1996 TOYOTA RAV4 Service Repair Manual

Q06053
PR07P−01
Q05963
Matchmarks
Q06058
SST
Q06082
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY
PR−5
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE CENTER SUPPORT BEARING
(a) Using a hammer and chisel, loosen the staked part of the
nut.
(b) Using a vise to hold the front flange, remove the nut and
plate washer.
(c) Place matchmarks on the flange and shaft.
(d) Using SST, remove the universal joint flange.
SST 09950−40010 (09951−04020, 09952−04010,
09953−04030, 09954−04010, 09955−04060,
09958−04010)
(e) Remove the center support bearing and plate washer.
2. INSPECT CENTER SUPPORT BEARING
(a) Turn the bearing by hand with applying force in the rota-
tion direction. Check the bearing turns smoothly.
(b) Check that the seals are not cracked or damaged.
If the bearing is damaged, worn, or does not turn freely, replace
it.

PR07Q−01
Q06054
Q06061
Q06062
Q05792
Q06046
PR−6
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT INTERMEDIATE AND REAR PROPELLER
SHAFTS RUNOUT
Using a dial indicator, inspect the intermediate shaft and propel-
ler shaft.
Maximum runout: 0.8 mm (0.031 in.)
If the shaft runout is greater than the maximum, replace the
shaft.
2. INSPECT UNIVERSAL JOINT FLANGE RUNOUT
(a) Using a dial indicator, inspect the rear side of universal
joint flange runout in the horizontal direction.
Maximum runout: 0.1 mm (0.004 in.)
(b) Using a dial indicator, inspect the rear side of universal
joint flange runout in the vertical direction.
Maximum runout: 0.1 mm (0.004 in.)
3. INSPECT SPIDER BEARING
Check the spider bearing axial play by turning the flange with
holding the shaft tightly.
4. INSPECT CROSS GROOVE JOINT
Check that the joint turns smoothly in the directions as shown.
Check for damage or grease leakage from the boot.
If a problem is found, replace the rear propeller shaft.

PR02T−01
Q08048
Q08119
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY
PR−7
1996 RAV4 (RM447U)
REPLACEMENT
REPLACE DUST COVER
(a) Using a screwdriver and hammer, remove the dust cover.
(b) Using 2 screwdrivers and hammers, install a new dust
cover.
NOTICE:
Be careful not to damage the dust cover.

Q05879
Rear
PR07R−01
Q06110
Matchmarks
PR−8
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY
1996 RAV4 (RM447U)
REASSEMBLY
1. INSTALL CENTER SUPPORT BEARING
(a) Set the center support bearing on the intermediate shaft
as shown.
(b) Install the plate washer to the intermediate shaft.
(c) Align the matchmarks on the flange and shaft and place
the flange on the shaft.
(d) Using a vise to hold the flange, press the bearing into
position by tightening down a new nut and washer.
Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf)
(e) Loosen the nut.
(f) Torque the nut again.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(g) Using a hammer and chisel, stake the nut.
2. INSTALL JOINT END COVER
(a) Align the matchmarks and install the universal joint flange
to the cross groove joint.
(b) Tighten the 6 bolts and 3 washers to press the joint end
cover.
HINT:
Tighten the bolts gradually and equally to prevent damaging the
end cover.
(c) Remove the 6 bolts and 3 washers and separate the uni-
versal joint flange from the cross groove joint.
3. INSPECT CROSS GROOVE JOINT (See page
PR−6)
4. CONNECT FRONT PROPELLER SHAFT WITH REAR
PROPELLER SHAFT
Using a hexagon wrench, tighten the 6 bolts and 3 washers
temporarily.
HINT:
Put a piece of cloth or an equivalent into the inside of the univer-
sal joint cover.

PR07S−01
Q05756
65.5 − 70.5 mm
(2.579 − 2.776 in.)
Q06145
11.5 − 13.5 mm
(0.453 − 0.536 in.)
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY
PR−9
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL INTERMEDIATE SHAFT
(a) Remove SST from the transfer.
(b) Insert the yoke into the transfer.
2. INSTALL CENTER SUPPORT BEARING TEMPORARI-
LY
3. INSTALL PROPELLER SHAFT
(a) Align the matchmarks on the flanges and connect the
shaft with the 4 bolts, washers and nuts.
(b) Torque the bolts and nuts.
Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
4. TIGHTEN CROSS GROOVE JOINT SET BOLT
(a) Depress the brake pedal and hold it.
(b) Using a hexagon wrench, tighten the cross groove joint
set bolts.
Torque: 27 N·m (275 kgf·cm, 20 ft·lbf)
5. INSTALL CENTER SUPPORT BEARING
(a) With the vehicle in the unladen condition, adjust the di-
mension between the rear side of cover and the shaft, as
shown in the illustration.
(b) With the same condition, adjust the dimension between
the rear side of center bearing housing and the rear side
of cushion at 11.5 − 13.5 mm (0.4528 − 0.5315 in.), as
shown in the illustration below, then torque the bolts.
Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
(c) Check that the center line of the bracket is at right angles
at the shaft axial direction.

RS02X−12
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS−7
1996 RAV4 (RM447U)
STEERING WHEEL PAD AND SPIRAL CABLE
COMPONENTS

RS02Y−08
RS−8
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 RAV4 (RM447U)
REMOVAL
(See page SR−12)

RS02Z−11
H13549
H13550
H13551
H13549
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS−9
1996 RAV4 (RM447U)
INSPECTION
1. VEHICLE NOT INVOLVED IN COLLISION
(a) Do a diagnostic system check (See page DI−285).
(b) Do a visual check which includes the following items with
the steering wheel pad (with airbag) installed in the ve-
hicle.
Check for cuts, minute cracks or marked discoloration of
the steering wheel pad top surface and grooved portion.
2. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
NOT DEPLOYED
(a) Do a diagnostic system check (See page DI−285).
(b) Do a visual check which includes the following items with
the steering wheel pad (with airbag) installed in the ve-
hicle.
Check for cuts and cracks in, or marked discolor-
ation of the steering wheel pad top surface and
grooved portion.
Check for cuts and cracks in wire harnesses, and for
chipping in connectors.
Check for deformation of the horn button contact
plate of the steering wheel.
HINT:
If the horn button contact plate of the steering wheel is de-
formed, never repair it. Always replace the steering wheel
assembly with a new one.
There should be no interference between the steering
wheel pad and the steering wheel, and the clearance
should be uniform all the way around when the new steer-
ing wheel pad is installed on the steering wheel.
CAUTION:
For removal and installation of the steering wheel pad, see
page SR−12 and SR−19, and be sure to follow the correct
procedure.