remove transaxle TOYOTA RAV4 1996 Service Workshop Manual

MX05O−02
Q08747
Q08748
A
B
Q08749
Q08750
A B
A
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
MX−3
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR
HOSE
2. REMOVE ENGINE COOLANT RESERVOIR TANK
3. REMOVE ENGINE WIRE CLAMP SET NUT
4. REMOVE STARTER
(a) Disconnect the connector and wire from the starter.
(b) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
5. DISCONNECT CLUTCH RELEASE CYLINDER AND
LINE
(a) Remove the 2 set bolts of the clutch line bracket.
Torque:
Bolt A: 12 N·m (120 kgf·cm, 9 ft·lbf)
Bolt B: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
(b) Remove the 2 bolts, release cylinder and line.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
6. DISCONNECT GROUND CABLE
Remove the set bolt of the ground cable from the transaxle.
7. DISCONNECT VEHICLE SPEED SENSOR AND
BACK−UP LIGHT SWITCH CONNECTORS
8. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
9. REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING
BOLTS
Torque:
Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf)
Bolt B: 35 N·m (360 kgf·cm, 26 ft·lbf)

Q08751
Q08752
Q10165
Filler Plug
Oil Level
0 − 5 mm
Drain Plug
Q08753
MX−4
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
1996 RAV4 (RM447U)
10. REMOVE ENGINE LEFT MOUNTING INSULATOR SET
BOLT AND 2 NUTS
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
11. INSTALL ENGINE SUPPORT FIXTURE
12. TIE PS GEAR ASSEMBLY TO ENGINE SUPPORT FIX-
TURE BY CORD OR EQUIVALENT
13. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
14. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
15. REMOVE LH AND RH ENGINE UNDER COVERS
16. DRAIN TRANSAXLE OIL
Oil grade: API GL−4 or GL−5
Viscosity: SAE 75W−90
Capacity: 3.9 liters (4.1 US qts, 3.4 Imp. qts)
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
17. REMOVE LH AND RH FRONT DRIVE SHAFTS
(See page SA−18)
18. REMOVE FRONT EXHAUST PIPE
(a) Remove the 3 nuts and gasket from the exhaust manifold.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Remove the 2 bolts, gasket and pipe.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
19. REMOVE FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY WITH STABILIZER BAR
(a) Support the front suspension crossmember with a jack.
(b) Disconnect the ring from the center exhaust pipe.
(c) Remove the 2 set bolts and nuts of the PS gear assembly.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)

Q08754
A
B A
B D
E
C
Q08755
Q08756DEC C
FG G
F
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
MX−5
1996 RAV4 (RM447U)
(d) Remove the 2 nuts, 6 bolts and front suspension cross-
member assembly with the stabilizer bar.
Torque:
Bolt A: 206 N·m (2,100 kgf·cm, 152 ft·lbf)
Bolt B: 137 N·m (1,400 kgf·cm, 101 ft·lbf)
Nut C: 115 N·m (1,170 kgf·cm, 85 ft·lbf)
20. REMOVE ENGINE MOUNTING CENTER MEMBER
Remove the 4 bolts and center member.
Torque:
Bolt D: 80 N·m (820 kgf·cm, 59 ft·lbf)
Bolt E: 35 N·m (360 kgf·cm, 26 ft·lbf)
21. JACK UP TRANSAXLE SLIGHTLY
Using a trasmission jack, support the transaxle.
22. DISCONNECT ENGINE LEFT MOUNTING BRACKET
FROM ENGINE LEFT MOUNTING INSULATOR
Remove the set bolt of the engine left mounting bracket.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
23. REMOVE STIFFENER PLATE, NO.2 REAR END
PLATE AND TRANSAXLE LOWER SIDE MOUNTING
BOLT
(a) Remove the 2 bolts and stiffener plate.
Torque:
Bolt G: 37 N·m (380 kgf·cm, 27 ft·lbf)
(b) Remove the 7 bolts and No.2 rear end plate.
Torque:
Bolt C: 29 N·m (300 kgf·cm, 22 ft·lbf)
Bolt D: 46 N·m (470 kgf·cm, 34 ft·lbf)
Bolt E: 25 N·m (250 kgf·cm, 18 ft·lbf)
Bolt F: 9.0 N·m (95 kgf·cm, 78 in.·lbf)
24. REMOVE TRANSAXLE
Lower the engine left side and remove the transaxle from the
engine.
HINT:
At the time of installation, please refer to the following items.
Align the input shaft with the clutch disc and install the
transaxle to the engine.
Temporarily tighten the transaxle mounting bolts.

MX−6
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
1996 RAV4 (RM447U)
25. REMOVE TRANSAXLE CASE PROTECTOR
Remove the 2 bolts and protector.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

MX05P−05
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
MX−7
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal.
(See page MX−3)
NOTICE:
When working with FIPG material, you must observe the following 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 re-
moved and reapplied.
HINT:
After installation, check and inspect items as follows.
Front wheel alignment (See page SA−4).
Do the road test.

MX05S−01
Q09031
B
A
C
FED A
A
C
Q08759
No.1
No.2 No.0
No.0
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (4WD)
MX−9
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE TRANSAXLE WITH ENGINE
(See page EM−80)
2. REMOVE TRANSAXLE CASE PROTECTOR
Remove the 2 bolts and transaxle case protector.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
3. REMOVE STARTER
(a) Disconnect the connector and wire from the starter.
(b) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
4. DISCONNECT DIFFERENTIAL LOCK INDICATOR
SWITCH, BACK−UP LIGHT SWITCH AND VEHICLE
SPEED SENSOR CONNECTORS
5. REMOVE TRANSFER VACUUM ACTUATOR BRACK-
ET
Remove the 4 bolts and bracket.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
6. REMOVE TRANSFER VACUUM ACTUATOR AS-
SEMBLY
(a) Disconnect the 4 solenoid hoses from the transfer vacu-
um actuator assembly.
NOTICE:
At the time of installation, please refer to the following item.
Check that the hose No.0, No.1 and No.2 are securely
installed to the solenoid.
(b) Remove the 2 bolts and transfer vacuum actuator assem-
bly.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
7. REMOVE RIGHT TRANSFER STIFFENER PLATE
Remove the 5 bolts and right transfer stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
8. REMOVE CENTER TRANSFER STIFFENER PLATE
Remove the 3 bolts and center transfer stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
9. REMOVE STIFFENER PLATE
Remove the 2 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
10. REMOVE TRANSAXLE FROM ENGINE
(a) Remove the 9 transaxle mounting bolts from the engine.
Torque:
Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf)
Bolt B: 35 N·m (360 kgf·cm, 26 ft·lbf)
Bolt C: 29 N·m (300 kgf·cm, 22 ft·lbf)
Bolt D: 46 N·m (470 kgf·cm, 34 ft·lbf)
Bolt E: 25 N·m (250 kgf·cm, 18 ft·lbf)
Bolt F: 9.0 N·m (95 kgf·cm, 78 in.·lbf)

MX05T−03
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (4WD)
MX−11
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal.
(See page MX−9)
NOTICE:
When working with FIPG material, you must observe the following 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 re-
moved and reapplied.
HINT:
After installation, do the road test.

MX05V−02
Q08757
FIPG
Z12375SST
Q09043
255.5 mm MX−16
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
DISASSEMBLY
1. 4WD:
REMOVE TRANSFER ASSEMBLY
(a) Remove the 3 bolts.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(b) Remove the 5 nuts.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(c) Using a plastic hammer, remove the transfer assembly
from the transaxle.
HINT:
At the time of reassembly, please refer to the following item.
Shift into the 4th gear, and install the transfer assembly while
turning the input shaft of the transaxle.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
2. 4WD:
REMOVE DIFFERENTIAL SIDE GEAR INTERMEDI-
ATE SHAFT
(a) Screw in a suitable bolt with a washer into the side gear
intermediate shaft.
(b) Using SST, remove the side gear intermediate shaft.
SST 09910−00015 (09911−00011, 09912−00010)
(c) Remove the snap ring from the differential side gear inter-
mediate shaft.
HINT:
At the time of reassembly, please refer to the following item.
Keeping the intermediate shaft on the differential pinion shaft,
measure the dimension, as shown in the illustration.
Protrusion length: 255.5 mm (10.06 in.)
3. REMOVE RELEASE FORK AND BEARING
4. REMOVE BACK−UP LIGHT SWITCH WITH GASKET
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
5. REMOVE BOLT AND VEHICLE SPEED SENSOR
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
6. REMOVE NO.2 SELECTING BELLCRANK WITH SE-
LECTING BELLCRANK SUPPORT
Remove the 2 bolts and No.2 selecting bellcrank with the se-
lecting bellcrank support.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

Q05816
FIPG
Q00449
Q05849
SST
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−17
1996 RAV4 (RM447U)
7. REMOVE SHIFT AND SELECT LEVER SHAFT LOCK
BOLT WITH GASKET
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
8. REMOVE SHIFT AND SELECT LEVER SHAFT AS-
SEMBLY WITH GASKET
Remove the 4 bolts, shift and select lever shaft assembly and
gasket.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
9. REMOVE TRANSMISSION CASE COVER
Remove the 10 bolts and transmission case cover.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
10. REMOVE BREATHER PLUG WITH GASKET
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
11. REMOVE OUTPUT SHAFT LOCK NUT
(a) Unstake the lock nut.
(b) Engage the gear double meshing.
(c) Remove the lock nut.
Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf)
(d) Disengage the gear double meshing.
12. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
(a) Remove the No.3 shift fork set bolt.
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
(b) Remove the No.3 hub sleeve and No.3 shift fork.
13. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950−30010

Z01304
Z01306
Q00299
Z01308
SST MX−18
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
14. MEASURE 5TH GEAR THRUST CLEARANCE AND
RADIAL CLEARANCE
(a) Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.10−0.57 mm (0.0039−0.0224 in.)
Maximum clearance:
0.65 mm (0.0256 in.)
(b) Using a dial indicator, measure the radial clearance.
Standard clearance:
0.009−0.050 mm (0.0004−0.0020 in.)
Maximum clearance:
0.070 mm (0.0028 in.)
15. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
At the time of the reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
a1.75 (0.0689)f2.00 (0.0787)
b1.80 (0.0709)g2.05 (0.0807)
c1.85 (0.0729)h2.10 (0.0827)
d1.90 (0.0748)j2.15 (0.0847)
e1.95 (0.0768)−−
(b) Using SST, remove the No.3 clutch hub with the synchro-
nizer ring and 5th gear.
SST 09950−30010
16. REMOVE NEEDLE ROLLER BEARING AND SPACER
17. REMOVE REAR BEARING RETAINER
Using a torx socket wrench (T45), remove the 7 torx screws and
rear bearing retainer.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)