1996 TOYOTA RAV4 Service Repair Manual

− SUSPENSION AND AXLEFRONT AXLE HUB
SA−15
1996 RAV4 (RM447U)
7. INSTALL LOWER BALL JOINT
(a) Install the lower ball joint and torque the nut.
Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf)
(b) Install a new cotter pin.

SA0TD−04
SA−16
− SUSPENSION AND AXLEFRONT AXLE HUB
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−10).
AFTER INSTALLATION, CHECK ABS SPEED SENSOR SIGNAL (See page DI−257) AND FRONT
WHEEL ALIGNMENT (See page SA−4)

SA0TE−01
R10733
SST
R10759
− SUSPENSION AND AXLEFRONT WHEEL HUB BOLT
SA−17
1996 RAV4 (RM447U)
FRONT WHEEL HUB BOLT
REPLACEMENT
1. REMOVE FRONT WHEEL
2. REMOVE FRONT BRAKE CALIPER AND DISC
(a) Remove the 2 bolts and brake caliper from the steering
knuckle.
(b) Support the brake caliper securely and remove the disc.
3. REMOVE HUB BOLT
Using SST, remove the hub bolt.
SST 09628−10011
4. INSTALL HUB BOLT
(a) Install a washer and nut to the hub bolt, as shown in the
illustration.
(b) Install the hub bolt with torquing the nut.
5. INSTALL FRONT BRAKE DISC AND CALIPER
Install the disc and brake caliper with the 2 bolts.
Torque: 107 N·m (1,090 kgf·cm, 79 ft·lbf)
HINT:
Check the disc runout (See page BR−26).
6. INSTALL FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm 76 ft·lbf)

SA0TF−06
W04172
2WD M/T
Snap RingCenter Bearing Bracket
RH Drive Shaft
Snap RingABS Speed Sensor
Tie Rod End
Cotter Pin
Lock Cap LH Drive Shaft
Boot Clamp
Engine
Under
Cover
3 Door vehicle
64 (650, 47)
5 Door vehicle,
All over fender
vehicle
113 (1,150, 83)


32 (330, 24)
64 (650, 47)
8 (80, 69 in.·lbf)
49 (500, 36)
216 (2,200, 159)
127 (1,300, 94)
Lower Suspension Arm X6
X7
Center Drive Shaft Inner Race Ball Cage Stabilizer Bar Link
Snap Ring
Snap Ring
Dust Cover
Center Bearing Dust Cover
Inboard Joint Tulip Outboard Joint
Shaft No.2 Dust
DeflectorBoot




 
N·m (kgf·cm, ft·lbf)
: Specified torque
Non−reusable part
LH SA−18
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 RAV4 (RM447U)
FRONT DRIVE SHAFT
COMPONENTS

− SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA−19
1996 RAV4 (RM447U)

SA1YB−02
FA1535
SST
R10849
SA−20
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 RAV4 (RM447U)
REMOVAL
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the ve-
hicle with the drive shaft bearing removed.
Therefore if it is absolutely necessary to place the ve-
hicle weight on the hub bearing, first support it with
the SST.
SST 09608−16042 (09608−02021, 09608−02041)
w/ ABS:
After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage ABS speed sensor
rotor serrations on the drive shaft.
1. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. REMOVE ENGINE UNDER COVER
3. DRAIN GEAR OIL (M/T) OR ATF (A/T)
4. w/ABS:
REMOVE BOLT AND ABS SPEED SENSOR
Torque: 8 N·m (80 kgf·cm, 69 in.·lbf)
5. REMOVE COTTER PIN, LOCK CAP AND LOCK NUT
(a) Remove the cotter pin and lock cap.
(b) With applying the brakes, remove the nut.
Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf)
6. D I S C O N N E C T T I E R O D E N D F R O M S T E E R I N G
KNUCKLE (See page SA−10)
7. DISCONNECT STABILIZER BAR LINK FROM LOWER
SUSPENSION ARM
HINT:
If the ball joint turns together with the nut, use a 5 mm hexagon
wrench to hold the stud.
Torque:
3 Door vehicle
64 N·m (650 kgf·cm, 47ft·lbf)
5 Door vehicle and all over fender vehicle
113 N·m (1,150 kgf·cm, 83 ft·lbf)
8. DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM (See page SA−12)

R10840
W01206
2WD M/T RH
W01207
2WD A/T RH
W01208
2WD LH and 4WD RH
W01209
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA−21
1996 RAV4 (RM447U)
9. DISCONNECT DRIVE SHAFT FROM AXLE HUB
Using a plastic hammer, disconnect the drive shaft from the axle
hub.
NOTICE:
Be careful not to damage the inner oil seal and ABS speed
sensor rotor.
10. 2WD (M/T) RH:
REMOVE DRIVE SHAFT
NOTICE:
Be careful not to damage the dust cover and oil seal.
(a) Using a screwdriver and hammer, remove the snap ring
from the center bearing bracket.
(b) Remove the bolt from the center bearing bracket.
Torque: 32 N·m (330 kgf·cm, 24 ft·lbf)
(c) Remove the drive shaft with the center drive shaft.
HINT:
If it is hard to remove the bearing, use a brass bar and hammer
and drive flange end of the drive shaft.
(d) Remove the 2 bolts and center bearing bracket.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
11. 2WD (A/T) RH:
REMOVE DRIVE SHAFT
(a) Remove the 2 bolts of the center bearing bracket and pull
out the drive shaft together with the center bearing case
and center drive shaft.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
(b) Remove the center drive shaft with the drive shaft to the
transaxle through the center bearing bracket.
(c) Remove the 3 bolts and center bearing bracket.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
12. 2WD LH:
REMOVE DRIVE SHAFT
(a) Using a brass bar and hammer, remove the drive shaft.
(b) Using a screwdriver, remove the snap ring.
13. 4WD RH:
REMOVE DRIVE SHAFT
(a) Using a brass bar and hammer, remove the drive shaft.
(b) Using a screwdriver, remove the snap ring.
(c) Using a screwdriver, remove the O−ring.
14. 4WD LH:
REMOVE DRIVE SHAFT
(a) Remove the air cleaner.
(b) Remove the transmission case protector.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(c) Using a hub nut wrench or an equivalent, remove the
drive shaft.
(d) Using a screwdriver, remove the snap ring.

N00191
SA0TH−01
W01766
Matchmarks
W01210
Matchmarks
SA−22
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 RAV4 (RM447U)
DISASSEMBLY
1. 2WD M/T:
DISASSEMBLE DRIVE SHAFT
(a) Check the drive shaft.
(1) Check to see that there is no play in the outboard
joint.
(2) Check to see that the inboard joint slides smoothly
in the thrust direction.
(3) Check to see that there is no significant play in the
radial direction of the inboard joint.
(4) Check for damage to boots.
(b) Remove the inboard and outboard joint boot clamps.
(1) Using a screwdriver, remove the 2 inboard joint boot
clamps.
(2) Using a side cutter, cut the 2 outboard joint boot
clamps and remove them.
(c) Remove the inboard joint tulip (or center drive shaft)
(1) Place matchmarks on the inboard joint tulip or cen-
ter drive shaft and drive shaft.
NOTICE:
Do not punch the marks.
(2) Using a screwdriver, remove the snap ring.
(3) Remove the inboard joint tulip from the drive shaft.
(d) Disassemble the inboard joint.
(1) Place matchmarks on the drive shaft, inner race
and cage.
(2) Remove the 6 balls and cage.
(3) Using a snap ring expander, remove the snap ring.
(4) Using a brass bar and hammer, remove the inner
race.
NOTICE:
Be careful not to damage the inner race.
(5) Using a snap ring expander, remove the snap ring.
(e) Remove inboard and outboard joint boots and inboard
joint clamps. Slide out the 2 boots and clamps.
NOTICE:
Do not disassemble the outboard joint.