1996 TOYOTA RAV4 shift

MX02F−04
Q06204
Front
Q06205
SST Align the holes
Z00225
Q06206
SST
− MANUAL TRANSAXLEOUTPUT SHAFT
MX−41
1996 RAV4 (RM447U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE
(a) Install the 3 springs and shifting keys to the clutch hub.
(b) Install the hub sleeve to the clutch hub.
HINT:
Direct identification groove of the hub sleeve to the front of the
transmission.
2. INSTALL 1ST GEAR BEARING INNER RACE
Using SST and a press, install the 1st gear bearing inner race.
SST 09506−35010
HINT:
Align the hole of the output shaft and inner race.
3. INSTALL NEEDLE ROLLER BEARING, 1ST GEAR,
SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO
OUTPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Install the 1st gear.
(c) Place the synchronizer ring (for the 1st gear) on the gear
and align the ring slots with the shifting keys.
(d) Using SST and a press, install the 1st gear and No.1 hub
sleeve.
SST 09316−60011 (09316−00041)
4. MEASURE 1ST GEAR THRUST CLEARANCE
(See page MX−37)

MX02I−02
Q06217
Shift Interlock Plate
Transmission Oil Baffle Shift Interlock Plate
No.1 Compression SpringControl Shaft Cover
Oil Seal
Snap Ring
No.1 Select Spring Seat
Slotted Spring Pin
No.1 Shift Inner Lever
Shift and Select Lever Shaft Snap Ring
Non−reusable part No.2 Select Spring SeatNo.2 Compression SpringNo.2 Shift Inner LeverSlotted Spring Pin
Apply MP grease 
Dust Boot
 MX−48
− MANUAL TRANSAXLESHIFT AND SELECT LEVER SHAFT
1996 RAV4 (RM447U)
SHIFT AND SELECT LEVER SHAFT
COMPONENTS

MX0C0−02
Q06152
− MANUAL TRANSAXLEDIFFERENTIAL LOCKING SYSTEM (4WD)
MX−73
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT CENTER DIFFERENTIAL LOCK SYSTEM
(a) Inspect the differential lock operation.
(1) Use a lift or jack stand to lift up the vehicle so that
all 4 tires can rotate.
(2) Apply the parking brake and start the engine.
(3) Set the center differential lock switch to ON.
(4) Depress the clutch pedal and shift into the 2nd gear.
(5) With the engine idling, gradually engage the clutch
and check that the engine stops.
(6) With the parking brake and engine ON, turn the cen-
ter differential lock switch OFF.
(7) Depress the clutch pedal and shift into the 2nd gear.
(8) With the engine idling, gradually engage the clutch
and check that the front wheels rotate.
HINT:
This inspection must be done when the engine is idling.
(b) Inspect the center differential lock indicator operation.
(1) Turn the ignition switch ON.
(2) Check that when the differential lock switch is
turned ON and OFF, the differential lock indicator
lamp lights up and goes off, respectively.
(c) Inspect the center differential lock warning buzzer opera-
tion.
(1) Start the engine and check that the differential lock
warning buzzer does not sound when the center dif-
ferential lock switch is turned ON.
(2) Interchange the solenoid hose No.1 and solenoid
hose No.2 between the differential lock control sole-
noid No.1 and No.2 and the differential lock actua-
tor. And check that the differential lock warning
buzzer sounds when the differential lock switch is
turned OFF.
(3) Return the solenoid hose No.1 and solenoid hose
No.2 to their original location, and check that the dif-
ferential lock warning buzzer stops.
HINT:
Do the inspection with the vehicle stopped.
After finishing the inspection, inspect the differential lock
control solenoid hoses.

MX065−01
D01958
Shift Lever Knob
Side Trim Cover
Side Trim Cover
Shift Control Cable Grommet Retainer
Shift Lever Assembly Select Control Cable
N·m (kgf·cm, ft·lbf) : Specified torqueWasherClip
Washer GrommetRetainerConsole Box Boot
12 (120, 9)
4.9 (50, 43 in.·lbf)
4.9 (50, 43 in.·lbf)
Clip Clip
Clip
Clip
ClipWasher
Bracket
− MANUAL TRANSAXLESHIFT LEVER AND CONTROL CABLE
MX−77
1996 RAV4 (RM447U)
SHIFT LEVER AND CONTROL CABLE
COMPONENTS

MX0C1−01
Q09037
Adjusting Shim
Transfer Oil PipeExtension Housing
x6
Dust Deflector
Transfer Pinion Bearing
Cage Assembly
Differential Lock
Indicator Switch Cushion
Differential Bearing
Adjusting Nut
Ring Gear Mounting
Case Assembly
Bearing Outer Race
Plate Washer
Transfer Left Case
Drain Plug Snap Ring
Shift Fork Shaft
Differential
Side Gear
Shaft Holder
Side Gear Shaft
Holder Bearing
Snap Ring
Adjusting Nut Lock Plate
N·m (kgf·cm, ft·lbf): Specified torque
Non−reusable part
Precoated part 
x10Transfer Right CaseDifferential Lock
Sleeve Differential Lock
Shift Fork Plug
Transfer Inspection
Hole Cover O−Ring

Plug
Oil Seal Dust BootGasket
 Oil Seal
44 (450, 33)


39 (400, 29)

16 (160, 12)
Gasket

39 (400, 29)
Gasket 
25 (250, 18)
40 (410, 30)16 (160, 12)

25 (260, 19)
Dynamic Damper
25 (260, 19)
 Bearing
Outer Race 
13 (130, 9)
O−Ring 
39 (400, 29)Oil Seal

− MANUAL TRANSAXLETRANSFER (4WD)
MX−79
1996 RAV4 (RM447U)
TRANSFER (4WD)
COMPONENTS

Z12395
SST
Z12545
Q06133
Q06142
SST
− MANUAL TRANSAXLETRANSFER (4WD)
MX−83
1996 RAV4 (RM447U)
10. REMOVE TRANSFER PINION BEARING CAGE AS-
SEMBLY
(a) Remove the 6 bolts, tap the transfer pinion bearing cage
assembly with a plastic hammer and remove it.
(b) Remove the O−ring and 2 adjusting shims from the trans-
fer pinion bearing cage.
(c) Remove the lock nut.
(1) Unstake the lock nut.
(2) Using SST, remove the lock nut.
SST 09326−20011
(d) Remove the transfer driven pinion.
Using a press, remove the transfer driven pinion, rear
bearing and spacer.
11. REMOVE DIFFERENTIAL LOCK SHIFT FORK, LOCK
SLEEVE AND SHIFT FORK SHAFT
Remove the bolt, shift fork, shift fork shaft and lock sleeve.
12. REMOVE TRANSFER RIGHT CASE
Remove the 10 bolts, tap the transfer right case with a plastic
hammer and remove it.
13. REMOVE RING GEAR MOUNTING CASE ASSEMBLY
(a) Remove the mounting case right side bearing.
Using SST, remove the right side bearing.
SST 09950−40010, 09950−60010 (09951−00500)

Q05709
SST
MX0E0−01
Z12397
SST
Z12546
Q08760
SST SST
Z16232
Socket Wrench MX−86
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
REPLACEMENT
1. REPLACE DRIVEN PINION FRONT BEARING
(a) Using SST and a press, remove the front bearing.
SST 09950−00020
(b) Using SST and a press, install a new front bearing.
SST 09316−60011 (09316−00051)
2. REPLACE FRONT AND REAR BEARING OUTER
RACE
(a) Using a brass bar and hammer, drive out the front and
rear bearing outer race lightly and evenly.
(b) Using SST and a press, install a new front bearing outer
race.
SST 09950−60020 (09951−00780), 09950−70010
(09951−07150)
(c) Using SST and a press, install a new rear bearing outer
race.
SST 09950−60010 (09951−00590), 09950−70010
(09951−07150)
3. REPLACE SHIFT FORK SHAFT OIL SEAL
(a) Using a screwdriver, remove the oil seal from the transfer
right case.
(b) Using a socket wrench and hammer, install a new oil seal.

Q06165
Z16229
Proper ContactHeel Contact Face Contact
Select an adjusting shim that will bring the
driven pinion closer to the ring gear.
Toe Contact Flank Contact
Select an adjusting shim that will shift the
driven pinion away from the ring gear. MX−94
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
6. CHECK TOOTH CONTACT
(a) Coat 3 or 4 teeth at 4 different positions on the ring gear
with red lead.
(b) Rotate the ring gear, inspect the teeth pattern.
(c) If the teeth are not contacting properly, again select the
proper shim and plate.
MarkThickness mm (in.)MarkThickness mm (in.)
A0.30 (0.0118)F0.45 (0.0177)
B0.33 (0.0130)G0.48 (0.0189)
C0.36 (0.0142)H0.51 (0.0201)
D0.39 (0.0154)J0.54 (0.0213)
E0.42 (0.0165)K0.57 (0.0224)
7. REMOVE RING GEAR MOUNTING CASE ASSEMBLY
(a) Remove the 10 bolts and transfer right case.
(b) Remove the ring gear mounting case assembly.
8. REMOVE TRANSFER PINION BEARING CAGE AS-
SEMBLY
Remove the 6 bolts and transfer pinion bearing cage assembly.