1996 TOYOTA RAV4 Service Repair Manual

Q06165
Z16229
Proper ContactHeel Contact Face Contact
Select an adjusting shim that will bring the
driven pinion closer to the ring gear.
Toe Contact Flank Contact
Select an adjusting shim that will shift the
driven pinion away from the ring gear. MX−94
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
6. CHECK TOOTH CONTACT
(a) Coat 3 or 4 teeth at 4 different positions on the ring gear
with red lead.
(b) Rotate the ring gear, inspect the teeth pattern.
(c) If the teeth are not contacting properly, again select the
proper shim and plate.
MarkThickness mm (in.)MarkThickness mm (in.)
A0.30 (0.0118)F0.45 (0.0177)
B0.33 (0.0130)G0.48 (0.0189)
C0.36 (0.0142)H0.51 (0.0201)
D0.39 (0.0154)J0.54 (0.0213)
E0.42 (0.0165)K0.57 (0.0224)
7. REMOVE RING GEAR MOUNTING CASE ASSEMBLY
(a) Remove the 10 bolts and transfer right case.
(b) Remove the ring gear mounting case assembly.
8. REMOVE TRANSFER PINION BEARING CAGE AS-
SEMBLY
Remove the 6 bolts and transfer pinion bearing cage assembly.

Q06135
Q06166
SST
Q06287
SST
Q06168
FIPG
− MANUAL TRANSAXLETRANSFER (4WD)
MX−95
1996 RAV4 (RM447U)
9. INSTALL TRANSFER PINION BEARING CAGE AS-
SEMBLY
(a) Coat the O−ring with gear oil.
(b) Install the O−ring to the transfer pinion bearing cage.
(c) Install the transfer pinion bearing cage with the adjusting
shim (previously selected) to the transfer left case.
(d) Install and torque the 6 bolts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
10. INSTALL RING GEAR MOUNTING CASE ASSEMBLY
11. INSTALL ADJUSTING NUT LOCK PLATE
Using snap ring pliers, install the lock plate so that the projection
from the lock plate fits properly into the groove of the adjusting
nut.
12. INSTALL DIFFERENTIAL SIDE GEAR SHAFT HOLD-
ER
(a) Using SST and a press, install the differential side gear
shaft holder to the transfer right case.
SST 09316−20011
(b) Using snap ring pliers, install the snap ring.
13. INSTALL TRANSFER RIGHT CASE OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09223−15020, 09950−70010 (09951−07150)
(b) Coat the lip of the oil seal with MP grease.
14. INSTALL TRANSFER RIGHT CASE
(a) Apply FIPG to the transfer left case, as shown.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
(b) Apply sealant to the bolt threads.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
(c) Install and torque the 10 bolts.

Q06133
Q06169
FIPG
Q06131
MX−96
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
15. CHECK TOTAL PRELOAD (See step 4)
16. INSTALL DIFFERENTIAL LOCK SHIFT FORK, LOCK
SLEEVE AND SHIFT FORK SHAFT
(a) Install the shift fork, shift fork shaft and lock sleeve.
(b) Install and torque the bolt.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
17. INSTALL TRANSFER INSPECTION HOLE COVER
(a) Apply FIPG to the transfer left case, as shown.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
(b) Install the cover on the transfer left case.
(c) Install and torque the 3 bolts.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
18. INSTALL PLUG AND DIFFERENTIAL LOCK INDICA-
TOR SWITCH
(a) Using a hexagon wrench (10 mm), install and torque the
plug and gasket.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Apply sealant to the plug threads.
Using a hexagon wrench (6 mm), install and torque the
plug.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Install and torque the differential lock indicator switch and
gasket.
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
19. INSTALL EXTENSION HOUSING
(a) Coat the O−ring with gear oil.
(b) Install a new O−ring to the extension housing.
(c) Install the extension housing to the transfer pinion bear-
ing cage.

− MANUAL TRANSAXLETRANSFER (4WD)
MX−97
1996 RAV4 (RM447U)
(d) Install and torque the 4 bolts.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
20. INSTALL DYNAMIC DAMPER
Install the dynamic damper and torque the 4 bolts.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
21. INSTALL DUST BOOT

PR02P−02
− PROPELLER SHAFTTROUBLESHOOTING
PR−1
1996 RAV4 (RM447U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Noise
3. Sleeve yoke spline (Worn)
4. Center support bearing (Worn)
5. Spider bearing (Worn or stuck)PR−6
PR−6
PR−6
Vibration
1. Rear propeller and intermediate shafts (Runout)
2. Propeller shafts (Imbalance)
3. Universal joint flange (Runout)
4. Cross groove joint (Stuck or damaged)
5. Sleeve yoke spline (Stuck)PR−6
PR−6
PR−6
PR−6
PR−6

PR02Q−01
Q08982
 Dust CoverIntermediate Shaft
Plate Washer
Center Support Bearing
Plate Washer
Universal Joint Flange
Cross Groove Joint Washer
Propeller Shaft
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable partx6
27 (275, 20)
74 (750, 54)

37 (375, 27)
See page PR−9 PR−2
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY
1996 RAV4 (RM447U)
PROPELLER SHAFT ASSEMBLY
COMPONENTS

PR02R−01
F03298
Q08983
Matchmarks
Q05852
Q05853
SST
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY
PR−3
1996 RAV4 (RM447U)
REMOVAL
1. LOOSEN CROSS GROOVE JOINT SET BOLT
(a) Depress the brake pedal and hold it.
(b) Using a hexagon wrench, loosen the cross groove joint
set bolts 1/2 turn.
HINT:
Put a piece of cloth, or equivalent, into the inside of the cross
groove joint cover so that the boot does not touch the inside of
the cross groove joint cover.
(c) Loosen the 2 bolts and center support bearing.
2. DISCONNECT PROPELLER SHAFT FROM DIFFER-
ENTIAL
(a) Place matchmarks on both flanges.
(b) Remove the 4 bolts, washers and nuts.
3. REMOVE PROPELLER SHAFT FROM TRANSAXLE
(a) Remove the 2 bolts and center support bearing.
(b) Pull out the propeller shaft yoke from the transaxle.
(c) Insert SST in the transaxle to prevent oil leakage.
SST 09325−20010

Q06266
Matchmarks PR−4
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY
1996 RAV4 (RM447U)
4. SEPARATE INTERMEDIATE SHAFT AND REAR PRO-
PELLER SHAFT
(a) Place matchmarks on the joint and flange.
HINT:
Do not place the matchmarks with a punch.
(b) Using a hexagon wrench, remove the 6 bolts and 3 wash-
ers to separate intermediate propeller shaft and propeller
shaft.