1996 TOYOTA RAV4 Service Repair Manual

Z03002
R09716
SST
Z02991
SST
Z03006
R11387
w/o ABS w/ ABS
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA−23
1996 RAV4 (RM447U)
(f) RH:
Remove the dust cover.
Using a press, remove the dust cover from the center
drive shaft.
(g) LH:
Remove the dust cover.
Using SST and a press, remove the dust cover from the
inboard joint tulip.
SST 09950−00020
(h) Remove the bearing.
(1) Using SST and a press, remove the dust cover from
the center drive shaft.
SST 09950−00020
(2) Using a snap ring expander, remove the snap ring.
(3) Using a press, remove the bearing.
(4) Remove the snap ring.
(i) Remove the No.2 dust defector.
(1) Mount outboard joint shaft in a soft jaw vise.
(2) Using a screwdriver and hammer, remove the No.2
dust deflector.
NOTICE:
Be careful not to damage the ABS speed sensor rotor.

N00191
FA1615
Matchmarks
N00194
Matchmarks
SA1446
SA−24
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 RAV4 (RM447U)
2. 2WD A/T and 4WD:
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.
Using a screwdriver, remove the 4 boot clamps.
(c) Remove the inboard joint tulip (or center drive shaft).
(1) Place matchmarks on the tripod, inboard joint tulip
or center drive shaft and drive shaft.
NOTICE:
Do not punch the marks.
(2) Remove the inboard joint tulip from the drive shaft.
(d) Remove the tripod.
(1) Using a snap ring expander, remove the snap ring.
(2) Place matchmarks on the drive shaft and tripod.
(3) Using a brass bar and hammer, remove the tripod
from the drive shaft.
(e) Remove the inboard and outboard joint boots and
clamps.
Slide out the 2 boots and 4 clamps.
NOTICE:
Do not disassemble the out board joint.
(f) 2WD RH:
Remove the dust cover.
Using a press, remove the dust cover from the center
drive shaft.

R09716
SST
SA1448
SA1449
SST
SA1451
R11387
w/o ABS w/ ABS
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA−25
1996 RAV4 (RM447U)
(g) 2WD LH and 4WD:
Remove the dust cover.
Using SST and a press, remove the dust cover from the
inboard joint tulip.
SST 09950−00020
(h) 2WD RH:
Disassemble the center drive shaft.
(1) Using a screwdriver, remove the snap ring.
(2) Using a press, remove the bearing case.
(3) Using a pin punch and hammer, remove the straight
pin from the bearing case.
(4) Using SST and a press, remove the dust cover.
SST 09950−00020
(5) Using a snap ring expander, remove the snap ring.
(6) Using a press, remove the bearing.
(i) Remove the No.2 dust deflector.
(1) Mount outboard joint shaft in a soft jaw vise.
(2) Using a screwdriver and hammer, remove the No.2
dust deflector.
NOTICE:
Be careful not to damage the ABS speed sensor rotor.

F01439
w/o ABS w/ ABS
SST
SA0TI−02
R10042
W01211
1.0 mm
(0.039 in.)
W01212
105.0 − 106.0 mm
(4.134 − 4.173 in.)
W01765
SA−26
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 RAV4 (RM447U)
REASSEMBLY
1. 2WD M/T:
REASSEMBLE DRIVE SHAFT
(a) Install No.2 dust deflector.
Using SST and a press, install a new No.2 dust deflector.
SST 09309−36010, 09316−20011
(b) Install the bearing.
(1) Install a new snap ring.
(2) Using a press, install the bearing.
(3) Using a snap ring expander, install a new snap ring.
(4) Using a press, install a new dust cover.
HINT:
The clearance between the dust cover and bearing should be
kept in the ranges shown in the illustration.
(c) RH:
Install the dust cover.
Using a press, install a new dust cover until the distance
from the tip of the center drive shaft reaches the specifica-
tion, as shown in the illustration.
(d) LH:
Install the dust cover.
Using a press, install a new dust cover.

W01994
Vinyl Tape
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA−27
1996 RAV4 (RM447U)
(e) Temporarily the install new outboard and inboard joint
boots and new boot clamps.
HINT:
Before installing the 2 boots, wrap vinyl tape around the spline
of the drive shaft to prevent damaging the boots.
(1) Place 2 new clamps on a new outboard joint boot
and install the boot to the drive shaft.
(2) Temporarily install a new inboard joint boot to the
drive shaft.
(f) Assembly the inboard joint.
(1) Using a snap ring expander, install a new snap ring.
(2) Install the cage to the drive shaft.
NOTICE:
The side with smaller diameter must face outboard.
(3) Align the matchmarks placed before disassembly.
(4) Using a brass bar and hammer, tap in the inner race
to the drive shaft.
NOTICE:
Be careful not to damage the inner race.
(5) Using a snap ring expander, install a new snap ring.
(g) Install the boot to outboard joint.
Before assembling the boot, pack the outboard joint and
boot with grease in the boot kit.
HINT:
Use the grease supplied in the boot kit.
Grease capacity (Color = Black):
115 − 135 g (4.1 − 4.8 oz.)
(h) Install the inboard joint tulip (or center drive shaft) to front
drive shaft.
(1) Pack the inboard joint and boot with grease in the
boot kit.
HINT:
Use the grease supplied in the boot kit.
Grease capacity (Color = Yellow ocher):
115 − 135 g (4.1 − 4.8 oz.)
(2) Align the matchmarks placed before removal, and
install the cage to the inner race.
(3) Install the 6 balls.
HINT:
Apply grease onto the balls to keep them from falling.
(4) Align the matchmarks placed before assembly, and
install the inboard joint tulip or center drive shaft to
the drive shaft.
(5) Install a new snap ring.
(6) Temporarily install the boot to the inboard joint tulip.
(i) Assemble the boot clamps to both boots.
(1) Make sure that the 2 boots are on the shaft groove.

W01213
RH
LH
R10353
SST
F01439
w/o ABS w/ ABS
SST
SA1453
W00880
SST SA−28
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 RAV4 (RM447U)
(2) Make sure that the 2 boots are not stretched or con-
tracted when the drive shaft is at standard length.
Drive shaft standard length:
RH842.9 ± 5.0 mm (33.185 ± 0.197 in.)
LH542.6 ± 5.0 mm (21.362 ± 0.197 in.)
(3) Place 2 new boot clamps to the inboard joint boot.
(4) Bend the band and lock it with a screwdriver.
(5) Secure the 2 clamps onto the boot.
(6) Place SST onto the clamps.
SST 09521−24010
(7) Tighten the SST so that the clamps.
NOTICE:
Do not overtighten the SST.
(8) Using SST, adjust the clearance of the clamps.
SST 09240−00020
Clearance: 1.9 mm (0.075 in.)
2. 2WD A/T and 4WD:
REASSEMBLE DRIVE SHAFT
(a) Install the No.2 dust deflector.
Using SST and a press, install a new No.2 dust deflector.
SST 09309−36010, 09316−20011
(b) 2WD RH:
Assemble the center drive shaft.
(1) Using a pin punch and hammer, install the straight
pin into the bearing case.
(2) Using SST and a press, install a new bearing into
the bearing case.
SST 09950−60010 (09951−00580),
09950−70010 (09951−07150)
(3) Using a screwdriver, install a new snap ring.

SA1456
SST
FA1971
SST 1.0 mm
(0.039 in.)
FA1889
86 − 87 mm
(3.39 − 3.43 in.)
SA1459
RA1310
Vinyl Tape
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA−29
1996 RAV4 (RM447U)
(4) Using SST and a press, install the bearing with the
bearing case assembly to the center drive shaft.
SST 09710−30021 (09710−03141)
(5) Using a snap ring expander, install a new snap ring.
(6) Using SST, an extension bar and press, install a
new dust cover.
SST 09506−35010
HINT:
The clearance between the dust cover and bearing should be
kept in the ranges shown in the illustration.
(c) 2WD RH:
Install the dust cover.
Using a steel plate and press, install a new dust cover until
the distance from the tip of the center drive shaft to the
dust cover reaches the specification, as shown in the il-
lustration.
(d) 2WD LH and 4WD:
Install the dust cover.
Using a press, install a new dust cover.
(e) Temporarily install the new outboard and inboard joint
boots.
HINT:
Before installing the 2 boots, wrap vinyl tape around the spline
of the drive shaft to prevent damaging the boots.
(1) Temporarily install a new outboard joint boot to the
drive shaft.
(2) Temporarily install a new inboard joint boot to the
drive shaft.
(f) Install the tripod.

W01214
2WD A/T RH
Others SA−30
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
1996 RAV4 (RM447U)
(1) Place the beveled side of the tripod axial spline to-
ward the outboard joint.
(2) Align the matchmarks placed before removal.
(3) Using a brass bar and hammer, tap in the tripod to
the drive shaft.
NOTICE:
Do not tap the roller.
(4) Using a snap ring expander, install a new snap ring.
(g) Install the boot to outboard joint.
Before assembling the boot, pack the outboard joint and
boot with grease in the boot kit.
HINT:
Use the grease supplied in the boot kit.
Grease capacity (Color = Black):
120 − 130 g (4.2 − 4.6 oz.)
(h) Install the inboard joint tulip or center drive shaft to front
drive shaft.
(1) Pack the inboard joint and boot with grease in the
boot kit.
HINT:
Use the grease supplied in the boot kit.
Grease capacity (Color = Yellow ocher):
180 − 190 g (6.3 − 6.7 oz.)
(2) Align the matchmarks placed before removal, and
install the inboard joint tulip on center drive shaft to
the drive shaft.
(3) Temporarily install the boot to the inboard joint tulip.
(i) Assemble the boot clamps to both boots.
(1) Make sure that the 2 boots are on the shaft groove.
(2) Make sure that the 2 boots are not stretched or con-
tracted when the drive shaft is at standard length.
Drive shaft standard length:
2WD A/T RH844.6 ± 5.0 mm (33.252 ± 0.197 in.)
2WD A/T LH548.5 ± 5.0 mm (21.594 ± 0.197 in.)
4WD RH511.2 ± 5.0 mm (20.126 ± 0.197 in.)
4WD LH508.0 ± 5.0 mm (20.000 ± 0.197 in.)
(3) Place 4 new boot clamps to the 2 boots.
(4) Bend the band and lock it with a screwdriver.