remove transaxle TOYOTA RAV4 1996 Service Manual PDF

Q00115
− MANUAL TRANSAXLEINPUT SHAFT
MX−31
1996 RAV4 (RM447U)
7. REMOVE NO.2 CLUTCH HUB ASSEMBLY, SYNCHRO-
NIZER RING AND 3RD GEAR
Using a press, remove the No.2 hub sleeve, 3rd gear and syn-
chronizer rings.
8. REMOVE NEEDLE ROLLER BEARING

MX02D−03
Q06370
1st Gear
2nd Gear
Z00218
Z00219
Z00220
− MANUAL TRANSAXLEOUTPUT SHAFT
MX−37
1996 RAV4 (RM447U)
DISASSEMBLY
1. MEASURE 1ST AND 2ND GEARS THRUST CLEAR-
ANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1st gear: 0.10 − 0.35 mm (0.0039 − 0.0138 in.)
2nd gear: 0.10 − 0.45 mm (0.0039 − 0.0177 in.)
Maximum clearance:
1st gear: 0.40 mm (0.0157 in.)
2nd gear: 0.50 mm (0.0197 in.)
2. CHECK 1ST AND 2ND GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between
the gear and shaft.
Standard clearance:
1st gear: 0.009 − 0.051 mm (0.0004 − 0.0020 in.)
2nd gear: 0.009 − 0.053 mm (0.0004 − 0.0021 in.)
Maximum clearance:
1st and 2nd gears: 0.070 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.
3. REMOVE OUTPUT SHAFT REAR BEARING, 4TH
DRIVEN GEAR AND SPACER
(a) Using a press, remove the bearing and 4th driven gear.
(b) Remove the spacer.
4. REMOVE 3RD DRIVEN GEAR AND 2ND GEAR
Using a press, remove the 3rd driven gear and 2nd gear.
5. REMOVE NEEDLE ROLLER BEARING, SPACER AND
SYNCHRONIZER RING
6. REMOVE INNER RACE AND BALL FROM OUTPUT
SHAFT

Z00222
Q06202
SST
Q00296
SST MX−38
− MANUAL TRANSAXLEOUTPUT SHAFT
1996 RAV4 (RM447U)
7. REMOVE NO.1 HUB SLEEVE ASSEMBLY AND 1ST
GEAR
Using a press, remove the No.1 hub sleeve and 1st gear.
8. REMOVE SYNCHRONIZER RING AND NEEDLE
ROLLER BEARING
9. REMOVE 1ST GEAR BEARING INNER RACE
Using SST and a press, remove the 1st gear bearing inner race.
SST 09950−00020
10. REMOVE OUTPUT SHAFT FRONT BEARING
Using SST, remove the output shaft front bearing.
SST 09950−00020, 09950−00030

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.

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.

− 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

MX02K−03
Z12377
Matchmarks
Z12483
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−59
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE NO.2 DIFFERENTIAL CASE
(a) Remove the 16 bolts.
(b) Remove the No.2 differential case upward.
2. REMOVE DIFFERENTIAL RING GEAR
(a) Place matchmarks on both the differential case and ring
gear.
(b) Using a plastic hammer, tap out the ring gear.
3. REMOVE NO.2 DIFFERENTIAL SIDE GEAR THRUST
WASHER AND CONICAL SPRING WASHER
4. REMOVE FRONT DIFFERENTIAL CASE ASSEMBLY
5. DISASSEMBLE FRONT DIFFERENTIAL CASE
(a) Remove the front differential side gear together with the
thrust washer from the front differential case.
(b) Remove the front differential side gear thrust washer from
the side gear.
(c) Using a snap ring expander, remove the snap ring and
spacer.
HINT:
Before removing the shaft snap ring, wrap vinyl tape around the
case to prevent from damage.

Q06218
Q06219
Q07870
SST MX−60
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
(d) Remove these parts from the front differential case:
2 front differential pinion shafts
No.2 front differential pinion shaft
Front differential pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
Front differential side gear
Front differential side gear thrust washer
6. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the spacer and vehicle speed sensor drive gear.
7. DISASSEMBLE NO.1 DIFFERENTIAL CASE
Remove these parts from the No.1 differential case:
4 differential pinion shafts
Pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
Differential side gear subassembly
Conical spring washer
No.2 differential side gear thrust washer
8. No.2 Differential Case Side:
REMOVE TAPERED ROLLER BEARING
Using SST, remove the tapered roller bearing.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00520)