TOYOTA RAV4 1996 Service Repair Manual

F03754
SST
R10668
SST
R10669
Front Rear
F03755
Matchmarks
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−77
1996 RAV4 (RM447U)
(c) Using SST and a hammer, remove the 2 plate washers.
SST 09504−22011
HINT:
Measure the plate washer and note down the thickness.
(d) Remove the differential case and 2 bearing outer races
from the carrier.
HINT:
Tag the 2 bearing outer races to show the location for reassem-
bling.
16. REMOVE DRIVE PINION FROM DIFFERENTIAL CAR-
RIER
17. REMOVE DRIVE PINION REAR BEARING
(a) Using SST and a press, remove the bearing from the drive
pinion.
SST 09950−00020
HINT:
If the drive pinion or ring gear are damaged, replace them a set.
(b) Remove the plate washer.
18. REMOVE FRONT AND REAR BEARING OUTER
RACES
Using a brass bar and hammer, remove the 2 outer races from
the carrier.
19. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Using a screwdriver and hammer, unstake the 4 lock
plates.
(c) Remove the 8 ring gear set bolts and 4 lock plates.
(d) Using a plastic hammer, tap on the ring gear to separate
it from the differential case.

F03756
SST
R07223
Z13195
SA−78
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
20. REMOVE SIDE BEARINGS
Using SST and a press, remove the 2 side bearings from the
differential case.
SST 09950−00020
NOTICE:
Be careful not to drop the differential case.
21. 2 Pinion Differential Only:
DISASSEMBLE DIFFERENTIAL CASE
NOTICE:
If equipped with Torque Sensing LSD, do not disassemble
the differential case.
(a) Using a pin punch and hammer, remove the straight pin.
(b) Remove these parts from the differential case:
Pinion shaft
2 pinion gears
2 pinion gear thrust washers
2 side gears
2 side gear thrust washers

SA0UM−01
FA1121
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−79
1996 RAV4 (RM447U) 1/17/01
REASSEMBLY
1. 2 Pinion Differential:
ADJUST DIFFERENTIAL SIDE GEAR BACKLASH
(a) Install the 2 proper thrust washers on the 2 side gears.
HINT:
Refer to the table below to table, select 2 thrust washers which
will ensure that the backlash is within the specification.
Thrust washer thickness
Thickness mm (in.)Thickness mm (in.)
0.93 − 0.97 (0.0366 − 0.0382)1.08 − 1.12 (0.0425 − 0.0441)
0.98 − 1.02 (0.0386 − 0.0402)1.13 − 1.17 (0.0445 − 0.0461)
1.03 − 1.07 (0.0406 − 0.0421)1.18 − 1.22 (0.0465 − 0.0480)
(b) Install the 2 side gears, 2 pinion gears, 2 pinion gear
thrust washers and pinion shaft in the differential case.
HINT:
Align the holes of the differential case and pinion shaft.

F14547
FA1124
SA1143
Boiling Water
F03758
Matchmarks
SA−80
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
(c) Measure the side gear backlash.
(1) Install the 2 side gear shafts.
(2) Measure the side gear backlash with holding 1 pin-
ion gear toward the differential case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within the specification, install the 2 side
gear thrust washers with different thicknesses.
(3) Remove the 2 side gear shafts.
2. 2 PINION DIFFERENTIAL:
INSTALL STRAIGHT PIN AND STAKE DIFFERENTIAL
CASE
(a) Using a pin punch and hammer, install the straight pin
through the differential case and hole of the pinion shaft.
(b) Using a chisel and hammer, stake the outside of the differ-
ential case pin hole.
3. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surfaces of the differential case and
ring gear.
(b) Heat the ring gear in boiling water.
(c) Carefully remove the ring gear from the boiling water.
(d) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
(e) Align the matchmarks on the ring gear and differential
case.
(f) Temporarily install the 4 lock plates and 8 bolts.
(g) After the ring gear cools down enough, torque the 8 bolts
uniformly at a time.
Torque: 97 N·m (985 kgf·cm, 71 ft·lbf)
(h) Using a chisel and hammer, stake the 4 lock plates.
HINT:
Stake one claw flush with the flat surface of the bolt. For the
claw contacting the protruding portion of the bolt, stake only the
half of it on the tightening side.

F03759
SST
F03760
W01226
SST SST FrontRear
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−81
1996 RAV4 (RM447U) 1/17/01
4. INSTALL SIDE BEARINGS
Using SST and a press, install the 2 side bearings into the differ-
ential case.
SST 09710−22021 (09710−01031)
5. INSPECT RING GEAR RUNOUT
(a) Install the differential case on the carrier, and install the
2 plate washers to fill the no play in the bearing.
(b) Install the bearing caps (See page SA−79).
(c) Using a dial indicator, measure the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 in.)
(d) Remove the 2 bearing caps, 2 plate washers and differen-
tial carrier (See page SA−74).
6. INSTALL FRONT AND REAR BEARING OUTER
RACES
(a) Front side:
Using SST and a press, install the 2 outer races to the car-
rier.
SST 09950−60020 (09951−00790),
09950−70010 (09951−07150)
(b) Rear side:
Using SST and a press, install the 2 outer races to the car-
rier.
SST 09950−60020 (09951−00710),
09950−70010 (09951−07150)
7. INSTALL DRIVE PINION REAR BEARING
(a) Install the reused washer on the drive pinion.

SA3102
SST
R10778
R10661
SST
R10768
SST
R10641
F03761
SA−82
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
(b) Using SST and a press, install the rear bearing onto the
drive pinion.
SST 09506−30012
8. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the drive pinion and front bearing.
HINT:
Assemble the spacer, oil slinger and oil seal after adjusting the
gear contact pattern.
(b) Using SST, install the companion flange.
SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03040, 09956−03020)
(c) Coat the threads of the nut with MP grease.
(d) Adjusting the drive pinion preload by tightening the com-
panion flange nut.
Using SST to hold the flange, torque the nut.
Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf)
SST 09330−00021
NOTICE:
As there is no spacer, torque a little at a time, being careful
not to overtighten it.
(e) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing:
1.0 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing:
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
9. INSTALL DIFFERENTIAL CASE IN CARRIER

F03762
Hold
R10647
F03763
F03762
Hold
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−83
1996 RAV4 (RM447U) 1/17/01
(a) Place the 2 bearing outer races on their respective bear-
ings. Make sure the left and right races are not inter-
changed.
(b) Install the differential case in the carrier.
10. ADJUST RING GEAR BACKLASH
(a) Install only the plate washer on the ring gear back side.
(b) Snug down the washer and bearing by tapping on the ring
gear with a plastic hammer.
(c) Using a dial indicator, hold the side bearing boss on the
teeth surface of the ring gear and measure the ring gear
backlash.
Backlash (reference): 0.13 mm (0.0051 in.)
(d) Select a ring gear back side plate washer so that the back-
lash is 0.13 mm (0.0051 in.).
(e) Select a ring gear teeth side washer with a thickness
which eliminates any clearance between the outer race
and case.
(f) Remove the plate washer and differential case.
(g) Install the plate washer into the ring gear back side.
(h) Place the outer plate washer onto the differential case to-
gether with the outer race, and install the differential case
with the outer race into the carrier.
(i) Using a plastic hammer, snug down the washer and bear-
ing by tapping the ring gear.
(j) Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
If it is not within the specification, adjust it by either increasing
or decreasing the thickness of washers on both sides by an
equal amount.
HINT:
There should be clearance between the plate washer and case.
Ensure that there is ring gear backlash.
11. ADJUST SIDE BEARING PRELOAD
(a) After adjustment with the ring gear backlash as reference,
remove the teeth side plate washer.

RA0090
F03764
F03753
Matchmarks
F03768
Hold
SA−84
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
(b) Using a micrometer, measure the thickness of the re-
moved plate washer.
(c) Install a new washer 0.06 − 0.09 mm (0.0024 − 0.0035 in.)
thicker than the removed washer.
HINT:
Select a washer which can be pressed in 2/3 of the way by fin-
ger.
(d) Using a brass bar and hammer, tap in the plate washer.
(e) Align the matchmarks on the cap and carrier, and install
the 2 bearing caps and 4 bolts.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
(f) Recheck the ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
If it is not within the specification, adjust it by either increasing
or decreasing the thickness washers on both sides by equal
amount.
HINT:
The backlash will change by about 0.02 mm (0.0008 in.) every
0.03 mm (0.0012 in.) change in the plate washer thickness.
Washer thickness
Thickness mm (in.)Thickness mm (in.)Thickness mm (in.)
2.26 − 2.28 (0.0890 − 0.0898)2.41 − 2.43 (0.0949 − 0.0957)2.56 − 2.58 (0.1008 − 0.1016)
2.29 − 2.31 (0.0902 − 0.0909)2.44 − 2.46 (0.0961 − 0.0969)2.59 − 2.61 (0.1020 − 0.1028)
2.32 − 2.34 (0.0913 − 0.0921)2.47 − 2.49 (0.0972 − 0.0980)2.62 − 2.64 (0.1031 − 0.1039)
2.35 −2.37 (0.0925 − 0.0933)2.50 − 2.52 (0.0984 − 0.0992)2.65 − 2.67 (0.1043 − 0.1051)
2.38 − 2.40 (0.0937 − 0.0945)2.53 − 2.55 (0.0996 − 0.1004)2.68 − 2.70 (0.1055 − 0.1063)

R10641
F03765
SA1653
Proper ContactHeel Contact
Toe ContactSelect an adjusting shim will bring the
drive pinion closer to the ring gear.Face Contact
Flank Contact
Select an adjusting shim that will shift the
drive pinion away from the ring gear.
SA1586
Plate Washer
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−85
1996 RAV4 (RM447U) 1/17/01
12. MEASURE TOTAL PRELOAD
Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus
0.3 − 0.5 N·m (3 − 5 kgf·cm, 2.6 − 4.3 in.·lbf)
13. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION
(a) Coat 3 or 4 teeth at 3 different positions on the ring gear
with red lead primer.
(b) Hold the companion flange firmly and rotate the ring gear
in both directions.
(c) Inspect the tooth contact pattern.
If the teeth are not contacting properly, use the following chart
to select a proper washer for correction.

R10649
R10673
R10661
SST SA−86
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
Washer thickness
Thickness mm (in.)Thickness mm (in.)Thickness mm (in.)
2.21 − 2.23 (0.0870 − 0.0878)2.57 − 2.59 (0.1012 − 0.1020)2.93 − 2.95 (0.1154 − 0.1161)
2.24 − 2.26 (0.0882 − 0.0890)2.60 − 2.62 (0.1024 − 0.1031)2.96 − 2.98 (0.1165 − 0.1173)
2.27 − 2.29 (0.0894 − 0.0902)2.63 − 2.65 (0.1035 − 0.1043)2.99 − 3.01 (0.1177 − 0.1185)
2.30 − 2.32 (0.0906 − 0.0913)2.66 − 2.68 (0.1047 − 0.1055)3.02 − 3.04 (0.1189 − 0.1197)
2.33 − 2.35 (0.0917 − 0.0925)2.69 − 2.71 (0.1059 − 0.1067)3.05 − 3.07 (0.1201 − 0.1209)
2.36 −2.38 (0.0929 − 0.0937)2.72 − 2.74 (0.1071 − 0.1079)3.08 − 3.10 (0.1213 − 0.1220)
2.39 − 2.41 (0.0941 − 0.0949)2.75 − 2.77 (0.1083 − 0.1091)3.11 − 3.13 (0.1224 − 0.1232)
2.42 − 2.44 (0.0953 − 0.0961)2.78 − 2.80 (0.1094 − 0.1102)3.14 − 3.16 (0.1236 − 0.1244)
2.45 − 2.47 (0.0965 − 0.0972)2.81 − 2.83 (0.1106 − 0.1114)3.17 − 3.19 (0.1248 − 0.1256)
2.48 − 2.50 (0.0976 − 0.0984)2.84 − 2.86 (0.1118 − 0.1126)3.20 − 3.22 (0.1260 − 0.1268)
2.51 − 2.53 (0.0988 − 0.0996)2.87 − 2.89 (0.1130 − 0.1138)−
2.54 − 2.56 (0.1000 − 0.1008)2.90 − 2.92 (0.1142 − 0.1150)−
14. REMOVE COMPANION FLANGE (See page SA−69)
15. REMOVE FRONT BEARING (See page SA−74)
16. INSTALL NEW BEARING SPACER AND FRONT
BEARING
Install a new bearing spacer and front bearing on the drive pin-
ion.
17. INSTALL OIL SLINGER
18. INSTALL NEW FRONT OIL SEAL
(a) Using SST and hammer, install a new oil seal.
SST 09554−22010
Oil seal drive in depth: 2.0 mm (0.079 in.)
(b) Apply MP grease to the oil seal lip.
19. INSTALL COMPANION FLANGE
(a) Using SST, install the companion flange on the drive pin-
ion.
SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03040, 09956−03020)
(b) Coat the threads of a new nut with hypoid gear oil.