TOYOTA RAV4 2006 Service Repair Manual

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)DS–15
DS
2. REMOVE FRONT AXLE INBOARD JOINT BOOT
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.
3. REMOVE FRONT AXLE INBOARD JOINT BOOT
(a) Remove the boot from the inboard joint.
4. 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.
(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.
C127645E01
C127646E02
C127648
C127649E01

DS–16DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)
DS
5. REMOVE FRONT DRIVE INBOARD JOINT
ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
6. REMOVE FRONT DRIVE SHAFT DAMPER CLAMP LH
(a) One touch type:
Using a screwdriver, remove the drive shaft damper
clamp, as shown in the illustration.
(b) Claw engagement type:
Using needle-nose pliers, remove the drive shaft
damper clamp, as shown in the illustration.
7. REMOVE FRONT DRIVE SHAFT DAMPER LH
(a) Remove the front drive shaft damper from the
outboard joint shaft.
8. REMOVE FRONT AXLE OUTBOARD JOINT BOOT
NO. 2 CLAMP
(a) Using a screwdriver, remove the outboard joint boot
clamp, as shown in the illustration.
9. REMOVE FRONT AXLE OUTBOARD JOINT BOOT
CLAMP
(a) Using a screwdriver, remove the outboard joint boot
clamp, as shown in the illustration.
10. 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.
C127651E01
C127653
C127660

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)DS–17
DS
11. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING
LH
(a) Using a screwdriver, remove the hole snap ring.
12. 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.
13. REMOVE FRONT DRIVE SHAFT DUST COVER RH
HINT:
Use the same procedures described for the LH side.
14. REMOVE DRIVE SHAFT BEARING CASE (for RH)
(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.
15. REMOVE FRONT DRIVE SHAFT DUST COVER (for
RH)
(a) Using SST and a press, press out the drive shaft
dust cover.
SST 09950-00020
NOTICE:
Be careful not to drop the inboard joint.
C127655
C127659E01
C127662
C127663
C127664E01

DS–18DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)
DS
16. 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 bearing case snap ring.
REASSEMBLY
(2005/11-2006/01)
1. INSTALL DRIVE SHAFT BEARING CASE SUB-
ASSEMBLY
(a) Using SST and a press, press in the drive shaft
bearing case to the inboard joint RH.
SST 09527-10011, 09710-04081
NOTICE:
The bearing should be installed completely.
(b) Using a snap ring expander, install a new drive shaft
hole snap ring.
2. INSTALL FRONT DRIVE SHAFT DUST COVER
(a) Using SST and a press, press in a new drive shaft
dust cover.
SST 09726-40010, 09527-10011
NOTICE:
Be careful not to damage the dust cover.
C127665
C127666E01
C127674E01
C127675
C127676E01

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)DS–19
DS
3. INSTALL FRONT DRIVE SHAFT DUST COVER RH
(a) Using SST and a press, press in a new drive shaft
dust cover until the distance from the tip of the
center drive shaft to the drive shaft dust cover
reaches the specification, as shown in the
illustration.
SST 09527-10011
Standard distance:
91.0 to 92.0 mm (3.583 to 3.622 in.)
NOTICE:
• The dust cover should be installed
completely.
• Be careful not to damage the dust cover.
4. INSTALL FRONT DRIVE SHAFT DUST COVER LH
(a) Using SST and a press, press in a new drive shaft
dust cover.
SST 09527-10011
NOTICE:
• The dust cover should be installed
completely.
• Be careful not to damage the dust cover.
5. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP
RING
(a) Install a new hole snap ring.
6. INSTALL FRONT AXLE OUTBOARD JOINT BOOT
HINT:
Before installing the boots, wrap the spline of the drive
shaft with vinyl tape to prevent the boots from being
damaged.
(a) Install new parts to the outboard joint shaft in the
following order.
(1) No. 2 outboard joint boot clamp
(2) Outboard joint boot
(3) Outboard joint boot clamp
(b) Pack the outboard joint shaft and boot with grease
from the boot kit.
Standard grease capacity:
190 to 200 g (6.7 to 7.1 oz.)
7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT
NO. 2 CLAMP LH
CAUTION:
Wear protective gloves while performing the
operation and be careful to avoid cutting your hands
or other body parts.
(a) Install a new boot clamp to the outboard joint boot
and temporarily bend the lever.
NOTICE:
• When temporarily bending the lever, make
sure not to deform the band and lever.
• Set the clamp correctly in the guide groove
and align it with the interior of the vehicle as
much as possible.
C127678E01
C127677E01
C127681E01
C127683

DS–20DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)
DS
(b) With the joint on the working surface, use your body
weight to press down on the joint with one hand.
Then, roll the joint forward, as shown in the
illustration, and press the lever in until a "click"
sound is heard.
NOTICE:
• Do not damage the deflector.
• Make sure the joint is in full contact with the
joint surface at all times.
(c) Using a plastic-faced hammer, fix the buckle into
place by tapping it. At the same time, use the
plastic-faced hammer to adjust the lift of the lever so
that the gaps between the buckle flange and lever
end flange become even.
NOTICE:
Do not damage the boot.
8. INSTALL FRONT AXLE OUTBOARD JOINT BOOT
NO. 2 CLAMP RH
HINT:
Use the same procedures described for the LH side.
9. INSTALL FRONT AXLE OUTBOARD JOINT BOOT
CLAMP LH
CAUTION:
Wear protective gloves while performing the
operation and be careful to avoid cutting your hands
or other body parts.
C127684
C127685
C129510

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)DS–21
DS
(a) Install a new boot clamp to the outboard joint boot
and temporarily bend the lever.
NOTICE:
When temporarily bending the lever, make sure
not to deform the band and lever.
(b) Using water pump pliers, temporarily lock the boot
clamp by clamping it down until a "click" sound is
heard.
(c) Using a plastic-faced hammer, fix the buckle into
place by tapping it. At the same time, use the
plastic-faced hammer to adjust the lift of the lever so
that the gaps between the buckle flange and lever
end flange become even.
NOTICE:
Do not strike the drive shaft forcefully with the
plastic-faced hammer.
10. INSTALL FRONT AXLE OUTBOARD JOINT BOOT RH
CLAMP
HINT:
Use the same procedures described for the LH side.
C129511
C129512

DS–22DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)
DS
11. INSTALL FRONT DRIVE SHAFT DAMPER LH
HINT:
Install the damper clamp to outboard joint side.
(a) Install a new drive shaft damper clamp and the drive
shaft damper to the drive shaft.
(b) Make sure that the damper is on the shaft groove.
(c) Set the distance, as described below.
Standard distance:
161 to 165 mm (6.339 to 6.496 in.)
12. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP LH
(a) Hold the front drive shaft lightly in a soft vise.
(b) Install the drive shaft damper clamp to the damper.
NOTICE:
Be sure to install the clamp in the correct
position.
(c) One touch type:
(1) Using a screwdriver, install the drive shaft
damper clamp, as shown in the illustration.
(d) Claw engagement type:
(1) Using needle-nose pliers, install the drive shaft
damper clamp, as shown in the illustration.
13. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY
LH
(a) Wrap the spline of the outboard joint shaft with vinyl
tape to prevent the boots from being damaged.
(b) Install new parts to the outboard joint shaft in the
following order.
(1) Inboard joint boot clamp
(2) No. 2 inboard joint boot clamp
(3) Inboard joint boot
(c) Place the beveled side of the tripod axial spline
toward the outboard joint.
(d) Align the matchmarks placed before removal.
(e) Using a brass bar and hammer, tap the tripod joint
onto the drive shaft.
NOTICE:
• Do not tap the rollers.
• Be sure to install the tripod joint in the correct
direction.
C127690E01
C127651E01
C127694E02

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)DS–23
DS
(f) Pack the inboard joint shaft and boot with grease
from the boot kit.
Standard grease capacity:
175 to 185 g (6.2 to 6.5 oz.)
(g) Using a snap ring expander, install a new shaft snap
ring.
(h) Align the matchmarks, and install the inboard joint to
the outboard joint shaft.
14. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY
RH
HINT:
Use the same procedures described for the LH side.
15. INSTALL FRONT AXLE INBOARD JOINT BOOT
(a) Install the inboard joint boot to the inboard joint.
16. INSTALL FRONT AXLE INBOARD JOINT BOOT
CLAMP LH
(a) One touch type:
(1) Using a screwdriver, install the inboard joint
boot clamp, as shown in the illustration.
NOTICE:
Be careful not to damage the boot.
(b) Claw engagement type:
(1) Using needle-nose pliers, install the inboard
joint boot clamp, as shown in the illustration.
NOTICE:
Be careful not to damage the boot.
17. INSTALL FRONT AXLE INBOARD JOINT BOOT
CLAMP RH
HINT:
Use the same procedures described for the LH side.
C127695
C127696E01

DS–24DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)
DS
18. INSTALL FRONT AXLE INBOARD JOINT BOOT NO. 2
CLAMP LH
(a) One touch type:
(1) Using a screwdriver, install the No. 2 inboard
joint boot clamp, as shown in the illustration.
NOTICE:
Be careful not to damage the boot.
(b) Claw engagement type:
(1) Using needle-nose pliers, install the No. 2
inboard joint boot clamp, as shown in the
illustration.
NOTICE:
Be careful not to damage the boot.
19. INSTALL FRONT AXLE INBOARD JOINT BOOT NO. 2
CLAMP RH
HINT:
Use the same procedures described for the LH side.
20. INSPECT FRONT DRIVE SHAFT
(a) Check that there is no severe play in the radial
direction of the outboard joint.
(b) Check that the inboard joint slides smoothly in the
thrust direction.
(c) Check that there is no severe play in the radial
direction of the inboard joint.
(d) Check the boots for damage.
NOTICE:
Keep the drive shaft assembly level during
inspection.
HINT:
For dimension (A), refer to the following values.
Reference value:
585.2 mm (23.039 in.) for LH side
902 mm (35.512 in.) for RH side
REASSEMBLY
(2006/01- )
1. INSTALL DRIVE SHAFT BEARING CASE SUB-
ASSEMBLY (for RH)
(a) Install the bearing snap ring.
(b) Using SST and a press, press in the drive shaft
bearing case to the inboard joint RH.
SST 09527-10011, 09710-04081
NOTICE:
The bearing should be installed completely.
C127697E01
C127698
C127699E01
C127674E01