shift TOYOTA RAV4 1996 Service Repair Manual

Q08125
Q08126
Z00182
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−21
1996 RAV4 (RM447U)
30. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from the re-
verse shift fork.
31. REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD
AND NO.1 SHIFT FORK
(a) Pull out the No.2 shift fork shaft.
(b) Remove the shift head and No.1 shift fork.
32. REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE
SHIFT FORK AND NO.2 SHIFT FORK
(a) Pull out the No.3 shift fork shaft with the reverse shift fork.
(b) Remove the No.2 shift fork.
33. REMOVE SNAP RING
(a) Using 2 screwdrivers and a hammer, remove the snap
ring and reverse shift fork from the No.3 shift fork shaft.
(b) Using 2 screwdrivers and a hammer, remove the 3 snap
rings from the No.1, No.2 and No.3 shift fork shafts.
34. REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY
(a) Leaning the output shaft to the differential side, remove
the input shaft assembly.
(b) Lift up the differential case assembly, remove the output
shaft assembly.
35. REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Remove the oil pump drive gear.
(b) Remove the differential case assembly.
36. REMOVE MAGNET FROM TRANSAXLE CASE
37. REMOVE TRANSMISSION OIL PUMP ASSEMBLY
AND OIL PIPE
(a) Remove the 2 bolts and oil pipe.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
(b) Remove the 2 bolts and oil pump assembly.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)

MX0DT−01
MT0782
WM0066
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−23
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT NO.5 SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
middle No.5 synchronizer ring in one direction while push-
ing it to the outer No.5 synchronizer ring. Check that the
ring locks.
If it does not lock, replace the synchronizer ring.
2. MEASURE SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.

MX028−02
MT0791
Rear Bearing4th GearSpacer
Synchronizer Ring
Snap Ring
Needle Roller Bearing3rd GearNeedle Roller Bearing
 Input Shaft Front Bearing Inner Race
Input Shaft Synchronizer Ring
No.2 Hub Sleeve
No.2 Clutch Hub
Shifting KeySpring
Snap Ring
 Non−reusable part
− MANUAL TRANSAXLEINPUT SHAFT
MX−29
1996 RAV4 (RM447U)
INPUT SHAFT
COMPONENTS

WM0066
Z19371
BAB
Q00173
− MANUAL TRANSAXLEINPUT SHAFT
MX−33
1996 RAV4 (RM447U)
3. MEASURE NO.2 SHIFT FORK AND HUB SLEEVE
CLEARANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
4. INSPECT INPUT SHAFT
(a) Check the input shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of the in-
put shaft journal surface.
Minimum outer diameter:
Part A: 27.950 mm (1.1004 in.)
Part B: 35.950 mm (1.4154 in.)
(c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.05 mm (0.0020 in.)

MX02B−04
Q00383
Front
MT0790
Q00183SST
Q00116
MX−34
− MANUAL TRANSAXLEINPUT SHAFT
1996 RAV4 (RM447U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
(a) Install the 3 springs and shifting keys to the clutch hub.
(b) Install the hub sleeve to the clutch hub.
HINT:
Direct identification groove of the hub sleeve to front of the
transmission.
2. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-
SEMBLY TO INPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Assemble the needle roller bearings into the 3rd gear.
(c) Place the synchronizer rings on the gear and align the
ring slots with the shifting keys.
(d) Using SST and a press, install the 3rd gear and No.2 hub
sleeve.
SST 09506−35010
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
H2.30 (0.0906)M2.50 (0.0984)
J2.35 (0.0925)N2.55 (0.1004)
K2.40 (0.0945)P2.60 (0.1024)
L2.45 (0.0965)−−
(b) Using a screwdriver and hammer, tap in the snap ring.

N00494
SST
Q00118
− MANUAL TRANSAXLEINPUT SHAFT
MX−35
1996 RAV4 (RM447U)
4. MEASURE 3RD GEAR THRUST CLEARANCE
(See page MX−30)
5. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE
ROLLER BEARING, 4TH GEAR AND REAR BALL
BEARING
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearings.
(c) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(d) Install the 4th gear.
(e) Using SST and a press, install the rear ball bearing.
SST 09506−35010
6. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
12.35 (0.0925)52.55 (0.1004)
22.40 (0.0945)62.60 (0.1024)
32.45 (0.0965)72.65 (0.1043)
42.50 (0.0984)82.70 (0.1063)
(b) Using a screwdriver and hammer, tap in the snap ring.
7. MEASURE 4TH GEAR THRUST CLEARANCE
(See page MX−30)

MX02C−02
Q06216
4th Driven Gear3rd Driven GearNeedle Roller Bearing
1st Gear Bearing Inner Race Spacer
Inner Race
2nd Gear
Spacer
Output Shaft Rear Bearing
SpringNo.1 Hub Sleeve
Needle Roller Bearing
1st Gear
Synchronizer Ring
Ball
Output Shaft Front
Bearing
Output Shaft Shifting Key
No.1 Clutch Hub
Synchronizer Ring
 Non−reusable part MX−36
− MANUAL TRANSAXLEOUTPUT SHAFT
1996 RAV4 (RM447U)
OUTPUT SHAFT
COMPONENTS

WM0066
Q06203
AB
A
Q06191
MX−40
− MANUAL TRANSAXLEOUTPUT SHAFT
1996 RAV4 (RM447U)
3. MEASURE NO.1 SHIFT FORK AND HUB SLEEVE
CLEARANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
4. INSPECT OUTPUT SHAFT
(a) Check the output shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of the
output shaft journal surface.
Minimum outer diameter:
Part A: 37.526 mm (1.4774 in.)
Part B: 34.512 mm (1.3588 in.)
(c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.06 mm (0.0024 in.)

MX02F−04
Q06204
Front
Q06205
SST Align the holes
Z00225
Q06206
SST
− MANUAL TRANSAXLEOUTPUT SHAFT
MX−41
1996 RAV4 (RM447U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE
(a) Install the 3 springs and shifting keys to the clutch hub.
(b) Install the hub sleeve to the clutch hub.
HINT:
Direct identification groove of the hub sleeve to the front of the
transmission.
2. INSTALL 1ST GEAR BEARING INNER RACE
Using SST and a press, install the 1st gear bearing inner race.
SST 09506−35010
HINT:
Align the hole of the output shaft and inner race.
3. INSTALL NEEDLE ROLLER BEARING, 1ST GEAR,
SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO
OUTPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Install the 1st gear.
(c) Place the synchronizer ring (for the 1st gear) on the gear
and align the ring slots with the shifting keys.
(d) Using SST and a press, install the 1st gear and No.1 hub
sleeve.
SST 09316−60011 (09316−00041)
4. MEASURE 1ST GEAR THRUST CLEARANCE
(See page MX−37)

MX02I−02
Q06217
Shift Interlock Plate
Transmission Oil Baffle Shift Interlock Plate
No.1 Compression SpringControl Shaft Cover
Oil Seal
Snap Ring
No.1 Select Spring Seat
Slotted Spring Pin
No.1 Shift Inner Lever
Shift and Select Lever Shaft Snap Ring
Non−reusable part No.2 Select Spring SeatNo.2 Compression SpringNo.2 Shift Inner LeverSlotted Spring Pin
Apply MP grease 
Dust Boot
 MX−48
− MANUAL TRANSAXLESHIFT AND SELECT LEVER SHAFT
1996 RAV4 (RM447U)
SHIFT AND SELECT LEVER SHAFT
COMPONENTS