1996 TOYOTA RAV4 steering

SR0G1−03
Z19807
3 Door vehicle 64 (650, 47)
5 Door vehicle 113 (1,150, 83)
 GasketTube ClampReturn Tube
No.2 Intermediate
Shaft Pressure Feed Tube
Stabilizer Bar with Link
Front Suspension
Crossmember
Assembly
Front Exhaust Pipe
13 (130, 9)
13 (130, 9)
113 (1, 150, 83)
29 (300, 22)
29 (300, 22)
44 (450, 32)
*36 (365, 26)
62 (630, 46)

62 (630, 46)
 Gasket
Clamp
(A/T)
48 (490, 35)
PS Gear Assembly
Bracket
Bushing
Bracket
Bushing
49 (500, 36)
35 (360, 26)
113 (1, 150, 83)

 Cotter Pin
127 (1, 300, 94)
206 (2, 100, 152)
137 (1, 400, 101)
8.3 (84, 73 in.·lbf)
112 (1, 140, 82)
127 (1, 300, 94)
206 (2, 100, 152)x7 Engine Under CoverN·m (kgf·cm, ft·lbf) : Specified torque
* For use with SST  Non−reusable partx6
127 (1, 300, 94)
137 (1, 400, 101)
137 (1, 400, 101)
W01195
49 (500, 36)
3 Door vehicle 64 (650, 47)
5 Door vehicle 113 (1,150, 83)
SR−44
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
POWER STEERING GEAR
COMPONENTS

F00871
29 (300, 22)
*23 (234, 17)
 Gasket
29 (300, 22)
*23 (234, 17)
44 (450, 32)
*32 (330, 24)
Union Bolt
 Snap Ring
 Oil Seal Turn Pressure TubeDust Cover
Rack GuideControl Valve
Assembly
 Rack Guide
Spring Cap
Lock Nut  Bearing
 Lock Nut  Gasket
 Oil Seal Teflon Ring
 Bearing Union Seat Bushing
 Precoated part
Molybdenum disulfide lithium base greaseRack Guide Seat Rack Guide
Spring Cap
 Rack Housing Cap
N·m (kgf·cm, ft·lbf) : Specified torque
* For use with SST  Non−reusable part
Power steering fluid
29 (300, 22)
69 (700, 51)
12 (125, 9)
29 (300, 22)
Rack Housing
Conical Spring Washer
Rack Guide Spring
− STEERINGPOWER STEERING GEAR
SR−45
1996 RAV4 (RM447U)

W01239
 Snap Ring
 Oil Seal Tie Rod End
Lock Nut
Rack Boot
Clip
Cylinder End Stopper
Rack Housing  Clamp
 Oil Seal  O−Ring  Teflon RingSteering RackRack End
 Claw Washer
Rack Housing
No.1 BracketGrommet
Lock Nut
Molybdenum disulfide lithium base grease
N·m (kgf·cm, ft·lbf) : Specified torque
* For use with SST  Non−reusable part
Power steering fluid


56 (570, 41)
61 (620, 45)
56 (570, 41)
83 (850, 61)
*60 (615, 44)
83 (850, 61)
*60 (612, 44)
Rack End
Claw Washer
Clamp
Rack BootClip
Tie Rod End SR−46
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)

SR0G2−03
R10984
SST
− STEERINGPOWER STEERING GEAR
SR−47
1996 RAV4 (RM447U)
REMOVAL
NOTICE:
Remove the steering wheel assembly before the steering
gear removal, because there is possibility of breaking of
the spiral cable.
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE STEERING WHEEL PAD (See page SR−12)
3. REMOVE STEERING WHEEL (See page SR−12)
4. REMOVE RH AND LH ENGINE UNDER COVERS
Remove the 13 bolts.
5. DISCONNECT RH AND LH TIE ROD ENDS
(See page SA−10)
6. REMOVE FRONT EXHAUST PIPE
Remove the 2 bolts, 3 nuts and 2 gaskets.
7. REMOVE STABILIZER BAR WITH LINK
(See page SA−48)
8. DISCONNECT NO.2 INTERMEDIATE SHAFT
(See page SR−12)
9. DISCONNECT PRESSURE FEED AND RETURN
TUBES
Using SST, disconnect the tube.
SST 09631−22020
10. DISCONNECT PRESSURE FEED AND RETURN TUBE
CLAMPS
Remove the bolt.
11. DISCONNECT RH AND LH LOWER SUSPENSION
ARMS (See page SA−40)
12. REMOVE 2 PS GEAR ASSEMBLY SET BOLTS AND
NUTS
HINT:
Securely suspend the steering gear assembly.
13. REMOVE FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY (See page SA−40)

SR0G3−01
W01241
SST
W01242
SST
R00429
Matchmarks
Matchmarks
R10982
W01243
SST SR−48
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the gear assembly in a vise.
SST 09612−00012
2. REMOVE 2 TURN PRESSURE TUBES
(a) Remove the union bolt and 2 gaskets.
(b) Using SST, remove the tube.
SST 09633−00020
3. REMOVE RH AND LH TIE ROD ENDS AND LOCK
NUTS
(a) Place matchmarks on the tie rod end and rack end.
(b) Loosen the lock nut.
4. REMOVE RH AND LH CLIPS, RACK BOOTS AND
CLAMPS
Remove the screw and loosen the clamp.
NOTICE:
Be careful not to damage the boot.
Mark the RH and LH boots.
5. REMOVE RH AND LH RACK ENDS AND CLAW WASH-
ERS
(a) Using a screwdriver and a hammer, unstake the washer.
NOTICE:
Avoid any impact to the steering rack.
(b) Using a spanner to hold the steering rack steady and us-
ing SST, remove the rack end.
SST 09922−10010
NOTICE:
Use SST 09922−10010 in the direction shown in the il-
lustration.
Mark the RH and LH rack ends.

W01244
Matchmarks
W01245
SST
Rack Guide Spring
Cap Lock Nut
W01246
SST
W01247
SST
Pin
Pin
− STEERINGPOWER STEERING GEAR
SR−49
1996 RAV4 (RM447U)
6. REMOVE RACK HOUSING NO.1 BRACKET AND
GROMMET
(a) Place matchmarks on the bracket and rack housing.
(b) Remove the bolt.
(c) Remove the grommet from the rack housing No.1 brack-
et.
7. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the nut.
SST 09922−10010
NOTICE:
Use SST 09922−10010 in the direction shown in the illustra-
tion.
8. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE
SPRING, RACK GUIDE AND RACK GUIDE SEAT
(a) Using a hexagon wrench (21 mm), remove the cap.
(b) Remove the seat from the guide.
9. REMOVE RACK HOUSING CAP
10. REMOVE LOCK NUT
Using SST to stop the control valve shaft rotating, remove the
nut.
SST 09616−00010
11. REMOVE DUST COVER
12. REMOVE CONTROL VALVE ASSEMBLY, OIL SEAL
AND BEARING
(a) Using snap ring pliers, remove the snap ring from the rack
housing.
(b) Using SST, remove the control valve with the oil seal and
bearing.
SST 09613−12010
NOTICE:
Never attempt to tap out the control valve as this would
damage it.
(c) Remove the oil seal and bearing from the control valve.
13. REMOVE BEARING
Remove the bearing and spacer from the rack housing.

W01248
SST
F00872
SST
Oil Seal
SR−50
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
14. REMOVE CYLINDER END STOPPER AND STEERING
RACK
(a) Using snap ring pliers, remove the snap ring from the rack
housing.
(b) Using SST, press out the steering rack and end stopper.
SST 09612−10093 (09612−10061)
(c) Remove the oil seal from the steering rack.
15. REMOVE OIL SEAL
Using SST, press out the oil seal.
SST 09950−60010 (09951−00260),
09950−70010 (09951−07360)
NOTICE:
Be careful not to damage the rack housing.

SR0G4−03
R10072
Dial Indicator
W01250
Cylinder Gauge
Bushing
Micrometer
W03557
SST
Bushing SST
R11295
Vinyl Tape
Oil Seal
− STEERINGPOWER STEERING GEAR
SR−51
1996 RAV4 (RM447U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. INSPECT STEERING RACK
(a) Using a dial indicator, check the rack for runout.
Maximum runout: 0.30 mm (0.0118 in.)
(b) Check the rack for teeth wear and damage.
(c) Check the back surface for wear and damage.
2. CHECK CONTROL VALVE ASSEMBLY AND BUSHING
Using a cylinder gauge and a micrometer, measure the inside
diameter of the bushing and outside diameter of the valve as-
sembly.
Maximum inside diameter: 28.20 mm (1.1102 in.)
Minimum outside diameter: 27.75 mm (1.0925 in.)
3. IF NECESSARY, REPLACE BUSHING AND OIL SEAL
(a) Using SST, remove the bushing from the rack housing.
SST 09612−24014 (09613−22011)
NOTICE:
Be careful not to damage the rack housing.
HINT:
Separate the SST as shown in the illustration to use it.
As shown, from the opposite side of SST confirm that its
claw is firmly caught on the bushing.
(b) Using a screwdriver, tap out the oil seal.
NOTICE:
To prevent rack housing damage, wind vinyl tape on the
screwdriver.