1996 TOYOTA RAV4 Cv axle

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)

Q08754
A
B A
B D
E
C
Q08755
Q08756DEC C
FG G
F
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
MX−5
1996 RAV4 (RM447U)
(d) Remove the 2 nuts, 6 bolts and front suspension cross-
member assembly with the stabilizer bar.
Torque:
Bolt A: 206 N·m (2,100 kgf·cm, 152 ft·lbf)
Bolt B: 137 N·m (1,400 kgf·cm, 101 ft·lbf)
Nut C: 115 N·m (1,170 kgf·cm, 85 ft·lbf)
20. REMOVE ENGINE MOUNTING CENTER MEMBER
Remove the 4 bolts and center member.
Torque:
Bolt D: 80 N·m (820 kgf·cm, 59 ft·lbf)
Bolt E: 35 N·m (360 kgf·cm, 26 ft·lbf)
21. JACK UP TRANSAXLE SLIGHTLY
Using a trasmission jack, support the transaxle.
22. DISCONNECT ENGINE LEFT MOUNTING BRACKET
FROM ENGINE LEFT MOUNTING INSULATOR
Remove the set bolt of the engine left mounting bracket.
Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
23. REMOVE STIFFENER PLATE, NO.2 REAR END
PLATE AND TRANSAXLE LOWER SIDE MOUNTING
BOLT
(a) Remove the 2 bolts and stiffener plate.
Torque:
Bolt G: 37 N·m (380 kgf·cm, 27 ft·lbf)
(b) Remove the 7 bolts and No.2 rear end plate.
Torque:
Bolt C: 29 N·m (300 kgf·cm, 22 ft·lbf)
Bolt D: 46 N·m (470 kgf·cm, 34 ft·lbf)
Bolt E: 25 N·m (250 kgf·cm, 18 ft·lbf)
Bolt F: 9.0 N·m (95 kgf·cm, 78 in.·lbf)
24. REMOVE TRANSAXLE
Lower the engine left side and remove the transaxle from the
engine.
HINT:
At the time of installation, please refer to the following items.
Align the input shaft with the clutch disc and install the
transaxle to the engine.
Temporarily tighten the transaxle mounting bolts.

MX−6
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
1996 RAV4 (RM447U)
25. REMOVE TRANSAXLE CASE PROTECTOR
Remove the 2 bolts and protector.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

MX05P−05
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
MX−7
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal.
(See page MX−3)
NOTICE:
When working with FIPG material, you must observe the following items.
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non−residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be re-
moved and reapplied.
HINT:
After installation, check and inspect items as follows.
Front wheel alignment (See page SA−4).
Do the road test.

MX05R−02
Q09030
Solenoid Hose No.1
Transfer Vacuum Actuator
Bracket
Transfer Vacuum Actuator Assembly
Right Transfer Stiffener Plate
Center Transfer Stiffener Plate
Differential Lock Indicator Switch Connector
Back−Up Light
Switch Connector
Vehicle Speed
Sensor Connector
Transaxle Case Protector
Starter Stiffener Plate
N·m (kgf·cm, ft·lbf): Specified torque
25 (250, 18)
37 (380, 27)
9.0 (95, 78 in.·lbf)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
37 (380, 27)
46 (470, 34)
29 (300, 22)
25 (250, 18)
64 (650, 47)
39 (400, 29)
64 (650, 47)
35 (360, 26)
29 (300, 22)
Solenoid Hose No.0
Solenoid Hose No.2
Solenoid Hose No.0 MX−8
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (4WD)
1996 RAV4 (RM447U)
MANUAL TRANSAXLE UNIT (4WD)
COMPONENTS

MX05S−01
Q09031
B
A
C
FED A
A
C
Q08759
No.1
No.2 No.0
No.0
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (4WD)
MX−9
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE TRANSAXLE WITH ENGINE
(See page EM−80)
2. REMOVE TRANSAXLE CASE PROTECTOR
Remove the 2 bolts and transaxle case protector.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
3. REMOVE STARTER
(a) Disconnect the connector and wire from the starter.
(b) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
4. DISCONNECT DIFFERENTIAL LOCK INDICATOR
SWITCH, BACK−UP LIGHT SWITCH AND VEHICLE
SPEED SENSOR CONNECTORS
5. REMOVE TRANSFER VACUUM ACTUATOR BRACK-
ET
Remove the 4 bolts and bracket.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
6. REMOVE TRANSFER VACUUM ACTUATOR AS-
SEMBLY
(a) Disconnect the 4 solenoid hoses from the transfer vacu-
um actuator assembly.
NOTICE:
At the time of installation, please refer to the following item.
Check that the hose No.0, No.1 and No.2 are securely
installed to the solenoid.
(b) Remove the 2 bolts and transfer vacuum actuator assem-
bly.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
7. REMOVE RIGHT TRANSFER STIFFENER PLATE
Remove the 5 bolts and right transfer stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
8. REMOVE CENTER TRANSFER STIFFENER PLATE
Remove the 3 bolts and center transfer stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
9. REMOVE STIFFENER PLATE
Remove the 2 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
10. REMOVE TRANSAXLE FROM ENGINE
(a) Remove the 9 transaxle mounting bolts from the engine.
Torque:
Bolt A: 64 N·m (650 kgf·cm, 47 ft·lbf)
Bolt B: 35 N·m (360 kgf·cm, 26 ft·lbf)
Bolt C: 29 N·m (300 kgf·cm, 22 ft·lbf)
Bolt D: 46 N·m (470 kgf·cm, 34 ft·lbf)
Bolt E: 25 N·m (250 kgf·cm, 18 ft·lbf)
Bolt F: 9.0 N·m (95 kgf·cm, 78 in.·lbf)

Q06187
Q06188
Q06189
MX−10
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (4WD)
1996 RAV4 (RM447U)
(b) Pull straight until there is a gap of about 60−80 mm
(2.4−3.1 in.) between the engine and transaxle case.
(c) Move the transmission case cover in the direction, as
shown in the illustration.
(d) While holding transfer output, gently pull out whole trans-
axle.

MX05T−03
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (4WD)
MX−11
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal.
(See page MX−9)
NOTICE:
When working with FIPG material, you must observe the following items.
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non−residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be re-
moved and reapplied.
HINT:
After installation, do the road test.