1996 TOYOTA RAV4 oil

Z12390
1.5 ± 0.4 mm SST
Z12536
Z12392
SST
Q06138
Q06139
− MANUAL TRANSAXLETRANSFER (4WD)
MX−87
1996 RAV4 (RM447U)
4. REPLACE EXTENSION HOUSING OIL SEAL
(a) Using a screwdriver, remove the oil seal.
(b) Using SST and a hammer, drive in a new oil seal.
SST 09325−20010
Oil seal depth: 1.5 ± 0.4 mm (0.059 ± 0.016 in.)
(c) Coat the lip of oil seal with MP grease.
5. REPLACE SIDE GEAR SHAFT HOLDER BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using a press, remove the bearing from the side gear
shaft holder.
(c) Using SST and a press, install a new bearing.
SST 09316−60011 (09316−00011)
(d) Using a snap ring expander, install the snap ring.
6. REPLACE TRANSFER OIL PIPE
(a) Remove the bolt and oil pipe from the transfer left case.
(b) Using a screwdriver, remove the cushion.
(c) Install a new cushion.
(d) Install the oil pipe.
(e) Install and torque the bolt.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

MX0C3−02
Z12547
Z12399
SST
Q08203
SST
− MANUAL TRANSAXLETRANSFER (4WD)
MX−89
1996 RAV4 (RM447U)
REASSEMBLY
NOTICE:
When working with FIPG material, you must observe the follow-
ing 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 removed and reap-
plied.
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. ASSEMBLE TRANSFER PINION BEARING CAGE
(a) Install the transfer pinion bearing cage.
(1) Install a new bearing spacer.
HINT:
Insert the spacer with the smaller diameter facing upwards.
(2) Using SST and a press, install the rear bearing.
HINT:
Press down until the pinion can move slightly up and down.
SST 09316−60011 (09316−00021)
(b) Adjust the driven pinion preload.
(1) Using SST, install and torque a new lock nut.
SST 09326−20011
Torque: 95 N·m (968 kgf·cm, 70 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 38 cm (14.96
in.).
The torque specification for without using SST is 108 N·m
(1,100 kgf·cm, 80 ft·lbf).

Z12401
SST MX−90
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
(2) Using SST and a spring tension gauge, measure
the driven pinion preload.
SST 09326−20011
HINT:
Turn the driven pinion right and left 2 or 3 times to allow the
bearing to settle.
Preload (at starting):
New bearing
17.7 − 28.4 N (1.8 − 2.9 kgf, 4.0 − 6.4 lbf)
Reused bearing
4.9 − 8.8 N (0.9 − 1.4 kgf, 1.1 − 2.0 lbf)
If the preload exceeds than the specification, re-
place the bearing spacer.
If the preload is less than the specification, retighten
the nut 5−10° gradually a time until the specified
preload is reached.
If the maximum torque is exceeded while retighten-
ing the nut, replace the bearing spacer and repeat
the preload procedure. Do not back off the pinion
nut to reduce the preload.
Torque: 214 N·m (2,184 kgf·cm, 158 ft·lbf) or less
HINT:
Use a torque wrench with a fulcrum length of 50 cm (19.69
in.).
The maximum torque specification for without using SST
is 235 N·m (2,400 kgf·cm, 174 ft·lbf).
(c) Stake the lock nut.
2. ASSEMBLE RING GEAR MOUNTING CASE
(a) Install the transfer ring gear.
(1) Clean the contact surface of the mounting case.
(2) Heat the ring gear to about 100°C (212°F) in boiling
water.
(3) Carefully take the ring gear out of the water.
(4) Clean the contact surface of the ring gear with
cleaning solvent.
(5) Quickly install the ring gear on the mounting case.
HINT:
Align the matchmarks on the mounting case and connect the
ring gear.
(6) Install and torque the 12 bolts.
Torque: 97 N·m (985 kgf·cm, 71 ft·lbf)
(b) Checking the ring gear runout (See page MX−82).

Q06135
Q06166
SST
Q06287
SST
Q06168
FIPG
− MANUAL TRANSAXLETRANSFER (4WD)
MX−95
1996 RAV4 (RM447U)
9. INSTALL TRANSFER PINION BEARING CAGE AS-
SEMBLY
(a) Coat the O−ring with gear oil.
(b) Install the O−ring to the transfer pinion bearing cage.
(c) Install the transfer pinion bearing cage with the adjusting
shim (previously selected) to the transfer left case.
(d) Install and torque the 6 bolts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
10. INSTALL RING GEAR MOUNTING CASE ASSEMBLY
11. INSTALL ADJUSTING NUT LOCK PLATE
Using snap ring pliers, install the lock plate so that the projection
from the lock plate fits properly into the groove of the adjusting
nut.
12. INSTALL DIFFERENTIAL SIDE GEAR SHAFT HOLD-
ER
(a) Using SST and a press, install the differential side gear
shaft holder to the transfer right case.
SST 09316−20011
(b) Using snap ring pliers, install the snap ring.
13. INSTALL TRANSFER RIGHT CASE OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09223−15020, 09950−70010 (09951−07150)
(b) Coat the lip of the oil seal with MP grease.
14. INSTALL TRANSFER RIGHT CASE
(a) Apply FIPG to the transfer left case, as shown.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
(b) Apply sealant to the bolt threads.
Sealant:
Part No. 08833−00080, THREE BOND 1344, LOCTITE
242 or equivalent
(c) Install and torque the 10 bolts.

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.

PR02R−01
F03298
Q08983
Matchmarks
Q05852
Q05853
SST
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY
PR−3
1996 RAV4 (RM447U)
REMOVAL
1. LOOSEN CROSS GROOVE JOINT SET BOLT
(a) Depress the brake pedal and hold it.
(b) Using a hexagon wrench, loosen the cross groove joint
set bolts 1/2 turn.
HINT:
Put a piece of cloth, or equivalent, into the inside of the cross
groove joint cover so that the boot does not touch the inside of
the cross groove joint cover.
(c) Loosen the 2 bolts and center support bearing.
2. DISCONNECT PROPELLER SHAFT FROM DIFFER-
ENTIAL
(a) Place matchmarks on both flanges.
(b) Remove the 4 bolts, washers and nuts.
3. REMOVE PROPELLER SHAFT FROM TRANSAXLE
(a) Remove the 2 bolts and center support bearing.
(b) Pull out the propeller shaft yoke from the transaxle.
(c) Insert SST in the transaxle to prevent oil leakage.
SST 09325−20010

SA0T5−01
− SUSPENSION AND AXLETROUBLESHOOTING
SA−1
1996 RAV4 (RM447U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below th 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
Wander/pulls
1. Tires (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Steering linkage (Loosen or worn)
4. Hub bearings (Loosen or worn)
5. Steering gear (Out of adjustment or broken)
6. Suspension parts (Worn out)SA−2
SA−4
−
SA−10
SA−52
SA−56
−
−
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn out)−
SA−32
SA−95
SA−35
SA−92
Sways/pitches
1. Tires (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn out)SA−2
SA−49
SA−35
SA−92
Front wheel shimmy
1. Tires (Worn or improperly inflated)
2. Wheels (Out of balance)
3. Shock absorber (Worn out)
4. Wheel alignment (Incorrect)
5. Ball joints (Worn)
6. Hub bearings (Loosen or worn)
7. Steering linkage (Loosen or worn)
8. Steering gear (Out of adjustment or broken)SA−2
SA−2
SA−35
SA−2
SA−45
SA−10
−
−
Abnormal tire wear
1. Tires (Improperly inflated)
2. Wheel alignment (Incorrect)
3. Suspension parts (Worn out)
4. Shock absorber (Worn out)SA−2
SA−4
−
SA−35
SA−92
Noise in rear differential
1. Oil level (Low or wrong grade)
2. Excessive backlash between pinion and ring gear
3. Ring, pinion or side gears (Worn or chipped)
4. Pinion shaft bearing (Worn)
5. Side bearing (Worn)
6. Differential bearing (Loosen or worn)SA−69
SA−79
SA−79
SA−79
SA−79
SA−79
Oil leak from rear differential
1. Oil level (Too high or wrong grade)
2. Drive pinion oil seal (Worn or damaged)
3. Side gear oil seal (Worn or damaged)
4. Companion flange (Loose or damaged)
5. Side gear shaft (Damaged)SA−69
SA−79
SA−79
SA−74
SA−79

R10657
− SUSPENSION AND AXLETIRE AND WHEEL
SA−3
1996 RAV4 (RM447U)
4. CHECK WHEEL BEARING LOOSENESS
(a) Check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
(b) Check the axle hub deviation.
Maximum: 0.07 mm (0.0028 in.)
5. CHECK FRONT SUSPENSION FOR LOOSENESS
6. CHECK STEERING LINKAGE FOR LOOSENESS
7. CHECK BALL JOINT FOR LOOSENESS
8. CHECK SHOCK ABSORBER WORKS PROPERLY
Check for oil leak
Check mounting bushings for wear
Check bounce for front and rear of the vehicle