remove transaxle TOYOTA RAV4 1996 Service Manual Online

Q07895
SST
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−61
1996 RAV4 (RM447U)
9. No.1 Differential Case Side:
REMOVE TAPERED ROLLER BEARING
Using SST, remove the tapered roller bearing.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00450)

Z12494
MX0DY−01
Z12381
SST
Z12496
Q06288
SST
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−63
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 transmission oil baffle.
(c) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly.
(d) Remove the adjust shim.
(e) Install the adjust shim.
(See page MX−65)
HINT:
First select and install a shim of less thickness than before.
(f) Using SST and a press, install the tapered roller bearing
outer race.
SST 09316−60011 (09316−00011, 09316−00041)
(g) Install the transmission oil baffle.
HINT:
Install the transmission oil baffle projection into the case side
cutout.
(h) Using SST, drive in a new oil seal.
SST 09223−15020, 09950−70010 (09951−07150)
(i) Coat the lip of the oil seal with MP grease.

Q06225
Thrust Washer
Thickness
1.0 mm (0.039 in.)
Q06213
Plastigage
Plastigage
Q06214Matchmarks
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−69
1996 RAV4 (RM447U)
10. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE
GEAR THRUST CLEARANCE (FRONT DIFFERENTIAL
CASE SIDE)
(a) Install these parts:
Front differential case assembly
Front differential side gear
Front differential side gear thrust washer
Temporarily install a 1.0 mm (0.039 in.) thick
No.2 differential side gear thrust washer
No.2 differential side gear thrust washer
HINT:
Engage the front differential side gear and pinion gear of
the No.1 differential case.
The temporarily installed a 1.0 mm (0.039 in.) thick No.2
side gear thrust washer is used for reference when check-
ing backlash.
(b) Clean the contact surface of the No.2 side gear thrust
washer and No.2 differential case.
(c) Apply plastigage on the No.2 side gear thrust washer, as
shown.
HINT:
Apply the plastigage on the No.2 side gear thrust washer in the
4 positions directly above the pinion shafts in the No.1 differen-
tial case’s position.
(d) Install the No.2 differential case downward.
HINT:
Align the matchmarks on the No.1 differential case and contact
the No.2 differential case.
(e) Install and torque the 16 bolts.
Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf)
(f) Remove the 16 bolts and No.2 differential case upward.

Q06273
Q06274
Q06214Matchmarks MX−70
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
(g) Measure the Plastigage at its widest point.
Standard clearance: 0.16−0.25 mm (0.006−0.010 in.)
(h) Refer to the table below, select the No.2 thrust washer
which will ensure that the backlash is within the specifica-
tion. Try to select a washer of the same size.
MarkThickness mm (in.)MarkThickness mm (in.)
−0.80 (0.0315)−1.15 (0.0453)
−0.85 (0.0335)−1.20 (0.0472)
−0.90 (0.0354)−1.25 (0.0492)
−0.95 (0.0374)−1.30 (0.0512)
−1.00 (0.0394)−1.35 (0.0531)
−1.05 (0.0413)−1.40 (0.0551)
−1.10 (0.0433)−−
(i) Remove the No.2 differential case, No.2 side gear thrust
washer and (temporarily install) a 1.0 mm (0.039 in.) thick
No.2 side gear thrust washer.
11. ASSEMBLE NO.2 DIFFERENTIAL CASE
(a) Install the No.2 side gear thrust washer (previously se-
lected) and conical spring washer to the front differential
case.
HINT:
Be careful not to mistake the direction of the conical spring
washer.
(b) Install the No.2 differential case to the No.1 differential
case.
HINT:
Align the matchmarks on the No.2 differential case and connect
the No.1 differential case.
(c) Install and torque the 16 bolts.
Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf)
12. ADJUST DIFFERENTIAL CASE SIDE BEARING PRE-
LOAD
(a) Install the differential case assembly to the transaxle
case.
(b) Install the transmission case.
HINT:
If necessary, tap on the transmission case with a plastic ham-
mer.
(c) Install and torque the 17 bolts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)

Q06275
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−71
1996 RAV4 (RM447U)
(d) Turn the differential case assembly right and left 2 or 3
times to allow the bearings to settle.
(e) Using a spring tension gauge, measure the preload.
Preload (at starting):
New bearing (Output shaft preload plus)
31−61 N (3.2−6.3 kgf, 7−14 lbf)
Reused bearing (Output shaft preload plus)
20−39 N (2.0−4.0 kgf, 4−9 lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.
HINT:
The total preload will change about 5.1 N (0.5 kgf, 1.1 lbf) for
every 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)
(f) Remove the 17 bolts, tap the transmission case with a
plastic hammer and remove it.
(g) Remove the differential case assembly.

Z13341
Q06243
Q06242
BE2682
MX−74
− MANUAL TRANSAXLEDIFFERENTIAL LOCKING SYSTEM (4WD)
1996 RAV4 (RM447U)
2. INSPECT DIFFERENTIAL LOCK CONTROL COM-
PONENTS
(a) Inspect the differential lock control switch continuity.
Switch PositionTester ConnectionSpecified Condition
OFF (Free)7−10Continuity
ON (Lock)7−8Continuity
Illumination circuit2−3Continuity
If continuity is not as specified, check the bulb or replace the
switch.
(b) Inspect the differential lock warning buzzer.
(1) Remove the combination meter, then remove the
differential lock warning buzzer.
(2) Taking care to match the polarity of the buzzer, ap-
ply battery positive voltage to the terminals of the
buzzer and check that the buzzer sounds.
(c) Inspect the differential lock indicator switch continuity.
Switch PositionTester ConnectionSpecified Condition
Free1 − 2No continuity
Push1 − 2Continuity
If continuity is not as specified, replace the switch.

MX−76
− MANUAL TRANSAXLEDIFFERENTIAL LOCKING SYSTEM (4WD)
1996 RAV4 (RM447U)
(c) Diaphragm (Free Side):
Inspect the transfer vacuum tank.
(1) Disconnect the solenoid hose No.0, No.1, No.2 and
No.3 from the solenoid.
(2) Fill in the No.3 hose with a plug.
(3) Check that the indicator needle remains steady
when a vacuum of 500 mmHg (19.685 in.Hg) are
applied to the hose No.0 and No.2.
Standard:
Indicator falls 45 mmHg (1.772 in.Hg) or less during 15
seconds.
NOTICE:
Apply vacuum simultaneously to the hose No.0 and hose
No.2.
(4) Reinstall the removed hoses to the solenoid.
NOTICE:
Check that the hose No.0, No.1, No.2 and No.3 are securely
installed to the solenoid.

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)

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)

Q06143
SST
Q06144
Q06161
Q06148
Q06134
SST MX−84
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
(b) Remove the mounting case left side bearing.
Using SST, remove the left side bearing.
SST 09950−40010, 09950−60010 (09951−00500)
(c) Check the ring gear runout.
Using a dial indicator, check the ring gear runout.
Maximum runout: 0.1 mm (0.004 in.)
(d) Remove the transfer ring gear.
(1) Place matchmarks on both the ring gear mounting
case and transfer ring gear.
(2) Remove the 12 bolts.
(3) Using a pin punch and hammer, tap out the transfer
ring gear.
14. REMOVE DIFFERENTIAL SIDE GEAR SHAFT HOLD-
ER
(a) Using snap ring pliers, remove the snap ring from the
transfer right case.
(b) Using SST and a press, remove the differential side gear
shaft holder.
SST 09527−17011