1996 TOYOTA RAV4 torque

MX02G−02
Z17558
GasketO−Ring
Oil Strainer
Oil Pump Driven Rotor
Oil Pump Drive Gear Oil Pump Drive Rotor
Oil Pump Cover Spring Holder Spring Ball Relief Valve Transmission Oil Pump
Case
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
10 (105, 8)
10 (105, 8)

 MX−44
− MANUAL TRANSAXLEOIL PUMP (2WD)
1996 RAV4 (RM447U)
OIL PUMP (2WD)
COMPONENTS

MX05Y−01
Z17559
GasketO−Ring
Oil Strainer
Oil Pump Driven Rotor
Oil Pump Drive Gear Oil Pump Drive Rotor
Oil Pump Cover
Spring Holder Spring
Ball Relief Valve Transmission Oil Pump Case
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable partOil Line Case
No.3 Oil Pipe
10 (105, 8)
10 (105, 8)
 MX−46
− MANUAL TRANSAXLEOIL PUMP (4WD)
1996 RAV4 (RM447U)
OIL PUMP (4WD)
COMPONENTS

MX060−01
Z17560
Transaxle Case Cover
Differential Spider
Differential Pinion
Differential Side Gear
Side Gear Thrust
Washer
Pinion Thrust Washer
 Tapered Roller Bearing
and Outer Race
Differential Right Case
Vehicle Speed Sensor Drive Gear
Differential Left Case
 Tapered Roller Bearing
and Outer Race Ring Gear
Oil Baffle
 Oil Seal x16
Shim  Oil Seal
54 (550, 40)
63 (640, 46)
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part 

x16
 Precoated partStud Bolt
54 (550, 40)
124 (1,260, 91)
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
MX−49
1996 RAV4 (RM447U)
DIFFERENTIAL CASE (2WD)
COMPONENTS

− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
MX−53
1996 RAV4 (RM447U)
(k) Install and torque the 4 bolts and 3 nuts.
Torque: 54 N·m (550 kgf·cm, 40 ft·lbf)

Z00297
Z00298
Z00299
Matchmarks
Z00303
Driven Gear
Side
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
MX−55
1996 RAV4 (RM447U)
(f) Refer to the table below, select the thrust washer which
will ensure that the backlash is within the specification.
Try to select a washer of the same size.
Thickness mm (in.)Thickness mm (in.)
0.80 (0.0315)1.20 (0.0472)
0.90 (0.0354)1.30 (0.0512)
1.00 (0.0394)1.40 (0.0551)
1.10 (0.0433)−
(g) Install the vehicle speed sensor drive gear.
(h) Align the matchmarks on the differential cases.
(i) Using a plastic hammer, carefully tap the differential case
to install it.
(j) Using a torx wrench (T50), install and torque the 16 torx
screws.
Torque: 63 N·m (640 kgf·cm, 46 ft·lbf)
2. INSTALL RING GEAR
(a) Clean the contact surface of the differential case and the
threads of the ring gear and differential case.
(b) Heat the ring gear to about 100°C (212°F) in boiling wa-
ter.
(c) Carefully take the ring gear out of the water.
(d) Clean the contact surface of the ring gear with cleaning
solvent.
(e) Quickly install the ring gear on the differential case.
HINT:
Align the matchmarks on the differential left case and contact
the ring gear.
(f) Temporarily install the 16 bolts.
NOTICE:
The ring gear set bolts should not be tightened until the
ring gear has cooled sufficiently.
(g) After the ring gear has cooled sufficiently, torque the ring
gear set bolts.
Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf)

Q06410
SST
SST
Q00036
Z00309
MX−56
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
1996 RAV4 (RM447U)
3. INSTALL TAPERED ROLLER BEARING
Using SST and a press, install new left and right bearings onto
the differential case.
SST 09316−20011, 09316−60011 (09316−00011)
HINT:
Press the bearing on the ring side first.
4. ADJUST OUTPUT SHAFT ASSEMBLY PRELOAD
(See page MX−27)
5. INSTALL DIFFERENTIAL CASE ASSEMBLY TO
TRANSAXLE CASE
6. INSTALL OUTPUT SHAFT ASSEMBLY
Lift up the differential case and install the output shaft assem-
bly.
7. INSTALL TRANSMISSION CASE
(a) Install the transmission case.
HINT:
If necessary, tap on the case with a plastic hammer.
(b) Install and torque the 17 bolts.
Torque: 29 N·m (300 kgf·cm 22 ft·lbf)
8. INSTALL OUTPUT SHAFT REAR TAPERED ROLLER
BEARING OUTER RACE
Using a plastic hammer, drive in the outer race.
9. INSTALL SHIM (See page MX−27)
HINT:
Install the previously selected shim.
10. INSTALL REAR BEARING RETAINER
Using a torx wrench (T45), install and torque the 7 torx screws.
Torque: 42 N·m (430 kgf·cm, 31 ft·lbf)
11. ADJUST DIFFERENTIAL CASE SIDE BEARING PRE-
LOAD
(a) Install a new lock nut to the output shaft.
(b) Turn the output shaft right and left 2 or 3 times to allow the
bearings to settle.
(c) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing (Output shaft preload plus)
0.2 − 0.3 N·m (1.8 − 3.5 kgf·cm, 1.6 − 3.0 in.·lbf)
Reused bearing (Output shaft preload plus)
0.1 − 0.2 N·m (1.1 − 2.2 kgf·cm, 1.0 − 1.9 in.·lbf)
If the preload is not within the specification, select an appropri-
ate adjusting shim.

MX02J−02
Z17561
Tapered Roller Bearing and Outer Race
Snap Ring
Spacer
Vehicle Speed Sensor
Drive Gear
No.1 Differential
Case No.2 Differential Side
Gear Thrust Washer
Differential Side Gear
Subassembly
Differential Pinion Shaft
Differential Pinion Thrust Washer
Differential Pinion
Differential Pinion
Thrust Washer
Differential Pinion
No.2 Front Differential Pinion Shaft
Front Differential Pinion
Shaft Holder
Spacer
Snap Ring Conical Spring
Washer
Pinion Shaft
Holder
No.2 Differential Side
Gear Thrust Washer
Front Differential Case
Front Differential
Pinion Shaft Conical Spring
Washer
No.2 Differential Case
Differential Ring Gear
x16
Oil Baffle Front Differential Side
Gear Thrust Washer
Tapered Roller Bearing and Outer Race
Oil Seal
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable partFront Differential Side Gear
Shim

124 (1,260, 91)
 MX−58
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
DIFFERENTIAL CASE (4WD)
COMPONENTS

Q06225
Thrust Washer
Thickness
1.0 mm (0.039 in.)
Q06213
Plastigage
Plastigage
Q06214Matchmarks
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−69
1996 RAV4 (RM447U)
10. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE
GEAR THRUST CLEARANCE (FRONT DIFFERENTIAL
CASE SIDE)
(a) Install these parts:
Front differential case assembly
Front differential side gear
Front differential side gear thrust washer
Temporarily install a 1.0 mm (0.039 in.) thick
No.2 differential side gear thrust washer
No.2 differential side gear thrust washer
HINT:
Engage the front differential side gear and pinion gear of
the No.1 differential case.
The temporarily installed a 1.0 mm (0.039 in.) thick No.2
side gear thrust washer is used for reference when check-
ing backlash.
(b) Clean the contact surface of the No.2 side gear thrust
washer and No.2 differential case.
(c) Apply plastigage on the No.2 side gear thrust washer, as
shown.
HINT:
Apply the plastigage on the No.2 side gear thrust washer in the
4 positions directly above the pinion shafts in the No.1 differen-
tial case’s position.
(d) Install the No.2 differential case downward.
HINT:
Align the matchmarks on the No.1 differential case and contact
the No.2 differential case.
(e) Install and torque the 16 bolts.
Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf)
(f) Remove the 16 bolts and No.2 differential case upward.