TOYOTA RAV4 1996 Service Repair Manual

W01135
Non−tilt Steering Column :
Bearing
Tilt Steering Column :
Bearing
W00088
− STEERINGNON−TILT STEERING COLUMN
SR−17
1996 RAV4 (RM447U)
8. INSPECT BEARING
(a) Check the bearing rotation condition and check for abnor-
mal noise.
If the bearing is worn or damaged, replace the steering column
tube.
(b) Coat the bearing with molybdenum disulfide lithium base
grease.
9. Tilt Steering Column:
INSPECT BEARING
Check the bearing of the steering main shaft rotation condition
and check for abnormal noise.
10. Tilt Steering Column:
IF NECESSARY, REPLACE BEARING
(a) Remove the bearing from the steering main shaft.
(b) Coat a new bearing with molybdenum disulfide lithium
base grease.
(c) Install the bearing.

SR0F4−01
W01201
SR−18
− STEERINGNON−TILT STEERING COLUMN
1996 RAV4 (RM447U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. INSTALL STEERING MAIN SHAFT ASSEMBLY
(a) Using snap ring expander, install a new snap ring to the
shaft assembly.
(b) Install the shaft assembly into the steering column tube.
(c) Using snap ring expander, install a new snap ring to the
shaft assembly.
2. INSTALL STEERING COLUMN UPPER BRACKET
AND COLUMN UPPER CLAMP
(a) Install the bracket with 2 new tapered−head bolts.
HINT:
Insert the bracket pin into the column tube hole.
(b) Tighten the tapered−head bolts until the bolt heads
breaks off.

SR0F5−03
W02018
− STEERINGNON−TILT STEERING COLUMN
SR−19
1996 RAV4 (RM447U)
INSTALLATION
1. Tilt Steering Column:
CONNECT SLIDING YOKE
(a) Align the matchmarks on the main shaft and sliding yoke,
and connect them.
(b) Torque the bolt.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
2. Non−Tilt Steering Column:
INSTALL STEERING COLUMN ASSEMBLY
(a) Temporarily tighten the 2 column assembly set bolts and
2 nuts.
(b) Connect the connectors.
3. Tilt Steering Column:
INSTALL STEERING COLUMN ASSEMBLY
(a) Torque the 2 column assembly set bolts and 2 nuts.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(b) Connect the connectors.
4. INSTALL STEERING COLUMN PROTECTOR
Torque the bolt.
Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf)

W02017
Non−tilt Steering Column :
Tilt−Steering Column :
MatchmarksBA
SR−20
− STEERINGNON−TILT STEERING COLUMN
1996 RAV4 (RM447U)
5. Non−Tilt Steering Column:
INSTALL NO.2 INTERMEDIATE SHAFT
(a) Connect the No.2 intermediate shaft to the main shaft.
(b) Temporarily tighten the bolt A.
6. Tilt Steering Column:
INSTALL No.2 INTERMEDIATE SHAFT
(a) Connect the No.2 intermediate shaft to the sliding yoke.
(b) Temporarily tighten the bolt A.
7. CONNECT NO.2 INTERMEDIATE SHAFT
(a) Align the matchmarks on the No.2 intermediate shaft and
control valve shaft, and connect them.
(b) Torque the bolt B.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
(c) Torque the bolt A.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
8. INSTALL SPIRAL CABLE (See page BE−14)
9. INSTALL COMBINATION SWITCH WITH SPIRAL
CABLE
(a) Tighten the 3 screws.
(b) Connect the connectors.
(c) Connect the airbag connector.
10. INSTALL NO.2 HEATER TO REGISTER DUCT
11. Non−Tilt Steering Column:
INSTALL UPPER AND LOWER COLUMN COVERS
(a) Install the protector to the lower cover and tighten the 3
screws.
(b) Tighten the 3 screws.
(c) Torque the 2 column assembly set bolts and 2 nuts.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
12. Tilt Steering Column:
INSTALL UPPER AND LOWER COLUMN COVERS
(a) Install the protector to the lower cover and tighten the 3
screws.
(b) Tighten the 3 screws.
13. INSTALL INSTRUMENT PANEL LOWER INSERT
Tighten the 3 screws.
14. INSTALL LOWER FINISH PANEL
(a) Tighten the 2 panel set bolts.
(b) Connect the hood lock control lever with the 2 screws.
15. CENTER SPIRAL CABLE
(a) Check that the front wheels are facing straight ahead.
(b) Turn the cable counterclockwise until it locks.
(c) Then rotate the cable clockwise about 2.5 turns to left of
the center.
HINT:
The spiral cable rotates approx. 5 turns maximum.

− STEERINGNON−TILT STEERING COLUMN
SR−21
1996 RAV4 (RM447U)
16. INSTALL STEERING WHEEL
(a) Align the matchmarks on the wheel and steering main
shaft assembly.
(b) Torque the wheel set nut.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
(c) Connect the airbag connector.
17. INSTALL STEERING WHEEL PAD
NOTICE:
Make sure that the pad is installed to the specified
torque.
If the pad has been dropped, or there are cracks,
dents or other defects in the case or connector, re-
place the wheel pad with a new one.
When installing the pad, take care that the wiring
does not interfere with other parts and is not pinched
between other parts.
(a) Connect the airbag connector.
(b) Install the pad after confirming that the circumference
groove of the torx screws are caught on the screw case.
(c) Using a torx socket wrench, torque the 2 screws.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(d) Install the steering wheel lower No.2 and No.3 covers.
18. CHECK STEERING WHEEL CENTER POINT

SR0F6−03
SR−22
− STEERINGTILT STEERING COLUMN
1996 RAV4 (RM447U)
TILT STEERING COLUMN
COMPONENTS

− STEERINGTILT STEERING COLUMN
SR−23
1996 RAV4 (RM447U)

SR0F7−02
SR−24
− STEERINGTILT STEERING COLUMN
1996 RAV4 (RM447U)
REMOVAL
(See page SR−12)

SR0F8−04
W01117
W01123
Vinyl Tape
W01124
SST
− STEERINGTILT STEERING COLUMN
SR−25
1996 RAV4 (RM447U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. REMOVE 3 TENSION SPRINGS
HINT:
Remove the springs with the tilt function at maximum tilt up.
2. REMOVE STEERING COLUMN UPPER BRACKET
AND STEERING COLUMN UPPER CLAMP
(See page SR−15)
3. REMOVE COMBINATION SWITCH BRACKET
Remove the 2 bracket set bolts.
4. REMOVE STEERING COLUMN UPPER TUBE WITH
STEERING MAIN SHAFT
(a) Using a hexagon wrench, remove the 2 tilt steering bolts.
(b) Remove the upper tube with the shaft from the steering
column tube.
5. REMOVE TILT LEVER RETAINER
Using screwdriver, remove the retainer from the steering col-
umn upper tube.
NOTICE:
Tape the screwdriver tip before use.
6. REMOVE STEERING MAIN SHAFT
(a) Using SST, compress the compression spring.
SST 09950−40010 (09958−04010)
NOTICE:
Do not bend the universal joint of the shaft more than 20°.
(b) Using a snap ring expander, remove the snap ring from
the shaft.
(c) Remove the shaft from the steering column upper tube.

W01125
Collar
W01126
Pin Punch
No.2 Tilt Steering
Shaft SR−26
− STEERINGTILT STEERING COLUMN
1996 RAV4 (RM447U)
(d) Remove the compression spring and bearing thrust collar
from the shaft.
(e) Using a screwdriver and a hammer, remove the collar
from the shaft.
7. REMOVE TILT STEERING PAWL
(a) Using a pin punch and a hammer, tap out the tilt steering
No.2 shaft.
(b) Remove the pin from the pawl.