TOYOTA RAV4 2006 Service Repair Manual

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)DS–57
DS
20. 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.
21. INSTALL FRONT AXLE INBOARD JOINT BOOT NO. 2
CLAMP RH
HINT:
Use the same procedures described for the LH side.
22. 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:
572.5 mm (22.539 in.) for LH side
918 mm (36.142 in.) for RH side
REASSEMBLY
(2006/01- )
1. INSTALL FRONT DRIVE SHAFT BEARING (for RH)
(a) Install the bearing bracket snap ring to the inboard
shaft.
(b) Using SST and a press, press in the drive shaft
bearing to the inboard joint RH.
SST 09527-10011, 09710-04081
NOTICE:
The bearing should be installed completely.
C127697E01
C127698
C127699E01
C127672E01

DS–58DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)
DS
(c) Using a snap ring expander, install a new drive shaft
hole snap ring.
2. REMOVE 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:
104 +-0.5 mm (4.09 +-0.02 in.)
NOTICE:
Be careful not to damage the dust cover.
3. 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 so that the
drive shaft contacts the dust cover at the
location indicated by the arrows in the
illustration.
• Be careful not to damage the dust cover.
4. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING
LH
(a) Install a new hole snap ring.
5. INSPECT FRONT DRIVE SHAFT
C127673
C110168E01
C127677E02

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)DS–59
DS
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) Outboard joint boot No. 2 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
7. INSTALL FRONT AXLE OUTBOARD JOINT BOOT
NO. 2 CLAMP
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.
(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.
C127681E01
Item Grease capacity
2AZ-FE 190 to 200 g (6.7 to 7.1 oz.)
2GR-FE 205 to 215 g (7.2 to 7.6 oz.)
C127683E01
C127684

DS–60DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)
DS
(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.
8. INSTALL FRONT AXLE OUTBOARD JOINT BOOT
CLAMP
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.
C127685
C129510

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)DS–61
DS
(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.
C129511
C129512

DS–62DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)
DS
9. INSTALL FRONT DRIVE SHAFT DAMPER LH
(a) Install a new drive shaft damper clamp and the drive
shaft damper to the drive shaft.
HINT:
Install the damper clamp to the outboard joint side.
(b) Set the distance, as described below.
Standard distance:
161 to 165 mm (6.339 to 6.496 in.)
10. 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:
Using a screwdriver, install the drive shaft damper
clamp, as shown in the illustration.
(d) Claw engagement type:
Using needle-nose pliers, install the drive shaft
damper clamp, as shown in the illustration.
11. INSTALL FRONT DRIVE SHAFT DAMPER RH
HINT:
Use the same procedures described for the LH side.
12. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP RH
HINT:
Use the same procedures described for the LH side.
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) Inboard joint boot No. 2 clamp
(3) Inboard joint boot
C127692E01
C127651E01

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)DS–63
DS
(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.
(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
(a) One touch type:
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:
Using needle-nose pliers, install the inboard joint
boot clamp, as shown in the illustration.
NOTICE:
Be careful not to damage the boot.
C127694E02
C127695
C127696E01

DS–64DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)
DS
17. INSTALL FRONT AXLE INBOARD JOINT BOOT NO. 2
CLAMP
(a) One touch type:
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:
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.
18. 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.
Standard reference value
C127697E01
C127698
C127699E01
Item Drive shaft LH
(Dimension)Drive shaft RH
(Dimension)
2AZ-FE 585.2 mm (23.039 in.) 893.9 mm (35.193 in.)
2GR-FE 570.9 mm (22.476 in.) 922.4 mm (36.315 in.)

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)DS–65
DS
INSTALLATION
(2005/11-2006/01)
1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
(a) Coat the spline of the inboard joint shaft with gear
oil.
(b) Using a brass bar and hammer, align the shaft
splines in the drive shaft.
NOTICE:
• Set the snap ring with the opening side facing
downwards.
• Be careful not to damage the oil seal, boot
and dust cover.
2. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
(a) Coat the spline of the inboard joint shaft with gear
oil.
(b) Align the shaft splines and securely insert the drive
shaft.
NOTICE:
Do not damage the oil seal.
(c) Squeeze the ends of the bracket hole snap ring and
install it to the bearing bracket.
(d) Install the bearing bracket bolt
Torque: 32.4 N*m (330 kgf*cm, 24 ft.*lbf)
3. CONNECT STEERING KNUCKLE WITH AXLE HUB
LH
(a) Align the shaft splines in the drive shaft to the
steering knuckle with axle hub.
4. CONNECT STEERING KNUCKLE WITH AXLE HUB
RH
HINT:
Use the same procedures described for LH side.
5. CONNECT FRONT SUSPENSION LOWER NO. 1 ARM
SUB-ASSEMBLY LH (See page AH-10)
6. CONNECT FRONT SUSPENSION LOWER NO. 1 ARM
SUB-ASSEMBLY RH
HINT:
Use the same procedures described for LH side.
7. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
(See page SP-31)
8. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Use the same procedures described for LH side.
9. INSTALL TIE ROD END SUB-ASSEMBLY LH (See
page PS-45)
10. INSTALL TIE ROD END SUB-ASSEMBLY RH
HINT:
Use the same procedures described for LH side.
11. CONNECT FRONT SPEED SENSOR LH
(a) Connect the speed sensor (see page BC-193).
C127700
C127640

DS–66DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)
DS
12. CONNECT FRONT SPEED SENSOR RH
HINT:
Use the same procedures described for the LH side.
13. INSTALL FRONT AXLE HUB NUT (See page AH-10)
14. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
15. ADD AUTOMATIC TRANSAXLE FLUID
(a) Add automatic transaxle fluid for U140F (see page
AX-152).
(b) Add automatic transaxle fluid for U241E (see page
AX-151).
16. CHECK FOR AUTOMATIC TRANSAXLE FLUID
LEAKAGE
17. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust front wheel alignment (see page
SP-3).
INSTALLATION
(2006/01- )
1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
(a) Coat the spline of the inboard joint shaft with gear
oil.
(b) Align the shaft splines and tap in the drive shaft with
a brass bar and hammer.
NOTICE:
• Set the snap ring with the opening side facing
downwards.
• Be careful not to damage the oil seal, boot
and dust cover.
2. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
(a) Coat the spline of the inboard joint shaft with gear
oil.
(b) Align the shaft splines and securely insert the drive
shaft.
NOTICE:
Do not damage the oil seal.
(c) Squeeze the ends of the bracket hole snap ring and
install it to the bearing bracket.
(d) Install the bearing bracket bolt.
Torque: 32.4 N*m (330 kgf*cm, 24 ft.*lbf)
C127700
C127640