boot TOYOTA RAV4 2006 Service Repair Manual

AH–8AXLE – FRONT AXLE HUB
AH
10. REMOVE STEERING KNUCKLE WITH AXLE HUB
(a) Remove the 2 bolts and 2 nuts, and disconnect the
shock absorber from the steering knuckle.
HINT:
While fixing the nuts in place, loosen and remove
the bolts.
(b) Put matchmarks on the drive shaft and the axle hub.
(c) Using a plastic-faced hammer, remove 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.
11. REMOVE FRONT LOWER BALL JOINT ASSEMBLY
LH (See page SP-27)
12. REMOVE FRONT AXLE HUB SUB-ASSEMBLY LH
(a) Remove the 4 bolts and axle hub from the steering
knuckle.
NOTICE:
Do not place the hub and bearing's magnet rotor
side so that it is facing downward, and do not
allow the magnet rotor side to become damaged
or contact foreign matter.
(b) Remove the dust cover from the steering knuckle.
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MA–12MAINTENANCE – CHASSIS
MA
GENERAL MAINTENANCE
(2006/01- )
1. INSPECT STEERING LINKAGE AND GEAR HOUSING
(a) Check the steering wheel free play.
(b) Check the steering linkage for looseness or
damage.
(1) Check that the tie rod ends do not have
excessive play.
(2) Check that the dust seals and boots are not
damaged.
(3) Check that the boot clamps are not loose.
(4) Check that the steering gear housing is not
damaged.
(5) Check that the connectors are properly
connected to the steering gear housing.
2. INSPECT BALL JOINTS AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.
(1) Jack up the front of the vehicle and place
wooden blocks with a height of 180 to 200 mm
(7.09 to 7.87 in.) under the front tires.
(2) Lower the vehicle until the front coil spring has
about half its ordinary load. Place stands under
the vehicle for safety.
(3) Check that the front wheels are pointing
straight ahead. Use wheel chocks on all 4
wheels.
(4) Using a lever, pry up the end of the lower arm.
Check the amount of play.
Maximum ball joint vertical play:
0 mm (0 in.)
If there is any play, replace the ball joint.
(b) Check the dust cover for damage.
3. INSPECT DRIVE SHAFT BOOTS
(a) Check the drive shaft boots for loose clamps,
grease leakage, kinks or damage.
4. INSPECT AUTOMATIC TRANSAXLE FLUID LEVEL
(a) Visually check the transmission for fluid leakage. If
oil is leaking, find the cause and repair it.
5. INSPECT TRANSFER OIL (for 4WD)
(a) Visually check the transfer for oil leakage. If oil is
leaking, find the cause and repair it.
6. INSPECT REAR DIFFERENTIAL OIL (for 4WD)
(a) For the rear differential oil inspection, refer to the
following procedures (see page DF-3).
Type See procedures
U151E See page AX-126
U151F See page AX-126
Type See procedures
Front Oil See page TF-45
Rear Oil See page TF-45

STEERING COLUMN – STEERING SYSTEMSR–5
SR
(c) For the following 2steps, carry out the RH and LH
procedures separately.
(1) Draw a line on the tie rod and rack end where it
can easily be seen.
(2) Using a paper gauge, measure the distance
between the tie rod end and the rack end
screw.
(3) Remove the RH and LH boot clips from the
rack boots.
(4) Loosen the RH and LH lock nuts.
(5) Turn the RH and LH rack ends by the same
amount (but in opposite directions) in
accordance with the steering angle.
HINT:
Electronic power steering: 1 turn (360
) of rack
end (1.5 mm (0.059 in.) horizontal movement) -
10.8
of steering angle.
(6) Tighten the RH and LH lock nuts.
Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf)
NOTICE:
Make sure that the difference in length
between the RH and LH tie rod ends and
rack end screws is less than 1.5 mm (0.059
in.).
(7) Install the RH and LH boot clips.
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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.
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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)
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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.
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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)
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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.
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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.
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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
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