1996 TOYOTA RAV4 Service Repair Manual

MT0781
MX−22
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
38. REMOVE NO.5 SYNCHRONIZER RING WITH KEY
SPRING FROM NO.3 CLUTCH HUB
(a) Remove the No.5 synchronizer ring with the key spring
from the No.3 clutch hub.
(b) Using a screwdriver, remove the snap ring.
HINT:
Wrap vinyl tape on the screwdriver to prevent damaging the
synchronizer ring.
(c) Remove the synchronizer rings.

MX0DT−01
MT0782
WM0066
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−23
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT NO.5 SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
middle No.5 synchronizer ring in one direction while push-
ing it to the outer No.5 synchronizer ring. Check that the
ring locks.
If it does not lock, replace the synchronizer ring.
2. MEASURE SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.

Z00192
SST
MX0DU−01
Z00194
SST
Q08014
SST
Q05164
SST
Q00141
SST MX−24
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
REPLACEMENT
1. REPLACE INPUT SHAFT BEARING AND OIL SEAL
(a) Remove the 3 bolts and transaxle case receiver.
(b) Using SST, pull out the bearing.
SST 09612−65014
(c) Using a screwdriver, remove the oil seal.
(d) Using SST, drive in a new oil seal.
SST 09608−00081, 09950−70010 (09951−07150)
(e) Coat the lip of seal with MP grease.
(f) Using SST, drive in a new bearing.
SST 09950−60010 (09951−00580), 09950−70010
(09951−07150)
(g) Install the transaxle case receiver.
(h) Install and torque the 3 bolts.
Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf)
(i) Using SST and a press, remove the inner race.
SST 09950−00020
(j) Using SST and a press, install a new input shaft front
bearing inner race.
SST 09316−60011 (09316−00021)

Q00338
SST
Z00197
Q06368
SST
SST
Q00245
SSTSocket Wrench
Z00199SST
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−25
1996 RAV4 (RM447U)
2. REPLACE OUTPUT SHAFT FRONT BEARING OUTER
RACE AND OUTPUT SHAFT FRONT COVER
(a) Using SST, pull out the output shaft front bearing outer
race.
SST 09308−00010
(b) Remove the output shaft cover.
(c) Install a new output shaft cover.
HINT:
Install the output shaft cover projection into the case side
groove.
(d) Using SST and a hammer, drive in a new output shaft front
bearing outer race.
SST 09316−60011 (09316−00011, 09316−00021)
(e) Using SST and a socket wrench, remove the output shaft
front bearing.
SST 09950−00020, 09950−00030
(f) Using SST and a press, install a new output shaft front
bearing.
SST 09316−60011 (09316−00071)

Q01611
Z00201
MX−26
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
3. REPLACE REVERSE RESTRICT PIN
(a) Using a hexagon wrench (6 mm), remove the screw plug.
(b) Using a pin punch and hammer, drive out the slotted
spring pin.
(c) Replace the reverse restrict pin.
(d) Using a pin punch and hammer, drive in the slotted spring
pin.
(e) Apply sealant to the screw plug threads.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
(f) Using a hexagon wrench (6 mm), install and torque the
screw plug.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

MX05X−01
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−27
1996 RAV4 (RM447U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See
page MX−16).
NOTICE:
When working with FIPG material, you must observe the follow-
ing items.
Using a razor blade and gasket scraper, remove all the old
FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose
material.
Clean both sealing surfaces with a non−residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along
the sealing surface.
Parts must be assembled within 10 minutes of application.
Otherwise, the FIPG material must be removed and reap-
plied.
HINT:
Before reassembly, select a shim by adjusting output
shaft preload.
Coat all of the sliding and rotating surfaces with gear oil
before reassembly.
ADJUST OUTPUT SHAFT PRELOAD
(a) Install the output shaft assembly to the transaxle case.
(b) Install the transmission case to the transaxle case.
HINT:
If necessary, tap on the case with a plastic hammer.
(c) Install and torque the 17 bolts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(d) Install the output shaft rear taper roller bearing outer race.
(e) Install the adjusting shim.
HINT:
When reusing the output shaft bearing, first install a shim of the
same thickness as before. If installing a new taper roller bear-
ing, first select and install a shim of lesser thickness than be-
fore.
(f) Install the rear bearing retainer.
(g) Using a torx wrench (T45), install and torque the 7 torx
screws.
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)
(h) Install a new lock nut to the output shaft.
(i) Turn the output shaft right and left 2 or 3 times to allow the
bearing to settle.

Z12593
MX−28
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
(j) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing
0.8−1.6 N·m (8−16 kgf·cm, 6.9−13.9 in.·lbf)
Reused bearing
0.5−1.0 N·m (5−10 kgf·cm, 4.3−8.7 in.·lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.
(k) The preload will change about 0.4−0.5 N·m (4−5 kgf·cm,
3.5−4.3 in.·lbf) for every 0.05 mm change in adjusting
shim thickness.
MarkThickness mm (in.)MarkThickness mm (in.)
01.30 (0.0512)D1.95 (0.0768)
11.35 (0.0531)E2.00 (0.0787)
21.40 (0.0551)F2.05 (0.0807)
31.45 (0.0571)G2.10 (0.0827)
41.50 (0.0591)H2.15 (0.0846)
51.55 (0.0610)J2.20 (0.0866)
61.60 (0.0630)K2.25 (0.0886)
71.65 (0.0650)L2.30 (0.0906)
81.70 (0.0669)M2.35 (0.0925)
91.75 (0.0689)N2.40 (0.0945)
A1.80 (0.0709)P2.45 (0.0965)
B1.85 (0.0728)Q2.50 (0.0984)
C1.90 (0.0748)−−
(l) Remove the lock nut.
(m) Remove these parts. Removal is in the reverse order of
installation.
Rear bearing retainer
Shim
Transmission case
Output shaft assembly
Output shaft rear bearing outer race

MX028−02
MT0791
Rear Bearing4th GearSpacer
Synchronizer Ring
Snap Ring
Needle Roller Bearing3rd GearNeedle Roller Bearing
 Input Shaft Front Bearing Inner Race
Input Shaft Synchronizer Ring
No.2 Hub Sleeve
No.2 Clutch Hub
Shifting KeySpring
Snap Ring
 Non−reusable part
− MANUAL TRANSAXLEINPUT SHAFT
MX−29
1996 RAV4 (RM447U)
INPUT SHAFT
COMPONENTS