1996 TOYOTA RAV4 Service Repair Manual

SA0UI−03
Z17371
Rear Drive Shaft
Propeller Shaft
: Specified torqueRear DifferentialRear Mount Cushion
56 (570, 41)
137 (1,400, 101)
74 (750, 54)
56 (570, 41)
65 (660, 48)
132 (1,350, 98)
N·m (kgf·cm, ft·lbf)Rear Drive Shaft
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−71
1996 RAV4 (RM447U)
REAR DIFFERENTIAL CARRIER
COMPONENTS

F03751
2 PINION DEFERENTIAL
TORQUE SENSING LSD
Thrust Washer
Straight Pin
Pinion Shaft
Thrust Washer Side Gear
Pinion Gear
Plate WasherPlate Washer
Side Bearing
Ring Gear
Drive Pinion
Rear Bearing
Differential Case
Lock Plate

Plate Washer
97 (985, 71)



Side Bearing
Oil Deflector
Bearing Cap
Differential
Carrier CoverX87.4 (75, 65 in.·lbf)
78 (800, 58)
Snap Ring

Oil Seal 
Dust Cover 
Gasket

Drain Plug
49 (500, 36)
Differential
Carrier
Bearing Spacer
Oil Seal Side Gear Shaft
Companion FlangeSnap Ring


Dust Deflector

Oil Slinger
Front Bearing

Dust Cover 
Oil Seal 
Gasket

49 (500, 36)
Filler Plug
N·m (kgf·cm, ft·lbf)
Non−reusable part: Specified torque

Snap Ring 
See page SA−79
47 (475, 34)
SA−72
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)

SA0UJ−01
W04156
R10756
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−73
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE DRIVE SHAFTS (See page SA−62)
HINT:
Support the drive shafts securely.
2. REMOVAL PROPELLER SHAFT (See page PR−2)
HINT:
Support the propeller shaft securely.
3. DRAIN DIFFERENTIAL OIL
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
4. REMOVE DIFFERENTIAL
(a) Support the differential with a jack.
(b) Remove the 2 rear mounting bolts.
Torque: 65 N·m (660 kgf·cm, 48 ft·lbf)
(c) Remove the 2 front mounting bolts and differential.
Torque: 132 N·m (1,350 kgf·cm, 98 ft·lbf)
(d) Remove the 2 bolts and differential rear mount cushion
from the differential.
Torque: 137 N·m (1,400 kgf·cm, 101 ft·lbf)

SA0UK−01
R10640
R10650
F03752
Hold
R10645
SA−74
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE DIFFERENTIAL CARRIER COVER
(a) Remove the 8 bolts from the carrier cover.
(b) Using a brass bar and hammer, separate the cover and
carrier.
2. CHECK RUNOUT OF COMPANION FLANGE
Using a dial indicator, measure the runout of the companion
flange vortically and horizontally.
Maximum runout: 0.10 mm (0.0039 in.)
3. CHECK RING GEAR RUNOUT
Using a dial indicator, check the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 in.)
If the runout is greater than the maximum, replace with a new
ring gear.
4. CHECK RING GEAR BACKLASH
Using a dial indicator, check the backlash of the ring gear.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
If the backlash is not within the specification, adjust the side
bearing preload or repair as necessary.
5. CHECK TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA−79)
6. 2 PINION DIFFERENTIAL:
CHECK SIDE GEAR BACKLASH
Using a dial indicator, check the backlash of the side gear with
holding 1 pinion gear toward the differential case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within the specification, install the 2 side
gear thrust washers of different thickness (See page SA−79).

R10641
R10660
SST
R10788
SST
R10662
SST
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−75
1996 RAV4 (RM447U)
7. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the backlash
between the drive pinion and ring gear.
Preload (at starting):
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
8. CHECK TOTAL PRELOAD
Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus
0.3 − 0.5 N·m (3 − 5 kgf·cm, 2.6 − 4.3 in.·lbf)
If necessary, disassemble and inspect the differential.
9. 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)
10. REMOVE FRONT OIL SEAL AND OIL SLINGER
(a) Using SST, remove the oil seal from the housing.
SST 09308−10010
(b) Remove the oil slinger.

R10663
SST
R10664
SST
R10757
R10665
SST
F03753
Matchmarks
SA−76
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
11. REMOVE FRONT BEARING AND BEARING SPACER
(a) Using SST, remove the front bearing from the drive pinion.
SST 09556−22010
(b) Remove the bearing spacer.
12. Torque Sensing LSD:
REMOVE SIDE GEAR SHAFTS
(a) Using SST, remove the 2 side gear shafts from the differ-
ential.
SST 09520−24010
(b) Using a screwdriver, remove the 2 snap rings from the 2
side gear shafts.
13. 2 Pinion Differential:
REMOVE SIDE GEAR SHAFTS
(a) Using needle nose pliers, remove the 2 snap rings from
the 2 side gear shafts.
(b) Remove the 2 side gear shafts.
14. REMOVE SIDE GEAR SHAFT OIL SEALS
Using SST, remove the 2 oil seals from the housing.
SST 09308−00010
15. REMOVE DIFFERENTIAL CASE
(a) Place matchmarks on the bearing cap and differential car-
rier.
(b) Remove the 4 bolts and 2 bearing caps.

F03754
SST
R10668
SST
R10669
Front Rear
F03755
Matchmarks
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−77
1996 RAV4 (RM447U)
(c) Using SST and a hammer, remove the 2 plate washers.
SST 09504−22011
HINT:
Measure the plate washer and note down the thickness.
(d) Remove the differential case and 2 bearing outer races
from the carrier.
HINT:
Tag the 2 bearing outer races to show the location for reassem-
bling.
16. REMOVE DRIVE PINION FROM DIFFERENTIAL CAR-
RIER
17. REMOVE DRIVE PINION REAR BEARING
(a) Using SST and a press, remove the bearing from the drive
pinion.
SST 09950−00020
HINT:
If the drive pinion or ring gear are damaged, replace them a set.
(b) Remove the plate washer.
18. REMOVE FRONT AND REAR BEARING OUTER
RACES
Using a brass bar and hammer, remove the 2 outer races from
the carrier.
19. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Using a screwdriver and hammer, unstake the 4 lock
plates.
(c) Remove the 8 ring gear set bolts and 4 lock plates.
(d) Using a plastic hammer, tap on the ring gear to separate
it from the differential case.

F03756
SST
R07223
Z13195
SA−78
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
20. REMOVE SIDE BEARINGS
Using SST and a press, remove the 2 side bearings from the
differential case.
SST 09950−00020
NOTICE:
Be careful not to drop the differential case.
21. 2 Pinion Differential Only:
DISASSEMBLE DIFFERENTIAL CASE
NOTICE:
If equipped with Torque Sensing LSD, do not disassemble
the differential case.
(a) Using a pin punch and hammer, remove the straight pin.
(b) Remove these parts from the differential case:
Pinion shaft
2 pinion gears
2 pinion gear thrust washers
2 side gears
2 side gear thrust washers