shift TOYOTA RAV4 1996 Service Repair Manual

MX0C0−02
Q06152
− MANUAL TRANSAXLEDIFFERENTIAL LOCKING SYSTEM (4WD)
MX−73
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT CENTER DIFFERENTIAL LOCK SYSTEM
(a) Inspect the differential lock operation.
(1) Use a lift or jack stand to lift up the vehicle so that
all 4 tires can rotate.
(2) Apply the parking brake and start the engine.
(3) Set the center differential lock switch to ON.
(4) Depress the clutch pedal and shift into the 2nd gear.
(5) With the engine idling, gradually engage the clutch
and check that the engine stops.
(6) With the parking brake and engine ON, turn the cen-
ter differential lock switch OFF.
(7) Depress the clutch pedal and shift into the 2nd gear.
(8) With the engine idling, gradually engage the clutch
and check that the front wheels rotate.
HINT:
This inspection must be done when the engine is idling.
(b) Inspect the center differential lock indicator operation.
(1) Turn the ignition switch ON.
(2) Check that when the differential lock switch is
turned ON and OFF, the differential lock indicator
lamp lights up and goes off, respectively.
(c) Inspect the center differential lock warning buzzer opera-
tion.
(1) Start the engine and check that the differential lock
warning buzzer does not sound when the center dif-
ferential lock switch is turned ON.
(2) Interchange the solenoid hose No.1 and solenoid
hose No.2 between the differential lock control sole-
noid No.1 and No.2 and the differential lock actua-
tor. And check that the differential lock warning
buzzer sounds when the differential lock switch is
turned OFF.
(3) Return the solenoid hose No.1 and solenoid hose
No.2 to their original location, and check that the dif-
ferential lock warning buzzer stops.
HINT:
Do the inspection with the vehicle stopped.
After finishing the inspection, inspect the differential lock
control solenoid hoses.

MX065−01
D01958
Shift Lever Knob
Side Trim Cover
Side Trim Cover
Shift Control Cable Grommet Retainer
Shift Lever Assembly Select Control Cable
N·m (kgf·cm, ft·lbf) : Specified torqueWasherClip
Washer GrommetRetainerConsole Box Boot
12 (120, 9)
4.9 (50, 43 in.·lbf)
4.9 (50, 43 in.·lbf)
Clip Clip
Clip
Clip
ClipWasher
Bracket
− MANUAL TRANSAXLESHIFT LEVER AND CONTROL CABLE
MX−77
1996 RAV4 (RM447U)
SHIFT LEVER AND CONTROL CABLE
COMPONENTS

MX0C1−01
Q09037
Adjusting Shim
Transfer Oil PipeExtension Housing
x6
Dust Deflector
Transfer Pinion Bearing
Cage Assembly
Differential Lock
Indicator Switch Cushion
Differential Bearing
Adjusting Nut
Ring Gear Mounting
Case Assembly
Bearing Outer Race
Plate Washer
Transfer Left Case
Drain Plug Snap Ring
Shift Fork Shaft
Differential
Side Gear
Shaft Holder
Side Gear Shaft
Holder Bearing
Snap Ring
Adjusting Nut Lock Plate
N·m (kgf·cm, ft·lbf): Specified torque
Non−reusable part
Precoated part 
x10Transfer Right CaseDifferential Lock
Sleeve Differential Lock
Shift Fork Plug
Transfer Inspection
Hole Cover O−Ring

Plug
Oil Seal Dust BootGasket
 Oil Seal
44 (450, 33)


39 (400, 29)

16 (160, 12)
Gasket

39 (400, 29)
Gasket 
25 (250, 18)
40 (410, 30)16 (160, 12)

25 (260, 19)
Dynamic Damper
25 (260, 19)
 Bearing
Outer Race 
13 (130, 9)
O−Ring 
39 (400, 29)Oil Seal

− MANUAL TRANSAXLETRANSFER (4WD)
MX−79
1996 RAV4 (RM447U)
TRANSFER (4WD)
COMPONENTS

Z12395
SST
Z12545
Q06133
Q06142
SST
− MANUAL TRANSAXLETRANSFER (4WD)
MX−83
1996 RAV4 (RM447U)
10. REMOVE TRANSFER PINION BEARING CAGE AS-
SEMBLY
(a) Remove the 6 bolts, tap the transfer pinion bearing cage
assembly with a plastic hammer and remove it.
(b) Remove the O−ring and 2 adjusting shims from the trans-
fer pinion bearing cage.
(c) Remove the lock nut.
(1) Unstake the lock nut.
(2) Using SST, remove the lock nut.
SST 09326−20011
(d) Remove the transfer driven pinion.
Using a press, remove the transfer driven pinion, rear
bearing and spacer.
11. REMOVE DIFFERENTIAL LOCK SHIFT FORK, LOCK
SLEEVE AND SHIFT FORK SHAFT
Remove the bolt, shift fork, shift fork shaft and lock sleeve.
12. REMOVE TRANSFER RIGHT CASE
Remove the 10 bolts, tap the transfer right case with a plastic
hammer and remove it.
13. REMOVE RING GEAR MOUNTING CASE ASSEMBLY
(a) Remove the mounting case right side bearing.
Using SST, remove the right side bearing.
SST 09950−40010, 09950−60010 (09951−00500)

Q05709
SST
MX0E0−01
Z12397
SST
Z12546
Q08760
SST SST
Z16232
Socket Wrench MX−86
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
REPLACEMENT
1. REPLACE DRIVEN PINION FRONT BEARING
(a) Using SST and a press, remove the front bearing.
SST 09950−00020
(b) Using SST and a press, install a new front bearing.
SST 09316−60011 (09316−00051)
2. REPLACE FRONT AND REAR BEARING OUTER
RACE
(a) Using a brass bar and hammer, drive out the front and
rear bearing outer race lightly and evenly.
(b) Using SST and a press, install a new front bearing outer
race.
SST 09950−60020 (09951−00780), 09950−70010
(09951−07150)
(c) Using SST and a press, install a new rear bearing outer
race.
SST 09950−60010 (09951−00590), 09950−70010
(09951−07150)
3. REPLACE SHIFT FORK SHAFT OIL SEAL
(a) Using a screwdriver, remove the oil seal from the transfer
right case.
(b) Using a socket wrench and hammer, install a new oil seal.

Q06165
Z16229
Proper ContactHeel Contact Face Contact
Select an adjusting shim that will bring the
driven pinion closer to the ring gear.
Toe Contact Flank Contact
Select an adjusting shim that will shift the
driven pinion away from the ring gear. MX−94
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
6. CHECK TOOTH CONTACT
(a) Coat 3 or 4 teeth at 4 different positions on the ring gear
with red lead.
(b) Rotate the ring gear, inspect the teeth pattern.
(c) If the teeth are not contacting properly, again select the
proper shim and plate.
MarkThickness mm (in.)MarkThickness mm (in.)
A0.30 (0.0118)F0.45 (0.0177)
B0.33 (0.0130)G0.48 (0.0189)
C0.36 (0.0142)H0.51 (0.0201)
D0.39 (0.0154)J0.54 (0.0213)
E0.42 (0.0165)K0.57 (0.0224)
7. REMOVE RING GEAR MOUNTING CASE ASSEMBLY
(a) Remove the 10 bolts and transfer right case.
(b) Remove the ring gear mounting case assembly.
8. REMOVE TRANSFER PINION BEARING CAGE AS-
SEMBLY
Remove the 6 bolts and transfer pinion bearing cage assembly.

Q06133
Q06169
FIPG
Q06131
MX−96
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
15. CHECK TOTAL PRELOAD (See step 4)
16. INSTALL DIFFERENTIAL LOCK SHIFT FORK, LOCK
SLEEVE AND SHIFT FORK SHAFT
(a) Install the shift fork, shift fork shaft and lock sleeve.
(b) Install and torque the bolt.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
17. INSTALL TRANSFER INSPECTION HOLE COVER
(a) Apply FIPG to the transfer left case, as shown.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
(b) Install the cover on the transfer left case.
(c) Install and torque the 3 bolts.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
18. INSTALL PLUG AND DIFFERENTIAL LOCK INDICA-
TOR SWITCH
(a) Using a hexagon wrench (10 mm), install and torque the
plug and gasket.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Apply sealant to the plug threads.
Using a hexagon wrench (6 mm), install and torque the
plug.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Install and torque the differential lock indicator switch and
gasket.
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
19. INSTALL EXTENSION HOUSING
(a) Coat the O−ring with gear oil.
(b) Install a new O−ring to the extension housing.
(c) Install the extension housing to the transfer pinion bear-
ing cage.

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.

W02017
Non−Tilt Steering Column :
A
B Tilt Steering Column :
Matchmarks
W02018
Matchmarks
SR−14
− STEERINGNON−TILT STEERING COLUMN
1996 RAV4 (RM447U)
10. DISCONNECT NO.2 INTERMEDIATE SHAFT
(a) Loosen the bolt A.
(b) Remove the bolt B.
(c) Shift the No.2 intermediate shaft and place matchmarks
on the control valve shaft and No.2 intermediate shaft.
11. REMOVE NO.2 INTERMEDIATE SHAFT
12. REMOVE STEERING COLUMN PROTECTOR
Remove the bolt.
13. REMOVE STEERING COLUMN ASSEMBLY
(a) Disconnect the connectors.
(b) Remove the 2 column assembly set bolts and 2 nuts.
14. Tilt Steering Column:
REMOVE SLIDING YOKE
(a) Remove the bolt.
(b) Shift the sliding yoke and place matchmarks on the main
shaft and sliding yoke.