1996 TOYOTA RAV4 oil

W01215
SST
R10775
SST
R10762
SST
R10763
Less that 5 mm (0.20 in.) SA−70
− SUSPENSION AND AXLEREAR DIFFERENTIAL FRONT OIL SEAL
1996 RAV4 (RM447U)
(b) Using SST, install a new oil seal.
SST 09554−22010
Oil seal drive in depth: 2.0 mm (0.079 in.)
(c) Apply MP grease to the oil seal lip.
7. INSTALL COMPANION FLANGE
(a) Using SST, install the companion flange on the shaft.
SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03040, 09956−03020)
(b) Coat the threads of a new nut with hypoid gear oil.
(c) Using SST to hold the flange, torque the nut.
SST 09330−00021
Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf)
(d) Adjust the preload of bearing on drive pinion (See page
SA−79).
8. STAKE DRIVE PINION NUT
9. INSTALL PROPELLER SHAFT (See page PR−2)
10. FILL DIFFERENTIAL WITH DIFFERENTIAL OIL
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
Oil grade: Hypoid gear oil API GL−5
Recommended oil viscosity:
Above −18°C (0°F) SAE 90
Below −18°C (0°F) SAE 80W or 80W−90
Capacity: 0.9 liter (1.0 US qts, 0.8 lmp. qts)

F03751
2 PINION DEFERENTIAL
TORQUE SENSING LSD
Thrust Washer
Straight Pin
Pinion Shaft
Thrust Washer Side Gear
Pinion Gear
Plate WasherPlate Washer
Side Bearing
Ring Gear
Drive Pinion
Rear Bearing
Differential Case
Lock Plate

Plate Washer
97 (985, 71)



Side Bearing
Oil Deflector
Bearing Cap
Differential
Carrier CoverX87.4 (75, 65 in.·lbf)
78 (800, 58)
Snap Ring

Oil Seal 
Dust Cover 
Gasket

Drain Plug
49 (500, 36)
Differential
Carrier
Bearing Spacer
Oil Seal Side Gear Shaft
Companion FlangeSnap Ring


Dust Deflector

Oil Slinger
Front Bearing

Dust Cover 
Oil Seal 
Gasket

49 (500, 36)
Filler Plug
N·m (kgf·cm, ft·lbf)
Non−reusable part: Specified torque

Snap Ring 
See page SA−79
47 (475, 34)
SA−72
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)

SA0UJ−01
W04156
R10756
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−73
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE DRIVE SHAFTS (See page SA−62)
HINT:
Support the drive shafts securely.
2. REMOVAL PROPELLER SHAFT (See page PR−2)
HINT:
Support the propeller shaft securely.
3. DRAIN DIFFERENTIAL OIL
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
4. REMOVE DIFFERENTIAL
(a) Support the differential with a jack.
(b) Remove the 2 rear mounting bolts.
Torque: 65 N·m (660 kgf·cm, 48 ft·lbf)
(c) Remove the 2 front mounting bolts and differential.
Torque: 132 N·m (1,350 kgf·cm, 98 ft·lbf)
(d) Remove the 2 bolts and differential rear mount cushion
from the differential.
Torque: 137 N·m (1,400 kgf·cm, 101 ft·lbf)

R10641
R10660
SST
R10788
SST
R10662
SST
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−75
1996 RAV4 (RM447U)
7. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the backlash
between the drive pinion and ring gear.
Preload (at starting):
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
8. CHECK 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)
If necessary, disassemble and inspect the differential.
9. REMOVE COMPANION FLANGE
(a) Using a chisel and hammer, unstake the staked part of the
nut.
(b) Using SST to hold the flange, remove the nut.
SST 09330−00021
(c) Using SST, remove the companion flange.
SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03040, 09956−03020)
10. REMOVE FRONT OIL SEAL AND OIL SLINGER
(a) Using SST, remove the oil seal from the housing.
SST 09308−10010
(b) Remove the oil slinger.

R10663
SST
R10664
SST
R10757
R10665
SST
F03753
Matchmarks
SA−76
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
11. REMOVE FRONT BEARING AND BEARING SPACER
(a) Using SST, remove the front bearing from the drive pinion.
SST 09556−22010
(b) Remove the bearing spacer.
12. Torque Sensing LSD:
REMOVE SIDE GEAR SHAFTS
(a) Using SST, remove the 2 side gear shafts from the differ-
ential.
SST 09520−24010
(b) Using a screwdriver, remove the 2 snap rings from the 2
side gear shafts.
13. 2 Pinion Differential:
REMOVE SIDE GEAR SHAFTS
(a) Using needle nose pliers, remove the 2 snap rings from
the 2 side gear shafts.
(b) Remove the 2 side gear shafts.
14. REMOVE SIDE GEAR SHAFT OIL SEALS
Using SST, remove the 2 oil seals from the housing.
SST 09308−00010
15. REMOVE DIFFERENTIAL CASE
(a) Place matchmarks on the bearing cap and differential car-
rier.
(b) Remove the 4 bolts and 2 bearing caps.

F14547
FA1124
SA1143
Boiling Water
F03758
Matchmarks
SA−80
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
(c) Measure the side gear backlash.
(1) Install the 2 side gear shafts.
(2) Measure the side gear backlash with holding 1 pin-
ion gear toward the differential case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within the specification, install the 2 side
gear thrust washers with different thicknesses.
(3) Remove the 2 side gear shafts.
2. 2 PINION DIFFERENTIAL:
INSTALL STRAIGHT PIN AND STAKE DIFFERENTIAL
CASE
(a) Using a pin punch and hammer, install the straight pin
through the differential case and hole of the pinion shaft.
(b) Using a chisel and hammer, stake the outside of the differ-
ential case pin hole.
3. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surfaces of the differential case and
ring gear.
(b) Heat the ring gear in boiling water.
(c) Carefully remove the ring gear from the boiling water.
(d) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
(e) Align the matchmarks on the ring gear and differential
case.
(f) Temporarily install the 4 lock plates and 8 bolts.
(g) After the ring gear cools down enough, torque the 8 bolts
uniformly at a time.
Torque: 97 N·m (985 kgf·cm, 71 ft·lbf)
(h) Using a chisel and hammer, stake the 4 lock plates.
HINT:
Stake one claw flush with the flat surface of the bolt. For the
claw contacting the protruding portion of the bolt, stake only the
half of it on the tightening side.

SA3102
SST
R10778
R10661
SST
R10768
SST
R10641
F03761
SA−82
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
(b) Using SST and a press, install the rear bearing onto the
drive pinion.
SST 09506−30012
8. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the drive pinion and front bearing.
HINT:
Assemble the spacer, oil slinger and oil seal after adjusting the
gear contact pattern.
(b) Using SST, install the companion flange.
SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03040, 09956−03020)
(c) Coat the threads of the nut with MP grease.
(d) Adjusting the drive pinion preload by tightening the com-
panion flange nut.
Using SST to hold the flange, torque the nut.
Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf)
SST 09330−00021
NOTICE:
As there is no spacer, torque a little at a time, being careful
not to overtighten it.
(e) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing:
1.0 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing:
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
9. INSTALL DIFFERENTIAL CASE IN CARRIER

R10649
R10673
R10661
SST SA−86
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
Washer thickness
Thickness mm (in.)Thickness mm (in.)Thickness mm (in.)
2.21 − 2.23 (0.0870 − 0.0878)2.57 − 2.59 (0.1012 − 0.1020)2.93 − 2.95 (0.1154 − 0.1161)
2.24 − 2.26 (0.0882 − 0.0890)2.60 − 2.62 (0.1024 − 0.1031)2.96 − 2.98 (0.1165 − 0.1173)
2.27 − 2.29 (0.0894 − 0.0902)2.63 − 2.65 (0.1035 − 0.1043)2.99 − 3.01 (0.1177 − 0.1185)
2.30 − 2.32 (0.0906 − 0.0913)2.66 − 2.68 (0.1047 − 0.1055)3.02 − 3.04 (0.1189 − 0.1197)
2.33 − 2.35 (0.0917 − 0.0925)2.69 − 2.71 (0.1059 − 0.1067)3.05 − 3.07 (0.1201 − 0.1209)
2.36 −2.38 (0.0929 − 0.0937)2.72 − 2.74 (0.1071 − 0.1079)3.08 − 3.10 (0.1213 − 0.1220)
2.39 − 2.41 (0.0941 − 0.0949)2.75 − 2.77 (0.1083 − 0.1091)3.11 − 3.13 (0.1224 − 0.1232)
2.42 − 2.44 (0.0953 − 0.0961)2.78 − 2.80 (0.1094 − 0.1102)3.14 − 3.16 (0.1236 − 0.1244)
2.45 − 2.47 (0.0965 − 0.0972)2.81 − 2.83 (0.1106 − 0.1114)3.17 − 3.19 (0.1248 − 0.1256)
2.48 − 2.50 (0.0976 − 0.0984)2.84 − 2.86 (0.1118 − 0.1126)3.20 − 3.22 (0.1260 − 0.1268)
2.51 − 2.53 (0.0988 − 0.0996)2.87 − 2.89 (0.1130 − 0.1138)−
2.54 − 2.56 (0.1000 − 0.1008)2.90 − 2.92 (0.1142 − 0.1150)−
14. REMOVE COMPANION FLANGE (See page SA−69)
15. REMOVE FRONT BEARING (See page SA−74)
16. INSTALL NEW BEARING SPACER AND FRONT
BEARING
Install a new bearing spacer and front bearing on the drive pin-
ion.
17. INSTALL OIL SLINGER
18. INSTALL NEW FRONT OIL SEAL
(a) Using SST and hammer, install a new oil seal.
SST 09554−22010
Oil seal drive in depth: 2.0 mm (0.079 in.)
(b) Apply MP grease to the oil seal lip.
19. INSTALL COMPANION FLANGE
(a) Using SST, install the companion flange on the drive pin-
ion.
SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03040, 09956−03020)
(b) Coat the threads of a new nut with hypoid gear oil.