1996 TOYOTA RAV4 Service Repair Manual

R10987Screw Extractor
SR0F2−01
− STEERINGNON−TILT STEERING COLUMN
SR−15
1996 RAV4 (RM447U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. REMOVE STEERING COLUMN UPPER BRACKET
AND STEERING COLUMN UPPER CLAMP
(a) Using a centering punch, mark the center of the 2 ta-
pered−head bolts.
(b) Using a 3−4 mm (0.12−0.16 in.) drill, drill into the 2 bolts.
(c) Using a screw extractor, remove the 2 bolts.
2. REMOVE STEERING MAIN SHAFT ASSEMBLY
(a) Using snap ring expander, remove the snap ring from the
shaft assembly.
(b) Tap out the shaft assembly from the steering column tube.
(c) Using snap ring expander, remove the snap ring from the
shaft assembly.

W01114
SR0F3−03
W01115
ACC
W04213
W04212
SR−16
− STEERINGNON−TILT STEERING COLUMN
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT STEERING LOCK OPERATION
Check that the steering lock mechanism operates properly.
2. IF NECESSARY, REPLACE IGNITION KEY CYLINDER
(a) Place the ignition key at the ACC position.
(b) Using a screwdriver, push down the stop pin of the cylin-
der, and pull it out.
(c) Install a new key cylinder.
HINT:
Make sure that the ignition key is at the ACC position.
3. INSPECT IGNITION SWITCH (See page BE−11)
4. IF NECESSARY, REPLACE IGNITION SWITCH
(a) Remove the 2 screws.
(b) Install a new switch with the 2 screws.
5. INSPECT KEY UNLOCK WARNING SWITCH
(See page BE−11)
6. IF NECESSARY, REPLACE KEY UNLOCK WARNING
SWITCH
(a) Remove the 2 screws.
(b) Install a new switch with the 2 screws.
7. IF NECESSARY, REPLACE STEERING MAIN SHAFT
BUSHING
(a) Using a screwdriver, loosen the 3 projections of the bush-
ing, and remove the bushing from the steering column
tube.
(b) Coat the inside of a new bushing with molybdenum disul-
fide lithium base grease.
(c) Align the projections on the bushing with the holes in the
column tube, then install the bushing until the projections
are firmly engaged in the holes.

W01135
Non−tilt Steering Column :
Bearing
Tilt Steering Column :
Bearing
W00088
− STEERINGNON−TILT STEERING COLUMN
SR−17
1996 RAV4 (RM447U)
8. INSPECT BEARING
(a) Check the bearing rotation condition and check for abnor-
mal noise.
If the bearing is worn or damaged, replace the steering column
tube.
(b) Coat the bearing with molybdenum disulfide lithium base
grease.
9. Tilt Steering Column:
INSPECT BEARING
Check the bearing of the steering main shaft rotation condition
and check for abnormal noise.
10. Tilt Steering Column:
IF NECESSARY, REPLACE BEARING
(a) Remove the bearing from the steering main shaft.
(b) Coat a new bearing with molybdenum disulfide lithium
base grease.
(c) Install the bearing.

SR0F4−01
W01201
SR−18
− STEERINGNON−TILT STEERING COLUMN
1996 RAV4 (RM447U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. INSTALL STEERING MAIN SHAFT ASSEMBLY
(a) Using snap ring expander, install a new snap ring to the
shaft assembly.
(b) Install the shaft assembly into the steering column tube.
(c) Using snap ring expander, install a new snap ring to the
shaft assembly.
2. INSTALL STEERING COLUMN UPPER BRACKET
AND COLUMN UPPER CLAMP
(a) Install the bracket with 2 new tapered−head bolts.
HINT:
Insert the bracket pin into the column tube hole.
(b) Tighten the tapered−head bolts until the bolt heads
breaks off.

SR0F5−03
W02018
− STEERINGNON−TILT STEERING COLUMN
SR−19
1996 RAV4 (RM447U)
INSTALLATION
1. Tilt Steering Column:
CONNECT SLIDING YOKE
(a) Align the matchmarks on the main shaft and sliding yoke,
and connect them.
(b) Torque the bolt.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
2. Non−Tilt Steering Column:
INSTALL STEERING COLUMN ASSEMBLY
(a) Temporarily tighten the 2 column assembly set bolts and
2 nuts.
(b) Connect the connectors.
3. Tilt Steering Column:
INSTALL STEERING COLUMN ASSEMBLY
(a) Torque the 2 column assembly set bolts and 2 nuts.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(b) Connect the connectors.
4. INSTALL STEERING COLUMN PROTECTOR
Torque the bolt.
Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf)

W02017
Non−tilt Steering Column :
Tilt−Steering Column :
MatchmarksBA
SR−20
− STEERINGNON−TILT STEERING COLUMN
1996 RAV4 (RM447U)
5. Non−Tilt Steering Column:
INSTALL NO.2 INTERMEDIATE SHAFT
(a) Connect the No.2 intermediate shaft to the main shaft.
(b) Temporarily tighten the bolt A.
6. Tilt Steering Column:
INSTALL No.2 INTERMEDIATE SHAFT
(a) Connect the No.2 intermediate shaft to the sliding yoke.
(b) Temporarily tighten the bolt A.
7. CONNECT NO.2 INTERMEDIATE SHAFT
(a) Align the matchmarks on the No.2 intermediate shaft and
control valve shaft, and connect them.
(b) Torque the bolt B.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
(c) Torque the bolt A.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
8. INSTALL SPIRAL CABLE (See page BE−14)
9. INSTALL COMBINATION SWITCH WITH SPIRAL
CABLE
(a) Tighten the 3 screws.
(b) Connect the connectors.
(c) Connect the airbag connector.
10. INSTALL NO.2 HEATER TO REGISTER DUCT
11. Non−Tilt Steering Column:
INSTALL UPPER AND LOWER COLUMN COVERS
(a) Install the protector to the lower cover and tighten the 3
screws.
(b) Tighten the 3 screws.
(c) Torque the 2 column assembly set bolts and 2 nuts.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
12. Tilt Steering Column:
INSTALL UPPER AND LOWER COLUMN COVERS
(a) Install the protector to the lower cover and tighten the 3
screws.
(b) Tighten the 3 screws.
13. INSTALL INSTRUMENT PANEL LOWER INSERT
Tighten the 3 screws.
14. INSTALL LOWER FINISH PANEL
(a) Tighten the 2 panel set bolts.
(b) Connect the hood lock control lever with the 2 screws.
15. CENTER SPIRAL CABLE
(a) Check that the front wheels are facing straight ahead.
(b) Turn the cable counterclockwise until it locks.
(c) Then rotate the cable clockwise about 2.5 turns to left of
the center.
HINT:
The spiral cable rotates approx. 5 turns maximum.

− STEERINGNON−TILT STEERING COLUMN
SR−21
1996 RAV4 (RM447U)
16. INSTALL STEERING WHEEL
(a) Align the matchmarks on the wheel and steering main
shaft assembly.
(b) Torque the wheel set nut.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
(c) Connect the airbag connector.
17. INSTALL STEERING WHEEL PAD
NOTICE:
Make sure that the pad is installed to the specified
torque.
If the pad has been dropped, or there are cracks,
dents or other defects in the case or connector, re-
place the wheel pad with a new one.
When installing the pad, take care that the wiring
does not interfere with other parts and is not pinched
between other parts.
(a) Connect the airbag connector.
(b) Install the pad after confirming that the circumference
groove of the torx screws are caught on the screw case.
(c) Using a torx socket wrench, torque the 2 screws.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(d) Install the steering wheel lower No.2 and No.3 covers.
18. CHECK STEERING WHEEL CENTER POINT

SR0F6−03
SR−22
− STEERINGTILT STEERING COLUMN
1996 RAV4 (RM447U)
TILT STEERING COLUMN
COMPONENTS