TOYOTA RAV4 1996 Service Repair Manual

SR0G2−03
R10984
SST
− STEERINGPOWER STEERING GEAR
SR−47
1996 RAV4 (RM447U)
REMOVAL
NOTICE:
Remove the steering wheel assembly before the steering
gear removal, because there is possibility of breaking of
the spiral cable.
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE STEERING WHEEL PAD (See page SR−12)
3. REMOVE STEERING WHEEL (See page SR−12)
4. REMOVE RH AND LH ENGINE UNDER COVERS
Remove the 13 bolts.
5. DISCONNECT RH AND LH TIE ROD ENDS
(See page SA−10)
6. REMOVE FRONT EXHAUST PIPE
Remove the 2 bolts, 3 nuts and 2 gaskets.
7. REMOVE STABILIZER BAR WITH LINK
(See page SA−48)
8. DISCONNECT NO.2 INTERMEDIATE SHAFT
(See page SR−12)
9. DISCONNECT PRESSURE FEED AND RETURN
TUBES
Using SST, disconnect the tube.
SST 09631−22020
10. DISCONNECT PRESSURE FEED AND RETURN TUBE
CLAMPS
Remove the bolt.
11. DISCONNECT RH AND LH LOWER SUSPENSION
ARMS (See page SA−40)
12. REMOVE 2 PS GEAR ASSEMBLY SET BOLTS AND
NUTS
HINT:
Securely suspend the steering gear assembly.
13. REMOVE FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY (See page SA−40)

SR0G3−01
W01241
SST
W01242
SST
R00429
Matchmarks
Matchmarks
R10982
W01243
SST SR−48
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the gear assembly in a vise.
SST 09612−00012
2. REMOVE 2 TURN PRESSURE TUBES
(a) Remove the union bolt and 2 gaskets.
(b) Using SST, remove the tube.
SST 09633−00020
3. REMOVE RH AND LH TIE ROD ENDS AND LOCK
NUTS
(a) Place matchmarks on the tie rod end and rack end.
(b) Loosen the lock nut.
4. REMOVE RH AND LH CLIPS, RACK BOOTS AND
CLAMPS
Remove the screw and loosen the clamp.
NOTICE:
Be careful not to damage the boot.
Mark the RH and LH boots.
5. REMOVE RH AND LH RACK ENDS AND CLAW WASH-
ERS
(a) Using a screwdriver and a hammer, unstake the washer.
NOTICE:
Avoid any impact to the steering rack.
(b) Using a spanner to hold the steering rack steady and us-
ing SST, remove the rack end.
SST 09922−10010
NOTICE:
Use SST 09922−10010 in the direction shown in the il-
lustration.
Mark the RH and LH rack ends.

W01244
Matchmarks
W01245
SST
Rack Guide Spring
Cap Lock Nut
W01246
SST
W01247
SST
Pin
Pin
− STEERINGPOWER STEERING GEAR
SR−49
1996 RAV4 (RM447U)
6. REMOVE RACK HOUSING NO.1 BRACKET AND
GROMMET
(a) Place matchmarks on the bracket and rack housing.
(b) Remove the bolt.
(c) Remove the grommet from the rack housing No.1 brack-
et.
7. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the nut.
SST 09922−10010
NOTICE:
Use SST 09922−10010 in the direction shown in the illustra-
tion.
8. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE
SPRING, RACK GUIDE AND RACK GUIDE SEAT
(a) Using a hexagon wrench (21 mm), remove the cap.
(b) Remove the seat from the guide.
9. REMOVE RACK HOUSING CAP
10. REMOVE LOCK NUT
Using SST to stop the control valve shaft rotating, remove the
nut.
SST 09616−00010
11. REMOVE DUST COVER
12. REMOVE CONTROL VALVE ASSEMBLY, OIL SEAL
AND BEARING
(a) Using snap ring pliers, remove the snap ring from the rack
housing.
(b) Using SST, remove the control valve with the oil seal and
bearing.
SST 09613−12010
NOTICE:
Never attempt to tap out the control valve as this would
damage it.
(c) Remove the oil seal and bearing from the control valve.
13. REMOVE BEARING
Remove the bearing and spacer from the rack housing.

W01248
SST
F00872
SST
Oil Seal
SR−50
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
14. REMOVE CYLINDER END STOPPER AND STEERING
RACK
(a) Using snap ring pliers, remove the snap ring from the rack
housing.
(b) Using SST, press out the steering rack and end stopper.
SST 09612−10093 (09612−10061)
(c) Remove the oil seal from the steering rack.
15. REMOVE OIL SEAL
Using SST, press out the oil seal.
SST 09950−60010 (09951−00260),
09950−70010 (09951−07360)
NOTICE:
Be careful not to damage the rack housing.

SR0G4−03
R10072
Dial Indicator
W01250
Cylinder Gauge
Bushing
Micrometer
W03557
SST
Bushing SST
R11295
Vinyl Tape
Oil Seal
− STEERINGPOWER STEERING GEAR
SR−51
1996 RAV4 (RM447U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. INSPECT STEERING RACK
(a) Using a dial indicator, check the rack for runout.
Maximum runout: 0.30 mm (0.0118 in.)
(b) Check the rack for teeth wear and damage.
(c) Check the back surface for wear and damage.
2. CHECK CONTROL VALVE ASSEMBLY AND BUSHING
Using a cylinder gauge and a micrometer, measure the inside
diameter of the bushing and outside diameter of the valve as-
sembly.
Maximum inside diameter: 28.20 mm (1.1102 in.)
Minimum outside diameter: 27.75 mm (1.0925 in.)
3. IF NECESSARY, REPLACE BUSHING AND OIL SEAL
(a) Using SST, remove the bushing from the rack housing.
SST 09612−24014 (09613−22011)
NOTICE:
Be careful not to damage the rack housing.
HINT:
Separate the SST as shown in the illustration to use it.
As shown, from the opposite side of SST confirm that its
claw is firmly caught on the bushing.
(b) Using a screwdriver, tap out the oil seal.
NOTICE:
To prevent rack housing damage, wind vinyl tape on the
screwdriver.

W04190
SST
SST Oil Seal
W01253
SST
SST
SSTBushing
R10955
R06172
N00401
SR−52
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
(c) Coat a new oil seal lip with power steering fluid.
(d) Using SST, carefully tap in the oil seal.
SST 09950−60010 (09951−00230, 09951−00330,
09952−06010), 09950−70010 (09951−07150)
NOTICE:
Make sure to install the oil seal facing the correct direction.
(e) Coat a new bushing with molybdenum disulfide lithium
base grease.
(f) Using SST, press in the bushing.
SST 09950−60010 (09951−00270, 09951−00340,
09952−06010),09950−70010 (09951−07150)
4. IF NECESSARY, REPLACE TEFLON RING AND O−
RING
(a) Using a screwdriver, remove the teflon ring and O−ring
from the steering rack.
NOTICE:
Be careful not to damage the groove for the teflon ring.
(b) Coat a new O−ring with power steering fluid and install it.
(c) Expand a new teflon ring with your fingers.
NOTICE:
Be careful not to overexpand the ring.
(d) Coat the ring with power steering fluid.
(e) Install the ring to the steering rack and snug it down with
your fingers.

N00402SST
Z01716
N00406
SST
W01254
Screw Extractor
Union Seat
− STEERINGPOWER STEERING GEAR
SR−53
1996 RAV4 (RM447U)
(f) Carefully slide the tapered end of SST over the ring to
seat it.
SST 09630−24014 (09631−24031)
NOTICE:
Be careful not to damage the ring.
5. IF NECESSARY, REPLACE TEFLON RINGS
(a) Using a screwdriver, remove the 4 rings from the control
valve assembly.
NOTICE:
Be careful not to damage the grooves for the ring.
(b) Expand 4 new teflon rings with your fingers.
NOTICE:
Be careful not to overexpand the ring.
(c) Coat the rings with power steering fluid.
(d) Install the rings to the control valve assembly, and snug
them down with your fingers.
(e) Carefully slide the tapered end of SST over the rings to
seat them.
SST 09631−20081
NOTICE:
Be careful not to damage the rings.
6. IF NECESSARY, REPLACE 2 UNION SEATS
(a) Using a screw extractor, remove the union seats.

W01255
Union Seat
Extension Bar
W01202
Cylinder
End Stopper
SR−54
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
(b) Using an extension bar and a hammer, tap in 2 new union
seats.
NOTICE:
Before installing the union seat, remove dust sticking to
the rack housing.
7. INSPECT BUSHING
(a) Check for wear and damage on the inside of the bushing
of the cylinder end stopper.
If the bushing is worn or damaged, replace the cylinder end
stopper.
(b) Coat inside of the bushing with molybdenum disulfide lith-
ium base grease.

SR0G8−02
F00873
SST
Oil Seal
SST
W02101
Rack Teeth End
SST
SST Rack Teeth End
W01257
Vinyl Tape
− STEERINGPOWER STEERING GEAR
SR−55
1996 RAV4 (RM447U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH POWER STEERING FLUID OR MOLYBDE-
NUM DISULFIDE LITHIUM BASE GREASE
(See page SR−44)
2. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal.
SST 09950−60010 (09951−00230, 09951−00400,
09952−06010), 09950−70010 (09951−07360)
NOTICE:
Make sure to install the oil seal facing the correct
direction.
Take care that the oil seal does not get reversed as
you install it.
3. INSTALL STEERING RACK
(a) Install SST to the rack.
HINT:
If necessary, scrape the burrs off the rack teeth end and bur-
nish.
SST 09631−16020
(b) Coat SST with power steering fluid.
(c) Install the rack into the rack housing.
(d) Remove the SST.
4. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) To prevent oil seal lip damage, wind vinyl tape on the
steering rack end, and apply power steering fluid.
(c) Install the oil seal by pushing it into the rack housing, with-
out tilting.
NOTICE:
Make sure to install the oil seal facing the correct direction.

W01258
SST
W01259
SST
Bearing
W04191
SST
Oil SealPress SR−56
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
5. INSTALL CYLINDER END STOPPER
(a) Install the stopper into the rack housing.
(b) Using snap ring pliers, install a new snap ring to the rack
housing.
6. AIR TIGHTNESS TEST
(a) Install SST to the union of the rack housing.
SST 09631−22030
(b) Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for
about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil
seals.
7. INSTALL CONTROL VALVE ASSEMBLY
(a) Coat the teflon rings with power steering fluid.
(b) Install the control valve assembly into the rack housing.
NOTICE:
Be careful not to damage the teflon rings and oil seal.
8. INSTALL BEARING
Using SST, press in a new bearing.
SST 09612−22011
9. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST and a press, press in the oil seal.
SST 09612−22011
NOTICE:
Make sure to install the oil seal facing the correct direction.
(c) Using snap ring pliers, install a new snap ring to the rack
housing.
10. INSTALL DUST COVER
11. INSTALL BEARING
Install the spacer and a new bearing into the rack housing.