coil spring TOYOTA RAV4 1996 Service Repair Manual

SA0TK−03
Z19329
Suspension
Support
No.2
CapSpring Upper Seat
Spring
Bumper
Lower
Insulator
Shock Absorber Coil Spring Upper
Insulator
ABS Speed
Sensor Suspension
Support
Dust Seal Shock Absorber
with Coil Spring
Front Drive Shaft
Flexible Hose
Tie Rod End
Cotter Pin
Disc
Cotter Pin
Lock Cap
Lower Ball JointCotter Pin
Brake Caliper
Lower Suspension Arm80 (820, 59)
47 (475, 34)
5 (55, 48 in.·lbf)
158 (1,610, 117)
107 (1,090, 79)
127 (1,300, 94)
49 (500, 36)
216 (2,200, 159)
127 (1,300, 94)
19 (192, 14)
8 (80, 69 in.·lbf)
Dust Deflector
 

 
N·m (kgf·cm, ft·lbf): Specified torque
Non−reusable part
SA−32
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 RAV4 (RM447U)
FRONT SHOCK ABSORBER
COMPONENTS

SA0TL−03
R10850
R10823
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA−33
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. DISCONNECT FLEXIBLE HOSE AND ABS SPEED
SENSOR WIRE HARNESS (w/ ABS) FROM SHOCK
ABSORBER
Remove the 2 bolts and disconnect the flexible hose and ABS
speed sensor wire harness.
Torque:
Flexible hose: 19 N·m (192 kgf·cm, 14 ft·lbf)
ABS wire harness: 5 N·m (55 kgf·cm, 48 in.·lbf)
3. DISCONNECT SHOCK ABSORBER FROM STEERING
KNUCKLE
Torque: 158 N·m (1,610 kgf·cm, 117 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Coat the nut’s threads with engine oil.
4. REMOVE SHOCK ABSORBER WITH COIL SPRING
Remove the 3 nuts, suspension support No.2 and shock ab-
sorber with the coil spring.
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)

SA0TM−01
R10824
SST Vinyl
Tape
R10825
SST SA−34
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 RAV4 (RM447U)
DISASSEMBLY
REMOVE COIL SPRING
(a) Install 2 nuts and a bolt to the bracket at the lower portion
of the shock absorber and secure it in a vise.
(b) Using SST, compress the coil spring.
SST 09727−30021
HINT:
To prevent the coil spring from damaging, wind vinyl tape on the
coil spring.
NOTICE:
When holding the shock absorber with the coil spring
removed, do not hold it by the spring lower seat. Also,
do not knock the spring lower seat.
Do not use an impact wrench. It will damage the SST.
(c) Remove the cap.
(d) Using SST to hold the spring upper seat, remove the nut.
SST 09729−22031
(e) Remove these parts from the shock absorber:
Suspension support
Dust seal
Spring upper seat
Upper insulator and coil spring
Spring bumper and lower insulator

SA0TP−01
R10846
SST
Vinyl Tape
R10826
R10825
SST
R10848
MP Grease
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA−37
1996 RAV4 (RM447U)
REASSEMBLY
1. INSTALL LOWER INSULATOR ONTO SHOCK AB-
SORBER
2. INSTALL SPRING BUMPER TO PISTON ROD
3. INSTALL COIL SPRING AND SUSPENSION SUPPORT
(a) Using SST, compress the coil spring.
SST 09727−30021
HINT:
To prevent the coil spring from damaging, wind vinyl tape on the
coil spring.
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Install the coil spring to the shock absorber.
HINT:
Fit the lower end of the coil spring into the gap of lower spring
seat of the shock absorber.
(c) Align the tab of spring upper seat with the tabs of the up-
per insulator.
(d) Install the spring upper seat with upper insulator to the
shock absorber with the ’OUT’ mark facing the outside of
the vehicle.
(e) Install the dust seal and suspension support.
(f) Using SST to hold the spring upper seat, install a new nut.
SST 09729−22031
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)
(g) Remove the SST.
(h) Pack MP grease into the suspension support.
(i) Install the cap.

SA0TU−02
Z19329
Suspension
Support
No.2
CapSpring Upper Seat
Spring
Bumper
Lower
Insulator
Shock Absorber Coil Spring Upper
Insulator
ABS Speed
Sensor Suspension
Support
Dust Seal Shock Absorber
with Coil Spring
Front Drive Shaft
Flexible Hose
Tie Rod End
Cotter Pin
Disc
Cotter Pin
Lock Cap
Lower Ball JointCotter Pin
Brake Caliper
Lower Suspension Arm80 (820, 59)
47 (475, 34)
5 (55, 48 in.·lbf)
158 (1,610, 117)
107 (1,090, 79)
127 (1,300, 94)
49 (500, 36)
216 (2,200, 159)
127 (1,300, 94)
19 (192, 14)
8 (80, 69 in.·lbf)
Dust Deflector
 

 
N·m (kgf·cm, ft·lbf): Specified torque
Non−reusable part
− SUSPENSION AND AXLEFRONT LOWER BALL JOINT
SA−43
1996 RAV4 (RM447U)
FRONT LOWER BALL JOINT
COMPONENTS

SA0UO−04
W04028
Retainer Suspension Cap
Retainer Retainer Cushion
Rear
Shock
Absorber
Bushing
Brake Drum
25 (250, 18)
Cushion Retainer
Retainer
7.8 (80, 69 in.·lbf)
13 (130, 9)
18 (185, 13)
19 (195, 14)
19 (195, 14)
4WD
Lock cap
Cotter Pin
216 (2,200, 59)
80 (820, 59)

 Parking Brake Cable
113 (1,150, 83)
113 (1,150, 83)Upper Suspension Arm
113 (1,150, 83)Camber
Adjust
Cam
Lower Suspension Arm103 (1,050, 76)
Clip 
103 (1,050, 76)
132 (1,350, 98)
To e−adjust Cam
Attachment
Bushing
Rear No.1 Suspension Arm
Attachment Spring Bumper
Upper Insulator
Coil Spring
Shock Absorber
Lower Pivot pin
13 (130, 9)
140 (1,430, 103)
N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part

56 (570, 41)
37 (380, 27)
Rear Drive Shaft4WD: Rear Differential
13 (130, 9)
2WD
Rear Axle Shaft SA−90
− SUSPENSION AND AXLEREAR SHOCK ABSORBER
1996 RAV4 (RM447U)
REAR SHOCK ABSORBER
COMPONENTS

SA0UT−03
W04028
Retainer Suspension Cap
Retainer Retainer Cushion
Rear
Shock
Absorber
Bushing
Brake Drum
25 (250, 18)
Cushion Retainer
Retainer
7.8 (80, 69 in.·lbf)
13 (130, 9)
18 (185, 13)
19 (195, 14)
19 (195, 14)
4WD
Lock cap
Cotter Pin
216 (2,200, 59)
80 (820, 59)

 Parking Brake Cable
113 (1,150, 83)
113 (1,150, 83)Upper Suspension Arm
113 (1,150, 83)Camber
Adjust
Cam
Lower Suspension Arm103 (1,050, 76)
Clip 
103 (1,050, 76)
132 (1,350, 98)
To e−adjust Cam
Attachment
Bushing
Rear No.1 Suspension Arm
Attachment Spring Bumper
Upper Insulator
Coil Spring
Shock Absorber
Lower Pivot pin
13 (130, 9)
140 (1,430, 103)
N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part

56 (570, 41)
37 (380, 27)
Rear Drive Shaft4WD: Rear Differential
13 (130, 9)
2WD
Rear Axle Shaft
− SUSPENSION AND AXLEREAR SUSPENSION ARM AND COIL SPRING
SA−95
1996 RAV4 (RM447U)
REAR SUSPENSION ARM AND COIL SPRING
COMPONENTS

SA0UU−03
R10779
R10764
SST
R10765
SST SA−96
− SUSPENSION AND AXLEREAR SUSPENSION ARM AND COIL SPRING
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE REAR WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. 2WD:
REMOVE AXLE SHAFT (See page SA−52)
3. 4WD:
REMOVE REAR DRIVE SHAFT (See page SA−62)
4. REMOVE BRAKE DRUM
5. REMOVE 2 BRAKE LINE CLAMP BOLTS
Torque:
Bracket: 18 N·m (185 kgf·cm, 13 ft·lbf)
Clamp: 13 N·m (130 kgf·cm, 9 ft·lbf)
6. REMOVE PARKING BRAKE CABLE CLAMP BOLT
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
7. w/ ABS:
REMOVE ABS SPEED SENSOR AND WIRE HARNESS
Torque:
ABS speed sensor: 8 N·m (80 kgf·cm, 69 in.·lbf)
Wire harness: 13 N·m (130 kgf·cm, 9 ft·lbf)
8. REMOVE REAR AXLE HUB WITH BRAKE
(a) Remove the 4 bolts and rear axle hub with brake.
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)
(b) Support it securely.
9. DISCONNECT LOWER SIDE OF SHOCK ABSORBER
(See page SA−91)
10. REMOVE UPPER AND LOWER SUSPENSION ARMS
(a) Remove the 2 clips and 2 nuts.
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
(b) Using SST, disconnect the upper suspension arm.
SST 09628−62011
(c) Using SST, disconnect the lower suspension arm.
SST 09628−62011

W01762Matchmarks
W01764
Matchmarks
− SUSPENSION AND AXLEREAR SUSPENSION ARM AND COIL SPRING
SA−97
1996 RAV4 (RM447U)
(d) Place matchmarks on the camber adjust cam and sus-
pension member.
(e) Remove the bolt, camber adjust cam, nut and lower sus-
pension arm.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
After stabilizing the suspension, torque the bolt.
(f) Remove the bolt, nut and upper suspension arm.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
HINT:
At the time of installaion, please refer to the following item.
After stabilizing the suspension, torque the bolt.
11. REMOVE COIL SPRING AND REAR NO.1 SUSPEN-
SION ARM
(a) Place matchmarks on the toe−adjust cam and body.
(b) Loosen the bolt and remove the coil spring and upper in-
sulator.
HINT:
At the time of installation, please refer to the following item.
Fit the lower end of the coil spring into the gap of the No.1 sus-
pension arm.
(c) Remove the bolt, toe−adjust cam, 2 attachments, nut and
lower suspension arm.
Torque: 132 N·m (1,350 kgf·cm, 98 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
After stabilizing the suspension, torque the bolt.
12. REMOVE SPRING BUMPER
Remove the bolt and spring bumper.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

SA0UV−01
R10753
SA−98
− SUSPENSION AND AXLEREAR SUSPENSION ARM AND COIL SPRING
1996 RAV4 (RM447U)
INSPECTION
INSPECT BALL JOINT FOR ROTATION CONDITION
(a) As shown in the illustration, flip the ball joint stud back and
forth 5 times, before installing the nut.
(b) Using a torque wrench, turn the nut continuously one turn
each 2 − 4 seconds and take the torque reading on the 5th
turn.
Turning Torque:
Upper suspension arm:
0.5 − 3.5 N·m (5 − 35 kgf·cm, 7 − 30 in.·lbf)
Lower suspension arm:
0.5 − 3.5 N·m (5 − 35 kgf·cm, 7 − 30 in.·lbf)