1996 TOYOTA RAV4 torque

F03756
SST
R07223
Z13195
SA−78
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
20. REMOVE SIDE BEARINGS
Using SST and a press, remove the 2 side bearings from the
differential case.
SST 09950−00020
NOTICE:
Be careful not to drop the differential case.
21. 2 Pinion Differential Only:
DISASSEMBLE DIFFERENTIAL CASE
NOTICE:
If equipped with Torque Sensing LSD, do not disassemble
the differential case.
(a) Using a pin punch and hammer, remove the straight pin.
(b) Remove these parts from the differential case:
Pinion shaft
2 pinion gears
2 pinion gear thrust washers
2 side gears
2 side gear thrust washers

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

RA0090
F03764
F03753
Matchmarks
F03768
Hold
SA−84
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
(b) Using a micrometer, measure the thickness of the re-
moved plate washer.
(c) Install a new washer 0.06 − 0.09 mm (0.0024 − 0.0035 in.)
thicker than the removed washer.
HINT:
Select a washer which can be pressed in 2/3 of the way by fin-
ger.
(d) Using a brass bar and hammer, tap in the plate washer.
(e) Align the matchmarks on the cap and carrier, and install
the 2 bearing caps and 4 bolts.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
(f) Recheck the ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
If it is not within the specification, adjust it by either increasing
or decreasing the thickness washers on both sides by equal
amount.
HINT:
The backlash will change by about 0.02 mm (0.0008 in.) every
0.03 mm (0.0012 in.) change in the plate washer thickness.
Washer thickness
Thickness mm (in.)Thickness mm (in.)Thickness mm (in.)
2.26 − 2.28 (0.0890 − 0.0898)2.41 − 2.43 (0.0949 − 0.0957)2.56 − 2.58 (0.1008 − 0.1016)
2.29 − 2.31 (0.0902 − 0.0909)2.44 − 2.46 (0.0961 − 0.0969)2.59 − 2.61 (0.1020 − 0.1028)
2.32 − 2.34 (0.0913 − 0.0921)2.47 − 2.49 (0.0972 − 0.0980)2.62 − 2.64 (0.1031 − 0.1039)
2.35 −2.37 (0.0925 − 0.0933)2.50 − 2.52 (0.0984 − 0.0992)2.65 − 2.67 (0.1043 − 0.1051)
2.38 − 2.40 (0.0937 − 0.0945)2.53 − 2.55 (0.0996 − 0.1004)2.68 − 2.70 (0.1055 − 0.1063)

R10641
F03765
SA1653
Proper ContactHeel Contact
Toe ContactSelect an adjusting shim will bring the
drive pinion closer to the ring gear.Face Contact
Flank Contact
Select an adjusting shim that will shift the
drive pinion away from the ring gear.
SA1586
Plate Washer
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−85
1996 RAV4 (RM447U) 1/17/01
12. MEASURE 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)
13. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION
(a) Coat 3 or 4 teeth at 3 different positions on the ring gear
with red lead primer.
(b) Hold the companion flange firmly and rotate the ring gear
in both directions.
(c) Inspect the tooth contact pattern.
If the teeth are not contacting properly, use the following chart
to select a proper washer for correction.

R10768
SST
R10641
W01227
SST
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−87
1996 RAV4 (RM447U) 1/17/01
(c) Using SST to hold the flange, torque the nut.
SST 09330−00021
Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf)
20. CHECK DRIVE PINION PRELOAD
(a) Using a torque wrench, measure the preload of the back-
lash between the drive pinion and ring gear.
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)
If preload is larger than the specification, replace the bearing
spacer.
If preload is less than the specification, retorque the nut 13 N·m
(130 kgf·cm, 9 ft·lbf) at a time until the specified preload is
reached.
Torque: 235 N·m (2,400 kgf·cm, 174 ft·lbf) or less
If the maximum torque is exceeded while retighten the nut, re-
place the bearing spacer and repeat the preload procedure. Do
not loosen the pinion nut to reduce the preload.
21. RECHECK TOTAL PRELOAD (See page SA−74)
22. RECHECK RING GEAR BACKLASH
(See page SA−74)
23. RECHECK TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA−79)
24. CHECK COMPANION FLANGE RUNOUT
(See page SA−74)
25. STAKE DRIVE PINION NUT
26. INSTALL SIDE GEAR SHAFT OIL SEALS
(a) Using SST and a hammer, install 2 oil seals until they are
flush with the carrier end surface.
SST 09550−00032, 09950−70010 (09951−07150)
(b) Coat MP grease to the oil seal lip.
27. Torque Sensing LSD:
INSTALL SIDE GEAR SHAFTS

R10664
SST
R10757
Z12363
1 − 2 mm
(0.04 − 0.08 in.) SA−88
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
(a) Install 2 new snap rings to the side gear shafts.
(b) Using SST, install the 2 side gear shafts until it contacts
the pinion shaft.
SST 09520−24010
HINT:
Check that the shaft is fully inserted by confirming the noise it
should make when it is tapped.
28. 2 Pinion Differential:
INSTALL SIDE GEAR SHAFTS
(a) Install the 2 side gear shafts to the differential case.
(b) Install 2 new snap rings to the 2 side gear shafts.
29. INSTALL DIFFERENTIAL CARRIER COVER
(a) Clean contacting surfaces of any residual FIPG material
using gasoline or alcohol.
(b) Apply FIPG to the carrier.
FIPG:
Part No.08826−00090, THREE BOND 1281 or equiva-
lent
HINT:
Install the carrier cover within 3 minutes after applying FIPG.
(c) Torque the 8 bolts.
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)

SA0UO−04
W04028
Retainer Suspension Cap
Retainer Retainer Cushion
Rear
Shock
Absorber
Bushing
Brake Drum
25 (250, 18)
Cushion Retainer
Retainer
7.8 (80, 69 in.·lbf)
13 (130, 9)
18 (185, 13)
19 (195, 14)
19 (195, 14)
4WD
Lock cap
Cotter Pin
216 (2,200, 59)
80 (820, 59)

 Parking Brake Cable
113 (1,150, 83)
113 (1,150, 83)Upper Suspension Arm
113 (1,150, 83)Camber
Adjust
Cam
Lower Suspension Arm103 (1,050, 76)
Clip 
103 (1,050, 76)
132 (1,350, 98)
To e−adjust Cam
Attachment
Bushing
Rear No.1 Suspension Arm
Attachment Spring Bumper
Upper Insulator
Coil Spring
Shock Absorber
Lower Pivot pin
13 (130, 9)
140 (1,430, 103)
N·m (kgf·cm, ft·lbf) : Specified torque
Non−reusable part

56 (570, 41)
37 (380, 27)
Rear Drive Shaft4WD: Rear Differential
13 (130, 9)
2WD
Rear Axle Shaft SA−90
− SUSPENSION AND AXLEREAR SHOCK ABSORBER
1996 RAV4 (RM447U)
REAR SHOCK ABSORBER
COMPONENTS