOR DOES NOT OPERATE DESPITE THE MOTOR DRIVE SIGNAL BEING OUTPUT.
B) IF ANY OF THE FOLLOWING OPERATING CONDITIONS OCCURS DURING CRUISE CONTROL OPERATION, THE SET SPEED IS
ERASED, CURRENT FLOW TO THE MAGNETIC CLUTCH IS STOPPED AND THE CRUISE CONTROL IS RELEASED. (MAIN SW TURN
OFF).
WHEN THIS OCCURS, THE CANCEL STATE IS CLEARED AS THE MAIN SW WILL TURN ON AGAIN.
*OVER CURRENT TO TRANSISTOR DRIVING THE MOTOR AND/OR THE MAGNETIC CLUTCH.
*OPEN CIRCUIT IN THE MAGNETIC CLUTCH.
*MOMENTARY INTERRUPTION OF VEHICLE SPEED SIGNAL.
*SHORT CIRCUIT IN THE CRUISE CONTROL SW.
*WHEN THE VEHICLE SPEED FALLS MORE THAN 16 KM/H (10 MPH) BELOW THE SET SPEED, E.G. ON AN UPWARD SLOPE.
C) IF ANY OF THE FOLLOWING CONDITIONS OCCURS DURING CRUISE CONTROL OPERATION, THE SET SPEED IS ERASED AND
THE CRUISE CONTROL IS RELEASED. (THE POWER TO THE MAGNETIC CLUTCH IS CUT OFF UNTIL THE SET SW IS ONº AGAIN.)
*WHEN THE VEHICLE SPEED FALLS BELOW THE MINIMUM SPEED LIMIT, APPROX. 40 KM/H (25 MPH)
*WHEN POWER TO THE CRUISE CONTROL SYSTEM IS MOMENTARILY CUT OFF.
D) IF ANY OF THE FOLLOWING CONDITIONS OCCURS DURING CRUISE CONTROL OPERATION, THE CRUISE CONTROL IS
RELEASED.
*OPEN THE CIRCUIT FOR TERMINAL 2 OF THE STOP LIGHT SW.
8. AUTOMATIC TRANSMISSION CONTROL FUNCTION
*IN OVERDRIVE, IF THE VEHICLE SPEED BECOMES LOWER THAN THE OVERDRIVE CUT SPEED (SET SPEED MINUS APPROX. 4
KM/H, 2.5 MPH) DURING CRUISE CONTROL OPERATION, SUCH AS DRIVING UP A HILL, THE OVERDRIVE IS RELEASED AND THE
POWER INCREASED TO PREVENT A REDUCTION IN VEHICLE SPEED.
*AFTER RELEASING THE OVERDRIVE, VEHICLE SPEED BECOMES HIGHER THAN THE OVERDRIVE RETURN SPEED (SET SPEED
MINUS APPROX. 2 KM/H, 1.2 MPH) AND THE ECU JUDGES BY THE SIGNALS FROM THE ACTUATOR'S POTENTIOMETER THAT THE
UPWARD SLOPE HAS FINISHED, THE OVERDRIVE IS RESUMED AFTER APPROXIMATELY 2 SECONDS.
*DURING CRUISE CONTROL DRIVING, THE CRUISE CONTROL OPERATION SIGNAL IS OUTPUT FROM THE CRUISE CONTROL
ECU TO THE ENGINE CONTROL MODULE. UPON RECEIVING THIS SIGNAL, THE ENGINE CONTROL MODULE CHANGES THE SHIFT
PATTERN TO NORMAL.
TO MAINTAIN SMOOTH CRUISE CONTROL OPERATION (ON A DOWNWARD SLOPE ETC.), THE LOCK-UP RELEASE OF THE
TRANSMISSION WHEN THE IDLING POINT OF THE THROTTLE POSITION IS ONº IS FORBIDDEN.
C 3 CRUISE CONTROL ACTUATOR
1-3 : APPROX. 2 KW
5-4 : APPROX. 38 W
C12 CRUISE CONTROL SW [COMB. SW]
5-3 : CONTINUITY WITH THE CRUISE MAIN SW ON
4-3 : APPROX. 418 W WITH THE CANCEL SW ON
APPROX. 68 W WITH THE SET/COAST SW ON
APPROX. 198W WITH THE RESUME/ACCEL SW ON
C16 CRUISE CONTROL ECU
14-GROUND : APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION
15-GROUND : ALWAYS APPROX. 12 VOLTS
20-GROUND :4 PULSES WITH 1 ROTATION OF THE ROTOR SHAFT
18-GROUND : APPROX. 418 W WITH THE CANCEL SW ON IN THE CONTROL SW
APPROX. 198 W WITH THE SET/COAST SW ON IN THE CONTROL SW
APPROX. 68 W WITH THE RESUME/ACCEL SW ON IN THE CONTROL SW
13-GROUND : ALWAYS CONTINUITY
SERVICE HINTS

165
PERSONAL LIGHT
W IPER AND W ASHER SW
[COMB. SW ]
REAR WINDOW
DEFOGGER SW
COMBINATION M ETER
CRUISE CONTROL ECU
DOOR LO CK CONTROL
SW (
FRONT
PASSENGER' S SIDE)
DOOR KEY LOCK AND
UNLOCK SW (
FR ON T
PASSENGER' S SIDE)
BLOW ER SWTU RN SIG NA L FLA SHER
DATA LINK
CONNECTOR 3
CIGARETTE LIGHTER
O /D M AIN SW
REM OTE CONTROL
MIRROR SW
BUCKLE SW LH
CLOCK
CRUISE CONTROL SW
[COMB. SW ]
UNLOCK W ARNING SW
LIGHT CONTROL SW
[COMB. SW ]
FUEL SENDER (
MAIN)
RADIO AND PLAYER
C O M B IN A TIO N M E TE R SHIFT LOCK ECU
KEY INTERLOCK
SOLENOID
A/C AMPLIFIER
BLOW ER RESISTOR
DOOR LO CK CONTROL
RELAY
POWER W INDOW MASTER
SW
DOOR KEY LOCK AND
UNLOCK SW
(
DRIVER' S SIDE)
RHEOSTATIE 16
A A
A A
A A
A A
A A
IGA AB A
B A
B A
B A
B A
B 8
II1 16
B C
B C
B C A B
A B
A B
ID I 2 IC 116
B 2
IF IEID 110 W-B
W-B
W-BW-B
W-B
W-B
W-B
W-B
W-BW-B
W-B
W-B
W-B
W-B
W-B
W-B
W-B
W-B
W-B
W-B
BR
BR
BR W-
W-
W-
W-
W-
W-B
W-B
W-B
W-B
W-B W -B5
(
A/T)
B J10 , J11
A
JUNCTION CONNECTOR
B J10 , J11
A
JUNCTION CONNECTOR
(
A/
W-B
W-B W-B
W W-B
BR-B
W-B W-B
(
E2)
(
E1) AIRBAG SENSOR
ASSEMBLY
B
B
B
B
B T)W-B -BW
-B
4C3
4C10
4C7
4C8
4C94C 1
4C2
W
1D5
1H16
1H 71I 9

K
1
234
9 RAV4
AC C
IG 1 AM1 4
1F 81F 11B 8
1F 2
1I 11
2IG118 15
2C 2B
8B 5A
R-B
R-L R-L R-L R-B WG-W G-W
2 BK2 1ID1
R- B
R- B R- B R- BW-B
12
BATTERY
R 8
B ACK-UP LIGHT LH
[REAR COMB. LIGHT LH] H 5
HIGH M OUNTED
STOP LIGHT
2 1
G- W
W-B W-B
1BK1
G-W G-W
I1 0
IGN ITIO N S W
F 8
10A GAUGE
[FUSE BLOCK]
S 5
STOP LIGHT
SW BACK-UP LIGHT SW(
M/T)
BACK-UP LIGHT SW
(M/T)
R 9
BACK-UP LIGHT RH
[REAR COMB. LIGHT RH]
(
4WD A/T)
(
M/T)
(
2WD A/T)
(
4WD A/T)F 8
10A STOP
[FU SE BLO CK]
G-W
R 8
STOP LIGHT LH
[REAR COMB. LIGHT LH]
B B 1 GRAY
B 1 C
R 9
STOP LIG HT R H
[REAR COMB. LIGHT RH]
1I 14
To E ngine C ontrol
Module< 2-2 < 4-4G-W
BI BHBJ 43
55
100A ALT
2
4 4
5 3
F 7
FU SIBLE
LIN K B LO C K W
21D 7
21K 4 40A
AM 1WW W
W
W
681E
11KB
91DR-L
2
13IB1
W-B
W-B W-B
W-BW-B
G-W G-W
7IG114 1L 13 1I
R- W
D
D
W
U nder the center
pillar LHUnder the center
pillar RHB ack door left
Power
SourceBack-Up LightStop Light
BACK-UP LIGHT SW
[PARK/NEUTRAL
POSITION SW](A/T)
B-YG-W
To ABS ECU
< 17-4
1C 8
G-W
2
1 J 5
JUNCTION
CO N NEC TO RR-W
3
5 CA
BBJ10 A , J11 B
JUNCTION
CONNECTOR
6A
1C(
2WD A/T)
(
M/T) P 1 A , B
BAC K- U P LIGH T SW
[PARK/N EU TR AL PO SITION SW ](
A/T)
123
4
5
6789
1
756234
8910 A (
2WD)
P 1
B (
4WD)
P 1 GRAY
To Shift Lock ECU
<15-2
DG-WG-WG-W
(
A/T)(
A/T)(
M/T)
(
A/T) AAAAAA
BBBCCCB J11A J10
GRAY JUNCTION CONNECTOR
GRAY

K
1
234
15 RAV4
ACC
IG 1
IG 2
ST2 AM1
AM2
1D 9
1K 4
3A
2A 6A 1A 5A 2B 6B
5ID2 6ID2 IC 1 1 7 IC1 1 II1 II172
2
4A
1B 3B 7A
3ID2 4ID2
IG I1 0
IG N ITION S W
6
80A M A IN
L-R
F 8
7. 5A E C U- IG
[FUSE BLOCK] 24
BATTERY+B
FL- FR + FR- R L+ R L- FL+ACC
1122
F 9
FRONT SPEAKER
LHF10
FRONT SPEAKER
RH15A
DOME
RR+ RR- GND R 3 B , R 4 A RADIO AND PLAYER12 34
567891012
3456
A R 4B R 3 RADIO AND PLAYER
100A ALTP V LGL BB
L
LG
V
P
W W2
26
1D 5
1FL- R
12
131D 7
1F 4
B-Y GR GRY RR
Y W W BR
L-Y
W
19 18
W
R ight kick panel
Power SourceRadio and Player2
F 7
FU SIBLE
LIN K B LO CK
40A
AM1
1* 1 : 2- Door
* 2 : 4- Door
(
*1) (
*2)(
*2)
(
*1)REAR SPEAKER LH, RH
12
1 2
R12 A , B
REAR SPEAKER LHR13 A , B
REAR SPEAKER RH 1
B 2
A1
B 2
A 2
B1
A2
B1
AA (
*2)
R12, R13
B (
*1)
R12, R13W
1J 5
1I 22L-Y L-YD
6CD
J 3
JUNCTION
CONNECTOR J 3
JUNCTION
CON NECTOR 1H 101E 66
7F 8
15A
CIG & RAD
[FUSE BLOCK]
4C 3
4C 15
1
2P2
P1
P 3G-W
G- R
G 12
SLS+
SLS- L L-R SH IFT LO CK
SO LENO ID
SH IFT LO CK
CONTROL SW
Instrument panel
brace R HIF 1 2
10
4C1H 31E 4 B- Y 3
GR
B-Y B-YG-WGR
212
F rom S top Light S W
<9-3
IG ST P A CC
W-B
L-B
W-B
C
4EKLS+
W-B
S 4
SHIFT LOCK ECU
Shift Lock
K 2
KEY INTERLOCK
SOLENO ID

MX01Z−08
− MANUAL TRANSAXLETROUBLESHOOTING
MX−1
1996 RAV4 (RM447U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Noise
14.Oil (Level low) 2WD
4WD
15. Oil (Wrong) 2WD
4WD
16.Gear (Worn or damaged)
17.Bearing (Worn or damaged)MX−3
MX−9
MX−3
MX−9
MX−12
MX−79
MX−12
MX−79
Oil leakage
1. Oil (Level too high) 2WD
4WD
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O−Ring (Worn or damaged)MX−3
MX−9
MX−12
MX−79
MX−12
MX−79
MX−12
MX−78
MX−79
Hard to shift or will not shift
1. Control cable (Faulty)
2. Synchronizer ring (Worn or damaged)
3. Shift key spring (Damaged)MX−77
MX−12
MX−29
MX−36
MX−12
MX−29
MX−36
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MX−12
MX−12
MX−79
MX−12
MX−79
MX−12
MX−79
Tight corner braking1. Differential, Center differential (Faulty)MX−58
MX−72

Q09034

N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 Precoated partTransmission Case Cover Transmission CaseNo.2 Selecting Bellcrank with
Selecting Bellcrank Support Shift and Select Lever
Shaft Assembly
No.1 Oil Receiver Pipe Reverse Restrict
Pin Straight Screw PlugBack−Up Light SwitchNo.3 Shift Fork No.3 Shift Fork ShaftInterlock Roller
Snap RingShift Head
Shift and Select Lever
Shaft Lock BoltNo.2 Shift Fork Shaft Straight Screw Plug Reverse Shift Arm Bracket Assembly
Snap Ring
Reverse Shift Fork
No.1 Shift Fork
No.1 Shift Fork Shaft Seat
Spring
Ball
Slotted Spring
PinSnap RingSnap Ring
No.2 Shift Fork
No.2 Oil Receiver Pipe
Drain Plug Filler Plug
x10 x17


24 (240, 17)
25 (250, 18)
25 (250, 18)
24 (240, 17)
24 (240, 17)
25 (250, 18)
17 (175, 13)
40 (410, 30)
13 (130, 9)49 (500, 36)20 (200, 14)
17 (175, 13)
29 (300, 22)
49 (500, 36)
20 (200, 14)
49 (500, 36)
49 (500, 36)
29 (300, 22)
Breather Plug Gasket  Gasket
 Gasket  Gasket Gasket
 Gasket MX−14
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)

MX05V−02
Q08757
FIPG
Z12375SST
Q09043
255.5 mm MX−16
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
DISASSEMBLY
1. 4WD:
REMOVE TRANSFER ASSEMBLY
(a) Remove the 3 bolts.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(b) Remove the 5 nuts.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(c) Using a plastic hammer, remove the transfer assembly
from the transaxle.
HINT:
At the time of reassembly, please refer to the following item.
Shift into the 4th gear, and install the transfer assembly while
turning the input shaft of the transaxle.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
2. 4WD:
REMOVE DIFFERENTIAL SIDE GEAR INTERMEDI-
ATE SHAFT
(a) Screw in a suitable bolt with a washer into the side gear
intermediate shaft.
(b) Using SST, remove the side gear intermediate shaft.
SST 09910−00015 (09911−00011, 09912−00010)
(c) Remove the snap ring from the differential side gear inter-
mediate shaft.
HINT:
At the time of reassembly, please refer to the following item.
Keeping the intermediate shaft on the differential pinion shaft,
measure the dimension, as shown in the illustration.
Protrusion length: 255.5 mm (10.06 in.)
3. REMOVE RELEASE FORK AND BEARING
4. REMOVE BACK−UP LIGHT SWITCH WITH GASKET
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
5. REMOVE BOLT AND VEHICLE SPEED SENSOR
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
6. REMOVE NO.2 SELECTING BELLCRANK WITH SE-
LECTING BELLCRANK SUPPORT
Remove the 2 bolts and No.2 selecting bellcrank with the se-
lecting bellcrank support.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

Q05816
FIPG
Q00449
Q05849
SST
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−17
1996 RAV4 (RM447U)
7. REMOVE SHIFT AND SELECT LEVER SHAFT LOCK
BOLT WITH GASKET
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
8. REMOVE SHIFT AND SELECT LEVER SHAFT AS-
SEMBLY WITH GASKET
Remove the 4 bolts, shift and select lever shaft assembly and
gasket.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
9. REMOVE TRANSMISSION CASE COVER
Remove the 10 bolts and transmission case cover.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
10. REMOVE BREATHER PLUG WITH GASKET
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
11. REMOVE OUTPUT SHAFT LOCK NUT
(a) Unstake the lock nut.
(b) Engage the gear double meshing.
(c) Remove the lock nut.
Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf)
(d) Disengage the gear double meshing.
12. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
(a) Remove the No.3 shift fork set bolt.
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
(b) Remove the No.3 hub sleeve and No.3 shift fork.
13. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950−30010

MT0693
SST
Q06375
Z17557
Matchmarks
Q01614
Q08124
MX−20
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
23. REMOVE OUTPUT SHAFT REAR TAPER ROLLER
BEARING OUTER RACE
Using SST and a hammer, remove the output shaft rear taper
roller bearing outer race.
SST 09316−60011 (09316−00011)
24. REMOVE TRANSMISSION OIL PIPE
(a) Remove the gasket from the oil pipe.
(b) Remove the 2 bolts and oil pipe.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
25. REMOVE REVERSE SHIFT ARM BRACKET AS-
SEMBLY
Remove the bolt and pull off the reverse shift arm and bracket.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
26. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft, remove the reverse idler gear and thrust
washer.
HINT:
At the time of reassembly, please refer to the following item.
Align the matchmarks, as shown.
27. REMOVE STRAIGHT SCREW PLUG, LOCKING BALL
AND SPRING
(a) Using a hexagon wrench (6 mm), remove the 2 plugs.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Using a magnetic finger, remove the 2 seats, springs and
balls.
28. REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD
SET BOLT
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
29. REMOVE NO.1 SHIFT FORK SHAFT
Pull up the No.3 shift fork shaft, remove the No.1 shift fork shaft.
HINT:
At the time of reassembly, please refer to the following item.
When it is difficult to push the fork shaft through the reverse shift
fork, pull up the No.3 shift fork shaft.