differential TOYOTA RAV4 1996 Service Owner's 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)

MX060−01
Z17560
Transaxle Case Cover
Differential Spider
Differential Pinion
Differential Side Gear
Side Gear Thrust
Washer
Pinion Thrust Washer
 Tapered Roller Bearing
and Outer Race
Differential Right Case
Vehicle Speed Sensor Drive Gear
Differential Left Case
 Tapered Roller Bearing
and Outer Race Ring Gear
Oil Baffle
 Oil Seal x16
Shim  Oil Seal
54 (550, 40)
63 (640, 46)
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part 

x16
 Precoated partStud Bolt
54 (550, 40)
124 (1,260, 91)
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
MX−49
1996 RAV4 (RM447U)
DIFFERENTIAL CASE (2WD)
COMPONENTS

Q05166
SST
MX0DV−01
Z00281
Matchmarks
Z00284
MX−50
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE TAPERED ROLLER BEARING
Using SST, remove the left and right bearings.
SST 09950−40010
2. REMOVE RING GEAR
(a) Place matchmarks on both the differential case and ring
gear.
(b) Remove the 16 bolts.
(c) Using a plastic hammer, tap the ring gear and remove it.
3. DISASSEMBLE DIFFERENTIAL CASE
(a) Place matchmarks on the differential right and left cases.
(b) Using a torx wrench (T50), remove the 16 torx screws.
(c) Using a plastic hammer, tap the differential left case.
(d) Remove the vehicle speed sensor drive gear from the dif-
ferential right case.
(e) Remove the 2 differential side gears, side gear thrust
washers, 4 differential pinions and pinion thrust washers
from the differential left case.

Z00286
MX0DW−01
Z00288
SST
Z00289
Q06288
SST
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
MX−51
1996 RAV4 (RM447U)
REPLACEMENT
1. Transmission Case Side:
REPLACE OIL SEAL AND TAPERED ROLLER BEAR-
ING OUTER RACE
(a) Using a screwdriver, remove the oil seal.
(b) Remove the oil baffle.
(c) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly.
(d) Remove the shim.
(e) Install the shim (See page MX−49).
HINT:
First select and install a shim of lesser thickness than before.
(f) Using SST and a press, install a new tapered roller bear-
ing outer race.
SST 09316−60011 (09316−00011, 09316−00041)
(g) Install the oil baffle.
HINT:
Install the oil baffle projection into the case side cutout.
(h) Using SST and a hammer, drive in a new oil seal.
SST 09223−15020, 09950−70010 (09951−07150)
(i) Coat the lip of oil seal with MP grease.

MT0659
Z01427
SST
Z00292
SST
Z00293
SST
Z00294
FIPG
MX−52
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
1996 RAV4 (RM447U)
2. Transaxle Case Side:
REPLACE OIL SEAL AND TAPERED ROLLER BEAR-
ING OUTER RACE
(a) Remove the 4 bolts and 3 nuts.
(b) Using a plastic hammer, tap the stud bolt and remove the
transaxle case cover.
(c) Using a screwdriver and hammer, drive out the oil seal
from the transaxle case cover.
(d) Using SST, a brass bar and hammer, remove the tapered
roller bearing outer race.
SST 09612−65014
(e) Using SST and a press, install a new tapered roller bear-
ing outer race.
SST 09316−60011 (09316−00011, 09316−00041)
(f) Using SST and a hammer, drive in a new oil seal.
SST 09316−60011 (09316−00011)
(g) Coat the oil seal lip with MP grease.
(h) Apply FIPG to the transaxle case cover, as shown.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
(i) Apply sealant to the bolt threads.
Sealant:
Part No.08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
(j) Install the stud bolt and cover to the transaxle case.

− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
MX−53
1996 RAV4 (RM447U)
(k) Install and torque the 4 bolts and 3 nuts.
Torque: 54 N·m (550 kgf·cm, 40 ft·lbf)

MX062−03
Z00295
Z00296
MX−54
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
1996 RAV4 (RM447U)
REASSEMBLY
NOTICE:
When working with FIPG material, you must observe the follow-
ing items.
Using a razor blade and gasket scraper, remove all the old
FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose
material.
Clean both sealing surfaces with a non−residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along
the sealing surface.
Parts must be assembled within 10 minutes of application.
Otherwise, the FIPG material must be removed and reap-
plied.
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. ASSEMBLE DIFFERENTIAL CASE
(a) Install the thrust washer to the side gear.
(b) Install the 4 pinions and thrust washers to the spider.
(c) Install the side gear and spider with the 4 pinions to the
differential left case.
(d) Using a dial indicator, measure the backlash of the pinion
gear while holding the differential left case.
Standard backlash:
0.05 − 0.20 mm (0.0020 − 0.0079 in.)
HINT:
Push the pinion gear and spider with the 4 pinions to the differ-
ential left case.
(e) Install the side gear and spider with the 4 pinions to the
right side of the differential case. Check the side gear
backlash.

Z00297
Z00298
Z00299
Matchmarks
Z00303
Driven Gear
Side
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
MX−55
1996 RAV4 (RM447U)
(f) Refer to the table below, select the thrust washer which
will ensure that the backlash is within the specification.
Try to select a washer of the same size.
Thickness mm (in.)Thickness mm (in.)
0.80 (0.0315)1.20 (0.0472)
0.90 (0.0354)1.30 (0.0512)
1.00 (0.0394)1.40 (0.0551)
1.10 (0.0433)−
(g) Install the vehicle speed sensor drive gear.
(h) Align the matchmarks on the differential cases.
(i) Using a plastic hammer, carefully tap the differential case
to install it.
(j) Using a torx wrench (T50), install and torque the 16 torx
screws.
Torque: 63 N·m (640 kgf·cm, 46 ft·lbf)
2. INSTALL RING GEAR
(a) Clean the contact surface of the differential case and the
threads of the ring gear and differential case.
(b) Heat the ring gear to about 100°C (212°F) in boiling wa-
ter.
(c) Carefully take the ring gear out of the water.
(d) Clean the contact surface of the ring gear with cleaning
solvent.
(e) Quickly install the ring gear on the differential case.
HINT:
Align the matchmarks on the differential left case and contact
the ring gear.
(f) Temporarily install the 16 bolts.
NOTICE:
The ring gear set bolts should not be tightened until the
ring gear has cooled sufficiently.
(g) After the ring gear has cooled sufficiently, torque the ring
gear set bolts.
Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf)

Q06410
SST
SST
Q00036
Z00309
MX−56
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
1996 RAV4 (RM447U)
3. INSTALL TAPERED ROLLER BEARING
Using SST and a press, install new left and right bearings onto
the differential case.
SST 09316−20011, 09316−60011 (09316−00011)
HINT:
Press the bearing on the ring side first.
4. ADJUST OUTPUT SHAFT ASSEMBLY PRELOAD
(See page MX−27)
5. INSTALL DIFFERENTIAL CASE ASSEMBLY TO
TRANSAXLE CASE
6. INSTALL OUTPUT SHAFT ASSEMBLY
Lift up the differential case and install the output shaft assem-
bly.
7. INSTALL TRANSMISSION CASE
(a) Install the transmission case.
HINT:
If necessary, tap on the case with a plastic hammer.
(b) Install and torque the 17 bolts.
Torque: 29 N·m (300 kgf·cm 22 ft·lbf)
8. INSTALL OUTPUT SHAFT REAR TAPERED ROLLER
BEARING OUTER RACE
Using a plastic hammer, drive in the outer race.
9. INSTALL SHIM (See page MX−27)
HINT:
Install the previously selected shim.
10. INSTALL REAR BEARING RETAINER
Using a torx wrench (T45), install and torque the 7 torx screws.
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)
11. ADJUST DIFFERENTIAL CASE SIDE BEARING PRE-
LOAD
(a) Install a new lock nut to the output shaft.
(b) Turn the output shaft right and left 2 or 3 times to allow the
bearings to settle.
(c) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing (Output shaft preload plus)
0.2 − 0.3 N·m (1.8 − 3.5 kgf·cm, 1.6 − 3.0 in.·lbf)
Reused bearing (Output shaft preload plus)
0.1 − 0.2 N·m (1.1 − 2.2 kgf·cm, 1.0 − 1.9 in.·lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.

− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
MX−57
1996 RAV4 (RM447U)
HINT:
The total preload will change by about 0.1 − 0.2 N·m (1 − 2
kgf·cm, 0.9 − 1.7 in.·lbf) with each 0.05 mm change in adjusting
shim thickness.
MarkThickness mm (in.)MarkThickness mm (in.)
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
12. REMOVE REAR BEARING RETAINER
Using a torx wrench (T45), remove the 7 torx screws and rear
bearing retainer.
13. REMOVE SHIM
14. REMOVE TRANSMISSION CASE
(a) Remove the 17 bolts.
(b) Using a plastic hammer, tap the transmission case.
15. REMOVE OUTPUT SHAFT ASSEMBLY
16. REMOVE DIFFERENTIAL CASE ASSEMBLY