1996 TOYOTA RAV4 oil

LU06A−03
S01365
S01359
SST
S01366
LU−18
− LUBRICATIONOIL COOLER
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE FRONT EXHAUST PIPE (See page EM−33)
4. REMOVE GENERATOR (See page CH−7)
5. REMOVE OIL DIPSTICK
6. REMOVE EXHAUST MANIFOLD AND FRONT TWC
ASSEMBLY (See page EM−33)
7. REMOVE WATER BYPASS PIPE HEAT PROTECTOR
Remove the bolt, 2 nuts and heat protector.
8. REMOVE OIL FILTER
Using SST, remove the oil filter.
SST 09228−06501
9. REMOVE OIL COOLER
(a) Disconnect the 2 water bypass hoses from the oil cooler.
(b) Remove the union bolt and plate washer.
(c) Remove the nut and oil cooler.
(d) Remove the O−ring from the oil cooler.

P15377
Push
LU0O6−01
P15378
IN
OUT
− LUBRICATIONOIL COOLER
LU−19
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT RELIEF VALVE
Push the valve with a wooden stick to check if it is stuck.
If stuck, replace the relief valve.
2. INSPECT OIL COOLER
Check the oil cooler for damage or clogging.
If necessary, replace the oil cooler.

LU06C−02
LU−20
− LUBRICATIONOIL COOLER
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL OIL COOLER
(a) Clean the oil cooler contact surface on the oil cooler
mounting.
(b) Install a new O−ring to the oil cooler.
(c) Temporarily install the oil cooler with the nut.
(d) Apply a light coat of engine oil on the threads and under
the head of the relief valve.
(e) Install the plate washer and union bolt.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
(f) Tighten the nut.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(g) Connect the 2 water bypass hoses to the oil cooler.
2. INSTALL OIL FILTER
3. INSTALL WATER BYPASS HOSE HEAT PROTECTOR
Install the heat protector with the bolt and 2 nuts.
4. INSTALL EXHAUST MANIFOLD AND FRONT TWC AS-
SEMBLY (See page EM−55)
5. INSTALL OIL DIPSTICK
6. INSTALL GENERATOR (See page CH−19)
7. INSTALL FRONT EXHAUST PIPE (See page EM−55)
8. FILL WITH ENGINE COOLANT
9. START ENGINE AND CHECK FOR LEAKS
10. CHECK ENGINE OIL LEVEL
11. INSTALL RH ENGINE UNDER COVER

MX01Z−08
− MANUAL TRANSAXLETROUBLESHOOTING
MX−1
1996 RAV4 (RM447U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Noise
14.Oil (Level low) 2WD
4WD
15. Oil (Wrong) 2WD
4WD
16.Gear (Worn or damaged)
17.Bearing (Worn or damaged)MX−3
MX−9
MX−3
MX−9
MX−12
MX−79
MX−12
MX−79
Oil leakage
1. Oil (Level too high) 2WD
4WD
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O−Ring (Worn or damaged)MX−3
MX−9
MX−12
MX−79
MX−12
MX−79
MX−12
MX−78
MX−79
Hard to shift or will not shift
1. Control cable (Faulty)
2. Synchronizer ring (Worn or damaged)
3. Shift key spring (Damaged)MX−77
MX−12
MX−29
MX−36
MX−12
MX−29
MX−36
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MX−12
MX−12
MX−79
MX−12
MX−79
MX−12
MX−79
Tight corner braking1. Differential, Center differential (Faulty)MX−58
MX−72

Q08751
Q08752
Q10165
Filler Plug
Oil Level
0 − 5 mm
Drain Plug
Q08753
MX−4
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
1996 RAV4 (RM447U)
10. REMOVE ENGINE LEFT MOUNTING INSULATOR SET
BOLT AND 2 NUTS
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
11. INSTALL ENGINE SUPPORT FIXTURE
12. TIE PS GEAR ASSEMBLY TO ENGINE SUPPORT FIX-
TURE BY CORD OR EQUIVALENT
13. REMOVE FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
14. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
15. REMOVE LH AND RH ENGINE UNDER COVERS
16. DRAIN TRANSAXLE OIL
Oil grade: API GL−4 or GL−5
Viscosity: SAE 75W−90
Capacity: 3.9 liters (4.1 US qts, 3.4 Imp. qts)
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
17. REMOVE LH AND RH FRONT DRIVE SHAFTS
(See page SA−18)
18. REMOVE FRONT EXHAUST PIPE
(a) Remove the 3 nuts and gasket from the exhaust manifold.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Remove the 2 bolts, gasket and pipe.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
19. REMOVE FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY WITH STABILIZER BAR
(a) Support the front suspension crossmember with a jack.
(b) Disconnect the ring from the center exhaust pipe.
(c) Remove the 2 set bolts and nuts of the PS gear assembly.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)

MX05U−01
Q09032
2WD:
Clutch Release Fork Assembly
with Bearing
Clutch Release Fork SupportControl Lever Housing
Support Bracket
Boot O−Ring
Cover Clutch Release
Line Bracket
Transaxle Case
Transmission
Oil Cooler
Sub−Assembly
Elbow O−RingVehicle Speed Sensor
Transaxle Case Receiver
Transmission Oil
Pipe
Magnet
Transmission
Oil Pipe
 Output Shaft Cover
Tapered Roller Bearing
Outer Race
 Front Oil Seal
Input Shaft Front
Bearing
Transmission Oil Pump
Assembly
Differential Case Assembly
Oil Pump Drive Gear
17 (175, 13)
47 (480, 35)
34 (350, 25)
27 (275, 20)
7.4 (75, 65 in.·lbf)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part Gasket
  MX−12
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
MANUAL TRANSAXLE ASSEMBLY
COMPONENTS

Q09033
Clutch Release
Fork Assembly
with Bearing
Clutch Release Fork Support
Control Lever Housing
Support Bracket
Boot O−Ring
Cover
Clutch Release
Line Bracket
Transaxle Case
Elbow O−RingVehicle Speed Sensor
Transaxle Case Receiver
Transmission Oil
Pipe
Magnet
 Output Shaft Cover
 Tapered Roller Bearing
Outer Race
 Front Oil Seal
 Input Shaft Front
Oil Seal
Transmission Oil Pump
Assembly
Differential Case Assembly
Oil Pump Drive Gear
34 (350, 25)
27 (275, 20)
7.4 (75, 65 in.·lbf)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
17 (175, 13)
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 Precoated part 4WD:


Transfer Assembly
Transmission
Oil Pipe
17 (175, 13)
17 (175, 13)
69 (700, 51)
69 (700, 51)
39 (400, 29)
47 (480, 35)
Differential Side Gear
Intermediate Shaft
 Snap Ring
69 (700, 51)
Drain Plug
Oil Cooler Line Gasket
 Gasket 
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−13
1996 RAV4 (RM447U)

Q09034

N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 Precoated partTransmission Case Cover Transmission CaseNo.2 Selecting Bellcrank with
Selecting Bellcrank Support Shift and Select Lever
Shaft Assembly
No.1 Oil Receiver Pipe Reverse Restrict
Pin Straight Screw PlugBack−Up Light SwitchNo.3 Shift Fork No.3 Shift Fork ShaftInterlock Roller
Snap RingShift Head
Shift and Select Lever
Shaft Lock BoltNo.2 Shift Fork Shaft Straight Screw Plug Reverse Shift Arm Bracket Assembly
Snap Ring
Reverse Shift Fork
No.1 Shift Fork
No.1 Shift Fork Shaft Seat
Spring
Ball
Slotted Spring
PinSnap RingSnap Ring
No.2 Shift Fork
No.2 Oil Receiver Pipe
Drain Plug Filler Plug
x10 x17


24 (240, 17)
25 (250, 18)
25 (250, 18)
24 (240, 17)
24 (240, 17)
25 (250, 18)
17 (175, 13)
40 (410, 30)
13 (130, 9)49 (500, 36)20 (200, 14)
17 (175, 13)
29 (300, 22)
49 (500, 36)
20 (200, 14)
49 (500, 36)
49 (500, 36)
29 (300, 22)
Breather Plug Gasket  Gasket
 Gasket  Gasket Gasket
 Gasket MX−14
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)