1996 TOYOTA RAV4 Service Repair Manual

Q09034

N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 Precoated partTransmission Case Cover Transmission CaseNo.2 Selecting Bellcrank with
Selecting Bellcrank Support Shift and Select Lever
Shaft Assembly
No.1 Oil Receiver Pipe Reverse Restrict
Pin Straight Screw PlugBack−Up Light SwitchNo.3 Shift Fork No.3 Shift Fork ShaftInterlock Roller
Snap RingShift Head
Shift and Select Lever
Shaft Lock BoltNo.2 Shift Fork Shaft Straight Screw Plug Reverse Shift Arm Bracket Assembly
Snap Ring
Reverse Shift Fork
No.1 Shift Fork
No.1 Shift Fork Shaft Seat
Spring
Ball
Slotted Spring
PinSnap RingSnap Ring
No.2 Shift Fork
No.2 Oil Receiver Pipe
Drain Plug Filler Plug
x10 x17


24 (240, 17)
25 (250, 18)
25 (250, 18)
24 (240, 17)
24 (240, 17)
25 (250, 18)
17 (175, 13)
40 (410, 30)
13 (130, 9)49 (500, 36)20 (200, 14)
17 (175, 13)
29 (300, 22)
49 (500, 36)
20 (200, 14)
49 (500, 36)
49 (500, 36)
29 (300, 22)
Breather Plug Gasket  Gasket
 Gasket  Gasket Gasket
 Gasket MX−14
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)

Z17555
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 Precoated partOutput Shaft AssemblyInput Shaft Assembly
 Tapered Roller Bearing
Outer Race
Reverse Idler Gear ShaftReverse Idler Gear
Thrust Washer
Rear Bearing Retainer
Needle Roller Bearing 5th Driven Gear
Synchronizer Pull RingKey Spring
Middle Synchronizer
Ring
Snap Ring Output Shaft
Lock Nut5th Gear
No.3 Clutch Hub
No.3 Hub Sleeve Key Spring Outer Synchronizer RingInner Synchronizer RingSnap Ring
Spacer x7Shim
 Lock Bolt
29 (300, 22)
42 (430, 31)
123 (1,250, 90)
Snap Ring 
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−15
1996 RAV4 (RM447U)

MX05V−02
Q08757
FIPG
Z12375SST
Q09043
255.5 mm MX−16
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
DISASSEMBLY
1. 4WD:
REMOVE TRANSFER ASSEMBLY
(a) Remove the 3 bolts.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(b) Remove the 5 nuts.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(c) Using a plastic hammer, remove the transfer assembly
from the transaxle.
HINT:
At the time of reassembly, please refer to the following item.
Shift into the 4th gear, and install the transfer assembly while
turning the input shaft of the transaxle.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
2. 4WD:
REMOVE DIFFERENTIAL SIDE GEAR INTERMEDI-
ATE SHAFT
(a) Screw in a suitable bolt with a washer into the side gear
intermediate shaft.
(b) Using SST, remove the side gear intermediate shaft.
SST 09910−00015 (09911−00011, 09912−00010)
(c) Remove the snap ring from the differential side gear inter-
mediate shaft.
HINT:
At the time of reassembly, please refer to the following item.
Keeping the intermediate shaft on the differential pinion shaft,
measure the dimension, as shown in the illustration.
Protrusion length: 255.5 mm (10.06 in.)
3. REMOVE RELEASE FORK AND BEARING
4. REMOVE BACK−UP LIGHT SWITCH WITH GASKET
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
5. REMOVE BOLT AND VEHICLE SPEED SENSOR
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
6. REMOVE NO.2 SELECTING BELLCRANK WITH SE-
LECTING BELLCRANK SUPPORT
Remove the 2 bolts and No.2 selecting bellcrank with the se-
lecting bellcrank support.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

Q05816
FIPG
Q00449
Q05849
SST
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−17
1996 RAV4 (RM447U)
7. REMOVE SHIFT AND SELECT LEVER SHAFT LOCK
BOLT WITH GASKET
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
8. REMOVE SHIFT AND SELECT LEVER SHAFT AS-
SEMBLY WITH GASKET
Remove the 4 bolts, shift and select lever shaft assembly and
gasket.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
9. REMOVE TRANSMISSION CASE COVER
Remove the 10 bolts and transmission case cover.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
10. REMOVE BREATHER PLUG WITH GASKET
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
11. REMOVE OUTPUT SHAFT LOCK NUT
(a) Unstake the lock nut.
(b) Engage the gear double meshing.
(c) Remove the lock nut.
Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf)
(d) Disengage the gear double meshing.
12. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
(a) Remove the No.3 shift fork set bolt.
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
(b) Remove the No.3 hub sleeve and No.3 shift fork.
13. REMOVE 5TH DRIVEN GEAR
Using SST, remove the 5th driven gear.
SST 09950−30010

Z01304
Z01306
Q00299
Z01308
SST MX−18
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
14. MEASURE 5TH GEAR THRUST CLEARANCE AND
RADIAL CLEARANCE
(a) Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.10−0.57 mm (0.0039−0.0224 in.)
Maximum clearance:
0.65 mm (0.0256 in.)
(b) Using a dial indicator, measure the radial clearance.
Standard clearance:
0.009−0.050 mm (0.0004−0.0020 in.)
Maximum clearance:
0.070 mm (0.0028 in.)
15. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
At the time of the reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
a1.75 (0.0689)f2.00 (0.0787)
b1.80 (0.0709)g2.05 (0.0807)
c1.85 (0.0729)h2.10 (0.0827)
d1.90 (0.0748)j2.15 (0.0847)
e1.95 (0.0768)−−
(b) Using SST, remove the No.3 clutch hub with the synchro-
nizer ring and 5th gear.
SST 09950−30010
16. REMOVE NEEDLE ROLLER BEARING AND SPACER
17. REMOVE REAR BEARING RETAINER
Using a torx socket wrench (T45), remove the 7 torx screws and
rear bearing retainer.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)

Q06190
Q01615
Q00056
Q05815
FIPG
MT0669
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−19
1996 RAV4 (RM447U)
18. REMOVE SNAP RING
(a) Using a snap ring expander, remove the input shaft rear
bearing snap ring.
(b) Using 2 screwdrivers and a hammer, remove the 2 snap
rings.
19. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING
AND LOCKING BALL
(a) Using a hexagon wrench (6 mm), remove the plug.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Using a magnetic finger, remove the seat, spring and
locking ball.
20. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
21. REMOVE TRANSMISSION CASE
Remove the 17 bolts and tap the case with a plastic hammer.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
22. REMOVE SHIM
HINT:
At the time of reassembly, please refer to the following item.
Install the previously selected shim by adjusting output shaft
preload.
(See page MX−27)

MT0693
SST
Q06375
Z17557
Matchmarks
Q01614
Q08124
MX−20
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
23. REMOVE OUTPUT SHAFT REAR TAPER ROLLER
BEARING OUTER RACE
Using SST and a hammer, remove the output shaft rear taper
roller bearing outer race.
SST 09316−60011 (09316−00011)
24. REMOVE TRANSMISSION OIL PIPE
(a) Remove the gasket from the oil pipe.
(b) Remove the 2 bolts and oil pipe.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
25. REMOVE REVERSE SHIFT ARM BRACKET AS-
SEMBLY
Remove the bolt and pull off the reverse shift arm and bracket.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
26. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft, remove the reverse idler gear and thrust
washer.
HINT:
At the time of reassembly, please refer to the following item.
Align the matchmarks, as shown.
27. REMOVE STRAIGHT SCREW PLUG, LOCKING BALL
AND SPRING
(a) Using a hexagon wrench (6 mm), remove the 2 plugs.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Using a magnetic finger, remove the 2 seats, springs and
balls.
28. REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD
SET BOLT
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
29. REMOVE NO.1 SHIFT FORK SHAFT
Pull up the No.3 shift fork shaft, remove the No.1 shift fork shaft.
HINT:
At the time of reassembly, please refer to the following item.
When it is difficult to push the fork shaft through the reverse shift
fork, pull up the No.3 shift fork shaft.

Q08125
Q08126
Z00182
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−21
1996 RAV4 (RM447U)
30. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from the re-
verse shift fork.
31. REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD
AND NO.1 SHIFT FORK
(a) Pull out the No.2 shift fork shaft.
(b) Remove the shift head and No.1 shift fork.
32. REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE
SHIFT FORK AND NO.2 SHIFT FORK
(a) Pull out the No.3 shift fork shaft with the reverse shift fork.
(b) Remove the No.2 shift fork.
33. REMOVE SNAP RING
(a) Using 2 screwdrivers and a hammer, remove the snap
ring and reverse shift fork from the No.3 shift fork shaft.
(b) Using 2 screwdrivers and a hammer, remove the 3 snap
rings from the No.1, No.2 and No.3 shift fork shafts.
34. REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY
(a) Leaning the output shaft to the differential side, remove
the input shaft assembly.
(b) Lift up the differential case assembly, remove the output
shaft assembly.
35. REMOVE DIFFERENTIAL CASE ASSEMBLY
(a) Remove the oil pump drive gear.
(b) Remove the differential case assembly.
36. REMOVE MAGNET FROM TRANSAXLE CASE
37. REMOVE TRANSMISSION OIL PUMP ASSEMBLY
AND OIL PIPE
(a) Remove the 2 bolts and oil pipe.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)
(b) Remove the 2 bolts and oil pump assembly.
Torque: 17 N·m (175 kgf·cm, 13 ft·lbf)