1996 TOYOTA RAV4 Service Repair Manual

SA0TJ−07
− SUSPENSION AND AXLEFRONT DRIVE SHAFT
SA−31
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order removal (See page SA−20).
AFTER INSTALLATION, CHECK ABS SPEED SENSOR SIGNAL (See page DI−257) AND FRONT
WHEEL ALIGNMENT (See page SA−4)
HINT:
Coat the oil seal lip with MP grease.
Except 2WD RH:
Before installing the drive shaft, set the snap ring opening side facing downward.
Except 2WD RH:
Whether or not the drive shaft is making contact with the pinion shaft can be known by sound or feeling
when driving it in.
Except 2WD RH:
After installation, check that there is 2 − 3 mm (0.08 − 0.12 in.) of play in axial direction.
Except 2WD RH:
After installation, check that the drive shaft can not be pulled out by hand.

SA0TK−03
Z19329
Suspension
Support
No.2
CapSpring Upper Seat
Spring
Bumper
Lower
Insulator
Shock Absorber Coil Spring Upper
Insulator
ABS Speed
Sensor Suspension
Support
Dust Seal Shock Absorber
with Coil Spring
Front Drive Shaft
Flexible Hose
Tie Rod End
Cotter Pin
Disc
Cotter Pin
Lock Cap
Lower Ball JointCotter Pin
Brake Caliper
Lower Suspension Arm80 (820, 59)
47 (475, 34)
5 (55, 48 in.·lbf)
158 (1,610, 117)
107 (1,090, 79)
127 (1,300, 94)
49 (500, 36)
216 (2,200, 159)
127 (1,300, 94)
19 (192, 14)
8 (80, 69 in.·lbf)
Dust Deflector
 

 
N·m (kgf·cm, ft·lbf): Specified torque
Non−reusable part
SA−32
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 RAV4 (RM447U)
FRONT SHOCK ABSORBER
COMPONENTS

SA0TL−03
R10850
R10823
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA−33
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. DISCONNECT FLEXIBLE HOSE AND ABS SPEED
SENSOR WIRE HARNESS (w/ ABS) FROM SHOCK
ABSORBER
Remove the 2 bolts and disconnect the flexible hose and ABS
speed sensor wire harness.
Torque:
Flexible hose: 19 N·m (192 kgf·cm, 14 ft·lbf)
ABS wire harness: 5 N·m (55 kgf·cm, 48 in.·lbf)
3. DISCONNECT SHOCK ABSORBER FROM STEERING
KNUCKLE
Torque: 158 N·m (1,610 kgf·cm, 117 ft·lbf)
HINT:
At the time of installation, please refer to the following item.
Coat the nut’s threads with engine oil.
4. REMOVE SHOCK ABSORBER WITH COIL SPRING
Remove the 3 nuts, suspension support No.2 and shock ab-
sorber with the coil spring.
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)

SA0TM−01
R10824
SST Vinyl
Tape
R10825
SST SA−34
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 RAV4 (RM447U)
DISASSEMBLY
REMOVE COIL SPRING
(a) Install 2 nuts and a bolt to the bracket at the lower portion
of the shock absorber and secure it in a vise.
(b) Using SST, compress the coil spring.
SST 09727−30021
HINT:
To prevent the coil spring from damaging, wind vinyl tape on the
coil spring.
NOTICE:
When holding the shock absorber with the coil spring
removed, do not hold it by the spring lower seat. Also,
do not knock the spring lower seat.
Do not use an impact wrench. It will damage the SST.
(c) Remove the cap.
(d) Using SST to hold the spring upper seat, remove the nut.
SST 09729−22031
(e) Remove these parts from the shock absorber:
Suspension support
Dust seal
Spring upper seat
Upper insulator and coil spring
Spring bumper and lower insulator

SA0TN−01
N00203
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA−35
1996 RAV4 (RM447U)
INSPECTION
INSPECT SHOCK ABSORBER
Compress and extend the shock absorber rod and check that
there is no abnormal resistance or unusual operation sounds.
If there is any abnormality, replace the shock absorber with a
new one.
NOTICE:
When discarding the shock absorber, see DISPOSAL on
page SA−36.

SA0TO−01
N00204
SA−36
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 RAV4 (RM447U)
DISPOSAL
1. FULLY EXTEND SHOCK ABSORBER ROD
2. DRILL HOLE TO REMOVE GAS FROM CYLINDER
Using a drill, make a hole between the lines, as shown.
CAUTION:
The gas coming out is harmless, but be careful of chips
which may fly up when drilling.

SA0TP−01
R10846
SST
Vinyl Tape
R10826
R10825
SST
R10848
MP Grease
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA−37
1996 RAV4 (RM447U)
REASSEMBLY
1. INSTALL LOWER INSULATOR ONTO SHOCK AB-
SORBER
2. INSTALL SPRING BUMPER TO PISTON ROD
3. INSTALL COIL SPRING AND SUSPENSION SUPPORT
(a) Using SST, compress the coil spring.
SST 09727−30021
HINT:
To prevent the coil spring from damaging, wind vinyl tape on the
coil spring.
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Install the coil spring to the shock absorber.
HINT:
Fit the lower end of the coil spring into the gap of lower spring
seat of the shock absorber.
(c) Align the tab of spring upper seat with the tabs of the up-
per insulator.
(d) Install the spring upper seat with upper insulator to the
shock absorber with the ’OUT’ mark facing the outside of
the vehicle.
(e) Install the dust seal and suspension support.
(f) Using SST to hold the spring upper seat, install a new nut.
SST 09729−22031
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)
(g) Remove the SST.
(h) Pack MP grease into the suspension support.
(i) Install the cap.

SA0TQ−01
SA−38
− SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−33).
AFTER INSTALLATION, CHECK FRONT WHEEL ALIGNMENT (See page SA−4)