1996 TOYOTA RAV4 Service Repair Manual

MX0DX−01
Q06209
A
B
Case No.1 Differential
Case No.2 Differential
Q06210
A B
Z12920
MX−62
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
INSPECTION
1. MEASURE NO.1 AND NO.2 DIFFERENTIAL CASES
Using a cylinder gauge, measure the inner diameter of the No.1
and No.2 differential cases bushing.
Standard diameter:
A: 104.000−104.035 mm (4.0945−4.0959 in.)
B: 97.000−97.035 mm (3.8189−3.8203 in.)
Maximum diameter:
A: 104.060 mm (4.0969 in.)
B: 97.060 mm (3.8213 in.)
2. MEASURE FRONT DIFFERENTIAL CASE
Using a micrometer, measure the outer diameter of the front dif-
ferential case.
Standard diameter:
A: 103.929−103.964 mm (4.0917−4.0931 in.)
B: 96.929−96.964 mm (3.8161−3.8175 in.)
Minimum diameter:
A: 103.850 mm (4.0887 in.)
B: 96.850 mm (3.8130 in.)
3. MEASURE CONICAL SPRING WASHER
Using calipers, measure the height of the conical spring wash-
er.
Standard height:
No.2 differential case side
2.60−2.80 mm (0.102−0.110 in.)
No.1 differential case side
1.70−1.90 mm (0.067−0.075 in.)
Minimum height:
No.2 differential case side
2.50 mm (0.098 in.)
No.1 differential case side
1.60 mm (0.063 in.)

Z12494
MX0DY−01
Z12381
SST
Z12496
Q06288
SST
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−63
1996 RAV4 (RM447U)
REPLACEMENT
1. Transmission Case Side:
REPLACE OIL SEAL AND TAPERED ROLLER BEAR-
ING OUTER RACE
(a) Using a screwdriver, remove the oil seal.
(b) Remove the transmission oil baffle.
(c) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly.
(d) Remove the adjust shim.
(e) Install the adjust shim.
(See page MX−65)
HINT:
First select and install a shim of less thickness than before.
(f) Using SST and a press, install the tapered roller bearing
outer race.
SST 09316−60011 (09316−00011, 09316−00041)
(g) Install the transmission oil baffle.
HINT:
Install the transmission oil baffle projection into the case side
cutout.
(h) Using SST, drive in a new oil seal.
SST 09223−15020, 09950−70010 (09951−07150)
(i) Coat the lip of the oil seal with MP grease.

Z12497
Z12383
SST MX−64
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
2. Transaxle Case Side:
REPLACE TAPERED ROLLER BEARING OUTER
RACE
(a) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly through the cutout portion on the
transaxle case.
(b) Using SST and a press, install the tapered roller bearing
outer race.
SST 09316−60011 (09316−00011, 09316−00041)

Q06211
SST
MX02M−03
Q06212
SST
Q06224
Thrust Washer
Thickness
1.0 mm (0.039 in.)
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−65
1996 RAV4 (RM447U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. No.1 Differential Case Side:
INSTALL TAPERED ROLLER BEARING
Using SST, install a new tapered roller bearing.
SST 09316−20011
2. No.2 Differential Case Side:
INSTALL TAPERED ROLLER BEARING
Using SST, install a new tapered roller bearing.
SST 09316−20011
3. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE
GEAR BACKLASH (DIFFERENTIAL SIDE GEAR SUB-
ASSEMBLY SIDE)
(a) Install these parts to the No.1 differential case:
No.2 differential side gear thrust washer
Temporarily install a 1.0 mm (0.039 in.) thick thrust
washer
Differential side gear subassembly
Pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
4 differential pinion shafts

Q06192
Q06220
Q06193
MX−66
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
(b) Using a dial indicator, measure the backlash of one pinion
gear while holding the differential side gear sub assembly
toward the case.
Standard backlash: 0.05−0.20 mm (0.0020−0.0079 in.)
HINT:
Push the pinion gear of the right side of the differential case.
If the backlash is out of the specification, refer to the table below
and select a thrust washer which will ensure that the backlash
is within the specification.
MarkThickness mm (in.)MarkThickness mm (in.)
−0.80 (0.0315)−1.15 (0.0453)
−0.85 (0.0335)−1.20 (0.0472)
−0.90 (0.0354)−1.25 (0.0492)
−0.95 (0.0374)−1.30 (0.0512)
−1.00 (0.0394)−1.35 (0.0531)
−1.05 (0.0413)−1.40 (0.0551)
−1.10 (0.0433)−−
(c) Disassemble the No.1 differential case.
4. ASSEMBLE NO.1 DIFFERENTIAL CASE
Install these parts to the No.1 differential case:
No.2 side gear thrust washer (previously selected)
Conical spring washer
Differential side gear subassembly
Pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
4 differential pinion shafts
HINT:
Ensure that the conical spring washer is installed correctly.
5. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR
(a) Install the vehicle speed sensor drive gear and spacer.
(b) Using a snap ring expander, install the snap ring.

Q06218
Q06194
Q06195
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−67
1996 RAV4 (RM447U)
6. CHECK AND ADJUST FRONT SIDE GEAR BACK-
LASH (FRONT DIFFERENTIAL CASE SIDE)
(a) Install these parts to the front differential case:
Front differential side gear thrust washer
Front differential side gear
Front differential pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
No.2 front differential pinion shaft
2 front differential pinion shafts
(b) Using a dial indicator, measure the backlash of one pinion
gear while holding the front differential side gear toward
the case.
Standard backlash: 0.05−0.20 mm (0.0020−0.0079 in.)
NOTICE:
Do not mount the surface of front differential case which
contacts with bushing in a vise.
If the backlash is out of the specification, refer to the table below
and select a thrust washer which will ensure that the backlash
is within the specification.
MarkThickness mm (in.)
B1.00 (0.0394)
C1.05 (0.0413)
D1.10 (0.0433)
E1.15 (0.0453)
F1.20 (0.0472)
G1.25 (0.0492)
7. INSTALL SNAP RING
(a) Install the spacer.
(b) Using a snap ring expander, install the shaft snap ring, as
shown.
HINT:
Before installing the shaft snap ring, wrap vinyl tape around the
case to avoid damaging the case.

Q06221
Q06196
MX−68
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
8. CHECK AND ADJUST FRONT DIFFERENTIAL SIDE
GEAR THRUST CLEARANCE (NO.2 DIFFERENTIAL
CASE SIDE)
(a) Install these parts to the No.2 differential case:
No.2 differential side gear thrust washer
Front differential side gear thrust washer
Front differential side gear
Front differential case assembly
HINT:
Engage the front differential side gear and pinion gear of the
front differential case.
(b) Using a dial indicator, measure the thrust clearance of the
front differential side gear while holding the front differen-
tial case on the No.2 differential case side.
Standard clearance: 0.17−0.26 mm (0.007−0.010 in.)
HINT:
Turning the side gear a bit, check the maximum value of the
thrust clearance.
If the backlash is out of the specification, refer to the table below
and select a thrust washer which will ensure that the backlash
is within the specification.
MarkThickness mm (in.)MarkThickness mm (in.)
A0.95 (0.0374)F1.20 (0.0472)
B1.00 (0.0394)G1.25 (0.0492)
C1.05 (0.0413)H1.30 (0.0512)
D1.10 (0.0433)J1.35 (0.0531)
E1.15 (0.0453)K1.40 (0.0551)
(c) Disassemble the No.2 differential case.
9. INSTALL RING GEAR
(a) Clean the contact surface of the differential left 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 No.2 differential case and connect
the ring gear.

Q06225
Thrust Washer
Thickness
1.0 mm (0.039 in.)
Q06213
Plastigage
Plastigage
Q06214Matchmarks
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−69
1996 RAV4 (RM447U)
10. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE
GEAR THRUST CLEARANCE (FRONT DIFFERENTIAL
CASE SIDE)
(a) Install these parts:
Front differential case assembly
Front differential side gear
Front differential side gear thrust washer
Temporarily install a 1.0 mm (0.039 in.) thick
No.2 differential side gear thrust washer
No.2 differential side gear thrust washer
HINT:
Engage the front differential side gear and pinion gear of
the No.1 differential case.
The temporarily installed a 1.0 mm (0.039 in.) thick No.2
side gear thrust washer is used for reference when check-
ing backlash.
(b) Clean the contact surface of the No.2 side gear thrust
washer and No.2 differential case.
(c) Apply plastigage on the No.2 side gear thrust washer, as
shown.
HINT:
Apply the plastigage on the No.2 side gear thrust washer in the
4 positions directly above the pinion shafts in the No.1 differen-
tial case’s position.
(d) Install the No.2 differential case downward.
HINT:
Align the matchmarks on the No.1 differential case and contact
the No.2 differential case.
(e) Install and torque the 16 bolts.
Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf)
(f) Remove the 16 bolts and No.2 differential case upward.