1996 TOYOTA RAV4 Service Repair Manual

SA0UD−01
Z12871
Z12368
Matchmarks
N00194
Matchmarks
− SUSPENSION AND AXLEREAR DRIVE SHAFT
SA−63
1996 RAV4 (RM447U)
DISASSEMBLY
1. CHECK DRIVE SHAFT
(a) Check to see that there is no play in the outboard joint.
(b) Check to see that the inboard joint slides smoothly in the
thrust direction.
(c) Check to see that there is no noticeable play in the radial
direction of the inboard joint.
(d) Check for damage to the boots.
2. REMOVE INBOARD AND OUTBOARD JOINT BOOT
CLAMPS
Using a screwdriver, remove the 4 boot clamps.
3. REMOVE INBOARD JOINT TULIP
(a) Place matchmarks on the inboard joint tulip and drive
shaft.
NOTICE:
Do not punch the marks.
(b) Remove the inboard joint tulip from the drive shaft.
4. REMOVE TRIPOD
(a) Using a snap ring expander, remove the snap ring.
(b) Place matchmarks on the shaft and tripod.
NOTICE:
Do not punch the marks.
(c) Using a brass bar and hammer, remove the tripod from
the drive shaft.
NOTICE:
Do not tap the roller.
5. REMOVE INBOARD AND OUTBOARD JOINT BOOTS
AND CLAMPS
Slide out the 2 boots and 4 clamps.
NOTICE:
Do not disassemble the outboard joint.

R11387
w/o ABS w/ ABS SA−64
− SUSPENSION AND AXLEREAR DRIVE SHAFT
1996 RAV4 (RM447U)
6. REMOVE NO.2 DUST DEFLECTOR
Using a screwdriver and hammer, remove the No.2 dust deflec-
tor.

SA0UE−05
F01439
w/o ABS w/ ABS
SST
RA1310
Vinyl Tape
− SUSPENSION AND AXLEREAR DRIVE SHAFT
SA−65
1996 RAV4 (RM447U)
REASSEMBLY
1. INSTALL NEW NO.2 DUST DEFLECTOR
Using SST and a press, install a new No.2 dust deflector.
SST 09309−36010, 09316−20011
NOTICE:
Be careful not to damage the ABS speed sensor rotor.
2. TEMPORARILY INSTALL NEW OUTBOARD AND IN-
BOARD JOINT BOOTS
HINT:
Before installing the 2 boots, wrap vinyl tape around the spline
of the drive shaft to prevent damaging the boots.
(a) Temporarily install a new outboard joint boot to the drive
shaft.
(b) Temporarily install a new inboard joint boot to the drive
shaft.
3. INSTALL TRIPOD
(a) Place the beveled side of the tripod axial spline toward the
outboard joint.
(b) Align the matchmarks placed before removal.
(c) Using a brass bar and hammer, tap in the tripod to the
drive shaft.
NOTICE:
Do not tap the roller.
(d) Using a snap ring expander, install a new snap ring.
4. INSTALL INBOARD JOINT TULIP
(a) 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.)
(b) Align the matchmarks placed before removal, and install
the inboard joint tulip to the drive shaft.
5. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
(a) Before assembling the boot, pack the outboard joint and
boot with grease in the boot kit.
Use the grease supplied in the boot kit.
Grease capacity (Color = Black):
100 − 110 g (3.5 − 3.9 oz.)
(b) Make sure that the 2 boots are on the shaft groove.

Z13445
SA−66
− SUSPENSION AND AXLEREAR DRIVE SHAFT
1996 RAV4 (RM447U)
(c) Make sure that the 2 boots are not stretched or contracted
when the drive shaft is at standard length.
Standard length:
RH599.4 ± 5.0 mm (23.598 ± 0.197 in.)
LH553.4 ± 5.0 mm (21.787 ± 0.197 in.)
(d) Place 4 new boot clamps to the 2 boots.
(e) Bend the band and lock it with a screwdriver.

SA0UF−07
− SUSPENSION AND AXLEREAR DRIVE SHAFT
SA−67
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−62).
AFTER INSTALLATION, CHECK ABS SPEED SENSOR SIGNAL (See page DI−257)

SA0UG−01
W04154
Filer Plug
Companion Flange
Oil Slinger
Oil Seal
Front BearingBearing Spacer
Drain PlugGasket
Propeller Shaft
49 (500, 36)
49 (500, 36)
74 (750, 54)
 Gasket 

N·m (kgf·cm, ft·lbf)
: Specified torque
Non−reusable part
See page SA−79
SA−68
− SUSPENSION AND AXLEREAR DIFFERENTIAL FRONT OIL SEAL
1996 RAV4 (RM447U)
REAR DIFFERENTIAL FRONT OIL SEAL
COMPONENTS

SA0UH−01
R10762
SST
R10742
SST
R10743
SST
R10744
SST
− SUSPENSION AND AXLEREAR DIFFERENTIAL FRONT OIL SEAL
SA−69
1996 RAV4 (RM447U)
REPLACEMENT
1. REMOVE PROPELLER SHAFT (See page PR−3)
2. REMOVE COMPANION FLANGE
(a) Using a chisel and hammer, unstake the staked part of the
nut.
(b) Using SST to hold the flange, remove the nut.
SST 09330−00021
(c) Using SST, remove the companion flange.
SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03040, 09956−03020)
3. REMOVE FRONT OIL SEAL AND OIL SLINGER
(a) Using SST, remove the oil seal.
SST 09308−10010
(b) Remove the oil slinger.
4. REMOVE FRONT BEARING AND BEARING SPACER
(a) Using SST, remove the front bearing.
SST 09556−22010
(b) Remove the bearing spacer.
5. INSTALL NEW BEARING SPACER AND FRONT
BEARING
(a) Install a new bearing spacer on the shaft.
(b) Install the front bearing on the shaft.
6. INSTALL OIL SLINGER AND NEW OIL SEAL
(a) Install the oil slinger.

W01215
SST
R10775
SST
R10762
SST
R10763
Less that 5 mm (0.20 in.) SA−70
− SUSPENSION AND AXLEREAR DIFFERENTIAL FRONT OIL SEAL
1996 RAV4 (RM447U)
(b) Using SST, install a new oil seal.
SST 09554−22010
Oil seal drive in depth: 2.0 mm (0.079 in.)
(c) Apply MP grease to the oil seal lip.
7. INSTALL COMPANION FLANGE
(a) Using SST, install the companion flange on the shaft.
SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03040, 09956−03020)
(b) Coat the threads of a new nut with hypoid gear oil.
(c) Using SST to hold the flange, torque the nut.
SST 09330−00021
Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf)
(d) Adjust the preload of bearing on drive pinion (See page
SA−79).
8. STAKE DRIVE PINION NUT
9. INSTALL PROPELLER SHAFT (See page PR−2)
10. FILL DIFFERENTIAL WITH DIFFERENTIAL OIL
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
Oil grade: Hypoid gear oil API GL−5
Recommended oil viscosity:
Above −18°C (0°F) SAE 90
Below −18°C (0°F) SAE 80W or 80W−90
Capacity: 0.9 liter (1.0 US qts, 0.8 lmp. qts)