1996 TOYOTA RAV4 Service Repair Manual

MX062−03
Z00295
Z00296
MX−54
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
1996 RAV4 (RM447U)
REASSEMBLY
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:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. ASSEMBLE DIFFERENTIAL CASE
(a) Install the thrust washer to the side gear.
(b) Install the 4 pinions and thrust washers to the spider.
(c) Install the side gear and spider with the 4 pinions to the
differential left case.
(d) Using a dial indicator, measure the backlash of the pinion
gear while holding the differential left case.
Standard backlash:
0.05 − 0.20 mm (0.0020 − 0.0079 in.)
HINT:
Push the pinion gear and spider with the 4 pinions to the differ-
ential left case.
(e) Install the side gear and spider with the 4 pinions to the
right side of the differential case. Check the side gear
backlash.

Z00297
Z00298
Z00299
Matchmarks
Z00303
Driven Gear
Side
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
MX−55
1996 RAV4 (RM447U)
(f) Refer to the table below, select the thrust washer which
will ensure that the backlash is within the specification.
Try to select a washer of the same size.
Thickness mm (in.)Thickness mm (in.)
0.80 (0.0315)1.20 (0.0472)
0.90 (0.0354)1.30 (0.0512)
1.00 (0.0394)1.40 (0.0551)
1.10 (0.0433)−
(g) Install the vehicle speed sensor drive gear.
(h) Align the matchmarks on the differential cases.
(i) Using a plastic hammer, carefully tap the differential case
to install it.
(j) Using a torx wrench (T50), install and torque the 16 torx
screws.
Torque: 63 N·m (640 kgf·cm, 46 ft·lbf)
2. INSTALL RING GEAR
(a) Clean the contact surface of the differential case and the
threads of the ring gear and differential case.
(b) Heat the ring gear to about 100°C (212°F) in boiling wa-
ter.
(c) Carefully take the ring gear out of the water.
(d) Clean the contact surface of the ring gear with cleaning
solvent.
(e) Quickly install the ring gear on the differential case.
HINT:
Align the matchmarks on the differential left case and contact
the ring gear.
(f) Temporarily install the 16 bolts.
NOTICE:
The ring gear set bolts should not be tightened until the
ring gear has cooled sufficiently.
(g) After the ring gear has cooled sufficiently, torque the ring
gear set bolts.
Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf)

Q06410
SST
SST
Q00036
Z00309
MX−56
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
1996 RAV4 (RM447U)
3. INSTALL TAPERED ROLLER BEARING
Using SST and a press, install new left and right bearings onto
the differential case.
SST 09316−20011, 09316−60011 (09316−00011)
HINT:
Press the bearing on the ring side first.
4. ADJUST OUTPUT SHAFT ASSEMBLY PRELOAD
(See page MX−27)
5. INSTALL DIFFERENTIAL CASE ASSEMBLY TO
TRANSAXLE CASE
6. INSTALL OUTPUT SHAFT ASSEMBLY
Lift up the differential case and install the output shaft assem-
bly.
7. INSTALL TRANSMISSION CASE
(a) Install the transmission case.
HINT:
If necessary, tap on the case with a plastic hammer.
(b) Install and torque the 17 bolts.
Torque: 29 N·m (300 kgf·cm 22 ft·lbf)
8. INSTALL OUTPUT SHAFT REAR TAPERED ROLLER
BEARING OUTER RACE
Using a plastic hammer, drive in the outer race.
9. INSTALL SHIM (See page MX−27)
HINT:
Install the previously selected shim.
10. INSTALL REAR BEARING RETAINER
Using a torx wrench (T45), install and torque the 7 torx screws.
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)
11. ADJUST DIFFERENTIAL CASE SIDE BEARING PRE-
LOAD
(a) Install a new lock nut to the output shaft.
(b) Turn the output shaft right and left 2 or 3 times to allow the
bearings to settle.
(c) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing (Output shaft preload plus)
0.2 − 0.3 N·m (1.8 − 3.5 kgf·cm, 1.6 − 3.0 in.·lbf)
Reused bearing (Output shaft preload plus)
0.1 − 0.2 N·m (1.1 − 2.2 kgf·cm, 1.0 − 1.9 in.·lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.

− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
MX−57
1996 RAV4 (RM447U)
HINT:
The total preload will change by about 0.1 − 0.2 N·m (1 − 2
kgf·cm, 0.9 − 1.7 in.·lbf) with each 0.05 mm change in adjusting
shim thickness.
MarkThickness mm (in.)MarkThickness mm (in.)
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
12. REMOVE REAR BEARING RETAINER
Using a torx wrench (T45), remove the 7 torx screws and rear
bearing retainer.
13. REMOVE SHIM
14. REMOVE TRANSMISSION CASE
(a) Remove the 17 bolts.
(b) Using a plastic hammer, tap the transmission case.
15. REMOVE OUTPUT SHAFT ASSEMBLY
16. REMOVE DIFFERENTIAL CASE ASSEMBLY

MX02J−02
Z17561
Tapered Roller Bearing and Outer Race
Snap Ring
Spacer
Vehicle Speed Sensor
Drive Gear
No.1 Differential
Case No.2 Differential Side
Gear Thrust Washer
Differential Side Gear
Subassembly
Differential Pinion Shaft
Differential Pinion Thrust Washer
Differential Pinion
Differential Pinion
Thrust Washer
Differential Pinion
No.2 Front Differential Pinion Shaft
Front Differential Pinion
Shaft Holder
Spacer
Snap Ring Conical Spring
Washer
Pinion Shaft
Holder
No.2 Differential Side
Gear Thrust Washer
Front Differential Case
Front Differential
Pinion Shaft Conical Spring
Washer
No.2 Differential Case
Differential Ring Gear
x16
Oil Baffle Front Differential Side
Gear Thrust Washer
Tapered Roller Bearing and Outer Race
Oil Seal
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable partFront Differential Side Gear
Shim

124 (1,260, 91)
 MX−58
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
DIFFERENTIAL CASE (4WD)
COMPONENTS

MX02K−03
Z12377
Matchmarks
Z12483
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−59
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE NO.2 DIFFERENTIAL CASE
(a) Remove the 16 bolts.
(b) Remove the No.2 differential case upward.
2. REMOVE DIFFERENTIAL RING GEAR
(a) Place matchmarks on both the differential case and ring
gear.
(b) Using a plastic hammer, tap out the ring gear.
3. REMOVE NO.2 DIFFERENTIAL SIDE GEAR THRUST
WASHER AND CONICAL SPRING WASHER
4. REMOVE FRONT DIFFERENTIAL CASE ASSEMBLY
5. DISASSEMBLE FRONT DIFFERENTIAL CASE
(a) Remove the front differential side gear together with the
thrust washer from the front differential case.
(b) Remove the front differential side gear thrust washer from
the side gear.
(c) Using a snap ring expander, remove the snap ring and
spacer.
HINT:
Before removing the shaft snap ring, wrap vinyl tape around the
case to prevent from damage.

Q06218
Q06219
Q07870
SST MX−60
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
(d) Remove these parts from the front differential case:
2 front differential pinion shafts
No.2 front differential pinion shaft
Front differential pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
Front differential side gear
Front differential side gear thrust washer
6. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the spacer and vehicle speed sensor drive gear.
7. DISASSEMBLE NO.1 DIFFERENTIAL CASE
Remove these parts from the No.1 differential case:
4 differential pinion shafts
Pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
Differential side gear subassembly
Conical spring washer
No.2 differential side gear thrust washer
8. No.2 Differential Case Side:
REMOVE TAPERED ROLLER BEARING
Using SST, remove the tapered roller bearing.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00520)

Q07895
SST
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−61
1996 RAV4 (RM447U)
9. No.1 Differential Case Side:
REMOVE TAPERED ROLLER BEARING
Using SST, remove the tapered roller bearing.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00450)