TOYOTA RAV4 2006 Service Repair Manual

GF1A TRANSFER – ACTIVE TORQUE CONTROL 4WD SYSTEMTF–33
TF
DESCRIPTION
The 4WD control ECU receives signals from each sensor to control clutch fluid pressure for limiting the
center differential operation, which distributes torque according to the driving conditions.
WIRING DIAGRAM
INSPECTION PROCEDURE
(a) Remove the coupling connector.
(b) Measure the resistance of the solenoid.
Standard resistance
NG
OK
DTC C1298/98 Linear Solenoid Circuit
DTC No. DTC Detection Condition Trouble Area
C1298/98 1. When the following continues for 1
second or more:
- With the current of the 0.8 A or more, an
open or short in the linear solenoid circuit
occurs.• Wire harness
• Electromagnetic coupling
• 4WD control ECU
1INSPECT ELECTROMAGNETIC COUPLING (4WD LINEAR SOLENOID)
C128602E01
C131916E01
Tester Connection Specified Condition
1 (BSF) - 2 (SLC) 2.2 to 2.6
1 (BSF) - Body ground 10 k or higher
2 (SLC) - Body ground 10 k
or higher
REPLACE ELECTROMAGNETIC COUPLING

TF–34GF1A TRANSFER – ACTIVE TORQUE CONTROL 4WD SYSTEM
TF
(a) Disconnect the E57 ECU connector.
(b) Measure the resistance of the wire harness side
connector.
Standard resistance
NG
OK
2CHECK WIRE HARNESS (COUPLING - 4WD CONTROL ECU)
C130947E02
Tester Connection Specified Condition
E57-13 (SLC+) - Q1-1 (BSF) Below 1
E57-32 (SLC-) - Q1-2 (SLC) Below 1
E57-13 (SLC+) - Body ground 10 k or higher
E57-32 (SLC-) - Body ground 10 k
or higher
REPAIR OR REPLACE HARNESS AND
CONNECTOR
REPLACE 4WD CONTROL ECU

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)DS–7
DS
REMOVAL
(2005/11-2006/01)
1. REMOVE FRONT WHEEL
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Drain the automatic transaxle fluid for U140F (see
page AX-147).
(b) Drain the automatic transaxle fluid for U241E (see
page AX-146).
3. REMOVE FRONT AXLE HUB NUT (See page AH-6)
4. DISCONNECT FRONT SPEED SENSOR LH
(a) Disconnect the speed sensor (see page BC-191).
5. DISCONNECT FRONT SPEED SENSOR RH
HINT:
Use the same procedures described for the LH side.
6. DISCONNECT FRONT DISC BRAKE CYLINDER
ASSEMBLY LH (See page BR-40)
7. DISCONNECT FRONT DISC BRAKE CALIPER
ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
8. REMOVE FRONT STABILIZER LINK ASSEMBLY LH
(See page SP-30)
9. REMOVE FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
10. DISCONNECT FRONT SUSPENSION LOWER NO. 1
ARM SUB-ASSEMBLY LH (See page AH-7)
11. DISCONNECT FRONT SUSPENSION LOWER NO. 1
ARM SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
12. DISCONNECT STEERING KNUCKLE WITH AXLE
HUB LH
(a) Put matchmarks on the drive shaft and axle hub.
NOTICE:
Do not punch the marks.
(b) Using a plastic-faced hammer, disconnect the
steering knuckle with axle hub.
NOTICE:
Be careful not to damage the boot and speed
sensor rotor.
Do not excessively push out the drive shaft from
the axle assembly.
13. DISCONNECT STEERING KNUCKLE WITH AXLE
HUB RH
HINT:
Use the same procedures described for the LH side.
C129488E01

DS–8DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)
DS
14. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
(See page PS-42)
15. DISCONNECT TIE ROD END SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
16. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
(a) Using SST, remove the front drive shaft.
SST 09520-01010, 09520-24010 (09520-32040)
NOTICE:
• Be careful not to damage the transaxle case
oil seal, inboard joint boot and drive shaft
dust cover.
• Be careful not to drop the drive shaft.
17. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
(a) Remove the 2 bolts and pull out the drive shaft
together with the drive shaft bearing case.
(b) Remove the drive shaft from the transaxle.
NOTICE:
• Be careful not to damage the inboard joint
boot and drive shaft dust cover.
• Be careful not to drop the drive shaft.
18. FIX FRONT AXLE ASSEMBLY
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the
vehicle with the drive shaft removed. Therefore, if it
is absolutely necessary to place the vehicle weight
on the hub bearing, first support it with SST.
SST 09608-16042 (09608-02021, 09608-02041)
C127631E01
C127638
C129482E01

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)DS–9
DS
REMOVAL
(2006/01- )
1. REMOVE FRONT WHEEL
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Drain the automatic transaxle fluid for U140F (see
page AX-147).
(b) Drain the automatic transaxle fluid for U241E (see
page AX-146).
(c) Drain the automatic transaxle fluid for U151E (see
page AX-172).
3. REMOVE FRONT AXLE HUB NUT (See page AH-8)
4. DISCONNECT FRONT SPEED SENSOR LH
(a) Disconnect the speed sensor (see page BC-191).
5. REMOVE FRONT SPEED SENSOR RH
HINT:
Use the same procedures described for the LH side.
6. DISCONNECT FRONT DISC BRAKE CYLINDER
ASSEMBLY LH (See page BR-40)
7. DISCONNECT FRONT DISC BRAKE CYLINDER
ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
8. REMOVE FRONT STABILIZER LINK ASSEMBLY LH
(See page SP-30)
9. REMOVE FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
10. DISCONNECT FRONT SUSPENSION LOWER NO. 1
ARM SUB-ASSEMBLY LH (See page SP-21)
11. DISCONNECT FRONT SUSPENSION LOWER NO. 1
ARM SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
12. DISCONNECT STEERING KNUCKLE WITH AXLE
HUB LH
(a) Put matchmarks on the drive shaft and axle hub.
NOTICE:
Do not punch the marks.
(b) Using a plastic-faced hammer, disconnect the
steering knuckle with axle hub.
NOTICE:
Be careful not to damage the boot and speed
sensor rotor.
Do not excessively push out the drive shaft from
the axle assembly.
C129488E01

DS–10DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)
DS
13. DISCONNECT STEERING KNUCKLE WITH AXLE
HUB RH
HINT:
Use the same procedures described for the LH side.
14. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
(See page PS-42)
15. DISCONNECT TIE ROD END SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
16. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
(a) Using SST, remove the front drive shaft.
SST 09520-01010, 09520-24010 (09520-32040)
NOTICE:
• Be careful not to damage the transaxle case
oil seal, inboard joint boot and drive shaft
dust cover.
• Be careful not to drop the drive shaft.
17. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
(a) Remove the 2 bolts and pull out the drive shaft
together with the drive shaft bearing case.
(b) Remove the drive shaft from the transaxle.
NOTICE:
• Be careful not to damage the transaxle case
oil seal, inboard joint boot and drive shaft
dust cover.
• Be careful not to drop the drive shaft.
18. FIX FRONT AXLE ASSEMBLY
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the
vehicle with the drive shaft removed. Therefore, if it
is absolutely necessary to place the vehicle weight
on the hub bearing, first support it with SST.
SST 09608-16042 (09608-02021, 09608-02041)
C127631E01
C127638
C129482E01

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)DS–11
DS
DISASSEMBLY
(2005/11-2006/01)
1. REMOVE FRONT AXLE INBOARD JOINT BOOT NO.
2 CLAMP LH
(a) One touch type:
(1) Using a screwdriver, remove the inboard joint
boot clamp, as shown in the illustration.
(b) Claw engagement type:
(1) Using needle-nose pliers, remove the inboard
joint boot clamp, as shown in the illustration.
2. REMOVE FRONT AXLE INBOARD JOINT BOOT NO.
2 CLAMP RH
HINT:
Use the same procedures described for the LH side.
3. REMOVE FRONT AXLE INBOARD JOINT BOOT
CLAMP LH
(a) One touch type:
(1) Using a screwdriver, remove the inboard joint
boot clamp, as shown in the illustration.
(b) Claw engagement type:
(1) Using needle-nose pliers, remove the inboard
joint boot clamp, as shown in the illustration.
4. REMOVE FRONT AXLE INBOARD JOINT BOOT
CLAMP RH
HINT:
Use the same procedures described for the LH side.
5. REMOVE FRONT AXLE INBOARD JOINT BOOT
(a) Remove the boot from the inboard joint.
6. REMOVE FRONT DRIVE INBOARD JOINT
ASSEMBLY LH
(a) Remove any old grease from the inboard joint.
(b) Put matchmarks on the inboard joint and outboard
joint shaft.
NOTICE:
Do not punch the marks.
(c) Remove the inboard joint from the outboard joint
shaft.
C127644E01
C127645E01
C127646E02

DS–12DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)
DS
(d) Using a snap ring expander, remove the shaft snap
ring.
(e) Put matchmarks on the outboard joint shaft and
tripod joint.
NOTICE:
Do not punch the marks.
(f) Using a brass bar and hammer, tap out the tripod
joint from the outboard joint shaft.
NOTICE:
Do not tap the rollers.
(g) Remove the inboard joint boot.
7. REMOVE FRONT DRIVE SHAFT DAMPER CLAMP LH
(a) One touch type:
(1) Using a screwdriver, remove the drive shaft
damper clamp, as shown in the illustration.
(b) Claw engagement type:
(1) Using needle-nose pliers, remove the drive
shaft damper clamp, as shown in the
illustration.
8. REMOVE FRONT DRIVE SHAFT DAMPER LH
(a) Remove the front drive shaft damper from the
outboard joint shaft.
9. REMOVE FRONT AXLE OUTBOARD JOINT BOOT
NO. 2 CLAMP LH
(a) Using a screwdriver, remove the outboard joint boot
clamp, as shown in the illustration.
C127648
C127649E01
C127651E01
C127653

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)DS–13
DS
10. REMOVE FRONT AXLE OUTBOARD JOINT BOOT
CLAMP LH
(a) Using a screwdriver, remove the outboard joint boot
clamp, as shown in the illustration.
11. REMOVE FRONT AXLE OUTBOARD JOINT BOOT
(a) Remove the outboard joint boot from the outboard
joint shaft.
(b) Remove any old grease from the outboard joint.
12. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING
LH
(a) Using a screwdriver, remove the hole snap ring.
13. REMOVE FRONT DRIVE SHAFT DUST COVER LH
(a) Using SST and a press, press out the shaft dust
cover.
SST 09950-00020
NOTICE:
Be careful not to drop the inboard joint
14. REMOVE FRONT DRIVE SHAFT DUST COVER RH
HINT:
Use the same procedures described for the LH side.
15. REMOVE DRIVE SHAFT BEARING CASE
(a) Using a screwdriver, remove the bearing case snap
ring.
(b) Using a press, press out the drive shaft bearing
case.
HINT:
Be careful not to drop the inboard joint
C127660
C127655
C127659E01
C127662
C127663

DS–14DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)
DS
16. REMOVE FRONT DRIVE SHAFT DUST COVER
(a) Using SST and a press, press out the drive shaft
dust cover.
SST 09950-00020
HINT:
Be careful not to drop the inboard joint
17. REMOVE FRONT DRIVE SHAFT BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a press, press out the drive shaft
bearing.
SST 09527-10011
(c) Remove the snap ring.
DISASSEMBLY
(2006/01- )
1. REMOVE FRONT AXLE INBOARD JOINT BOOT NO.
2 CLAMP
(a) One touch type:
Using a screwdriver, remove the inboard joint boot
clamp, as shown in the illustration.
(b) Claw engagement type:
Using needle-nose pliers, remove the inboard joint
boot clamp, as shown in the illustration.
C127664E01
C127665
C127666E01
C127644E01