Q06133
Q06169
FIPG
Q06131
MX−96
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
15. CHECK TOTAL PRELOAD (See step 4)
16. INSTALL DIFFERENTIAL LOCK SHIFT FORK, LOCK
SLEEVE AND SHIFT FORK SHAFT
(a) Install the shift fork, shift fork shaft and lock sleeve.
(b) Install and torque the bolt.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
17. INSTALL TRANSFER INSPECTION HOLE COVER
(a) Apply FIPG to the transfer left case, as shown.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
(b) Install the cover on the transfer left case.
(c) Install and torque the 3 bolts.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
18. INSTALL PLUG AND DIFFERENTIAL LOCK INDICA-
TOR SWITCH
(a) Using a hexagon wrench (10 mm), install and torque the
plug and gasket.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Apply sealant to the plug threads.
Using a hexagon wrench (6 mm), install and torque the
plug.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Install and torque the differential lock indicator switch and
gasket.
Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
19. INSTALL EXTENSION HOUSING
(a) Coat the O−ring with gear oil.
(b) Install a new O−ring to the extension housing.
(c) Install the extension housing to the transfer pinion bear-
ing cage.
R10641
F03765
SA1653
Proper ContactHeel Contact
Toe ContactSelect an adjusting shim will bring the
drive pinion closer to the ring gear.Face Contact
Flank Contact
Select an adjusting shim that will shift the
drive pinion away from the ring gear.
SA1586
Plate Washer
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−85
1996 RAV4 (RM447U) 1/17/01
12. MEASURE 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)
13. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION
(a) Coat 3 or 4 teeth at 3 different positions on the ring gear
with red lead primer.
(b) Hold the companion flange firmly and rotate the ring gear
in both directions.
(c) Inspect the tooth contact pattern.
If the teeth are not contacting properly, use the following chart
to select a proper washer for correction.
W02017
Non−Tilt Steering Column :
A
B Tilt Steering Column :
Matchmarks
W02018
Matchmarks
SR−14
− STEERINGNON−TILT STEERING COLUMN
1996 RAV4 (RM447U)
10. DISCONNECT NO.2 INTERMEDIATE SHAFT
(a) Loosen the bolt A.
(b) Remove the bolt B.
(c) Shift the No.2 intermediate shaft and place matchmarks
on the control valve shaft and No.2 intermediate shaft.
11. REMOVE NO.2 INTERMEDIATE SHAFT
12. REMOVE STEERING COLUMN PROTECTOR
Remove the bolt.
13. REMOVE STEERING COLUMN ASSEMBLY
(a) Disconnect the connectors.
(b) Remove the 2 column assembly set bolts and 2 nuts.
14. Tilt Steering Column:
REMOVE SLIDING YOKE
(a) Remove the bolt.
(b) Shift the sliding yoke and place matchmarks on the main
shaft and sliding yoke.
