boot TOYOTA RAV4 1996 Service User Guide

D00697
Ok if hot
Add if hot
AT4252
0 − 1 mm
D02248
DI−182
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
(f) Check the fluid leaks.
Check for leaks in the transmission and transfer.
If there are leaks, it is necessary to repair or replace O − rings,
FIPG’s, oil seals or other parts.
(g) Inspect and adjust the throttle cable.
(1) Check that the throttle valve is fully closed.
(2) Check that the inner cable is not slack.
(3) Loosen the adjustment nuts.
(4) Adjust the outer cable so that the distance between
the end of the boot and stopper on the cable is as
standard.
Standard boot and cable stopper distance:
0 − 1 mm (0 − 0.04 in.)
(5) Tighten the adjusting nuts.
(6) Recheck the adjustments.
(h) Adjust the shift control cable.
(1) Loosen the nut on the lever.
(2) Push the manual lever fully toward the right side of
the vehicle.

B11562
P17875
Ohmmeter
IG0147
Megger
Ground
N00917
− IGNITIONIGNITION SYSTEM
IG−3
1996 RAV4 (RM447U)
2. INSPECT HIGH−TENSION CORDS
(a) Disconnect the high−tension cords from spark plug.
Disconnect the high−tension cords at the rubber boot. Do
not pull on the high−tension cords.
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
(b) Disconnect the high−tension cords from ignition coil.
(c) Disconnect the high−tension cords from distributor cap.
(d) Inspect the high−tension cord resistance.
Using an ohmmeter, measure the resistance.
Maximum resistance: 25 kΩ per cord
If the resistance is greater than maximum, check the terminals.
If necessary, replace the high−tension cord.
(e) Reconnect the high−tension cords to distributor cap.
(f) Reconnect the high−tension cord to ignition coil.
(g) Reconnect the high−tension cords to spark plugs.
3. INSPECT SPARK PLUGS
NOTICE:
Never use a wire brush for cleaning.
Never attempt to adjust the electrode gap on a used
spark plug.
Spark plugs should be replaced every 100,000 km
(60,000 miles).
(a) Disconnect the high−tension cords from the spark plugs.
(b) Using a megger (insulation resistance meter), measure
the insulation resistance.
Standard correct insulation resistance:
10 MΩ or more
If the resistance is less than specified, proceed to step (d).
HINT:
If a megger is not available, the following simple method of in-
spection provides fairly accurate results.
Simple Method:
Quickly race the engine to 4,000 rpm 5 times.
Remove the spark plug. (See step (c))
Visually check the spark plug.
If the electrode is dry... OK
If the electrode is wet... Proceed to step (d)
Reinstall the spark plug. (See step (g))

MX05U−01
Q09032
2WD:
Clutch Release Fork Assembly
with Bearing
Clutch Release Fork SupportControl Lever Housing
Support Bracket
Boot O−Ring
Cover Clutch Release
Line Bracket
Transaxle Case
Transmission
Oil Cooler
Sub−Assembly
Elbow O−RingVehicle Speed Sensor
Transaxle Case Receiver
Transmission Oil
Pipe
Magnet
Transmission
Oil Pipe
 Output Shaft Cover
Tapered Roller Bearing
Outer Race
 Front Oil Seal
Input Shaft Front
Bearing
Transmission Oil Pump
Assembly
Differential Case Assembly
Oil Pump Drive Gear
17 (175, 13)
47 (480, 35)
34 (350, 25)
27 (275, 20)
7.4 (75, 65 in.·lbf)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part Gasket
  MX−12
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
MANUAL TRANSAXLE ASSEMBLY
COMPONENTS

Q09033
Clutch Release
Fork Assembly
with Bearing
Clutch Release Fork Support
Control Lever Housing
Support Bracket
Boot O−Ring
Cover
Clutch Release
Line Bracket
Transaxle Case
Elbow O−RingVehicle Speed Sensor
Transaxle Case Receiver
Transmission Oil
Pipe
Magnet
 Output Shaft Cover
 Tapered Roller Bearing
Outer Race
 Front Oil Seal
 Input Shaft Front
Oil Seal
Transmission Oil Pump
Assembly
Differential Case Assembly
Oil Pump Drive Gear
34 (350, 25)
27 (275, 20)
7.4 (75, 65 in.·lbf)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 Precoated part 4WD:


Transfer Assembly
Transmission
Oil Pipe
17 (175, 13)
17 (175, 13)
69 (700, 51)
69 (700, 51)
39 (400, 29)
47 (480, 35)
Differential Side Gear
Intermediate Shaft
 Snap Ring
69 (700, 51)
Drain Plug
Oil Cooler Line Gasket
 Gasket 
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−13
1996 RAV4 (RM447U)

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

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

MX0DZ−01
Q06131
Q06157
SST
Q06158
MX−82
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE DUST BOOT
2. REMOVE DYNAMIC DAMPER
Remove the 4 bolts and dynamic damper.
3. REMOVE EXTENSION HOUSING
(a) Remove the 4 bolts, tap the extension housing with a
plastic hammer and remove it.
(b) Remove the O−ring from the extension housing.
4. REMOVE PLUG AND DIFFERENTIAL LOCK INDICA-
TOR SWITCH
(a) Using a hexagon wrench (6 mm), remove the plug.
(b) Using a hexagon wrench (10 mm), remove the plug and
gasket.
(c) Remove the differential lock indicator switch and gasket.
5. REMOVE TRANSFER RIGHT CASE OIL SEAL
Using a screwdriver and hammer, remove the oil seal.
6. CHECK PRELOAD
(a) Using SST and a spring tension gauge, measure the driv-
en pinion preload of the backlash between the driven pin-
ion and ring gear.
SST 09326−20011
Preload (at starting):
9−14 N (0.9−1.4 kgf, 2−3 lbf)
(b) Using SST and a spring tension gauge, measure the total
preload.
SST 09326−20011
Total preload (at starting):
Driven pinion preload plus
5−9 N (0.5−0.9 kgf, 1−2 lbf)
7. REMOVE TRANSFER INSPECTION HOLE COVER
(a) Remove the 3 bolts.
(b) Using a screwdriver and hammer, remove the transfer in-
spection hole cover.
8. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13−0.18 mm (0.0051−0.0071 in.)
9. CHECK TOOTH CONTACT (See page MX−89)

− MANUAL TRANSAXLETRANSFER (4WD)
MX−97
1996 RAV4 (RM447U)
(d) Install and torque the 4 bolts.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
20. INSTALL DYNAMIC DAMPER
Install the dynamic damper and torque the 4 bolts.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
21. INSTALL DUST BOOT

PR02R−01
F03298
Q08983
Matchmarks
Q05852
Q05853
SST
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY
PR−3
1996 RAV4 (RM447U)
REMOVAL
1. LOOSEN CROSS GROOVE JOINT SET BOLT
(a) Depress the brake pedal and hold it.
(b) Using a hexagon wrench, loosen the cross groove joint
set bolts 1/2 turn.
HINT:
Put a piece of cloth, or equivalent, into the inside of the cross
groove joint cover so that the boot does not touch the inside of
the cross groove joint cover.
(c) Loosen the 2 bolts and center support bearing.
2. DISCONNECT PROPELLER SHAFT FROM DIFFER-
ENTIAL
(a) Place matchmarks on both flanges.
(b) Remove the 4 bolts, washers and nuts.
3. REMOVE PROPELLER SHAFT FROM TRANSAXLE
(a) Remove the 2 bolts and center support bearing.
(b) Pull out the propeller shaft yoke from the transaxle.
(c) Insert SST in the transaxle to prevent oil leakage.
SST 09325−20010