1996 TOYOTA RAV4 Cv axle

MX02G−02
Z17558
GasketO−Ring
Oil Strainer
Oil Pump Driven Rotor
Oil Pump Drive Gear Oil Pump Drive Rotor
Oil Pump Cover Spring Holder Spring Ball Relief Valve Transmission Oil Pump
Case
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
10 (105, 8)
10 (105, 8)

 MX−44
− MANUAL TRANSAXLEOIL PUMP (2WD)
1996 RAV4 (RM447U)
OIL PUMP (2WD)
COMPONENTS

MX02H−01
Z00242
Z00243
Z00244
− MANUAL TRANSAXLEOIL PUMP (2WD)
MX−45
1996 RAV4 (RM447U)
INSPECTION
1. CHECK ROTOR BODY CLEARANCE
(a) Install the oil pump drive gear to the drive rotor.
(b) Using a feeler gauge, measure the body clearance be-
tween the drive rotor and oil pump case.
Standard clearance:
0.10 − 0.16 mm (0.0039 − 0.0063 in.)
Maximum clearance:
0.30 mm (0.0118 in.)
2. CHECK ROTOR TIP CLEARANCE
(a) Install the oil pump drive gear to the drive rotor.
(b) Using a feeler gauge, measure the tip clearance between
the drive and driven rotors.
Standard clearance:
0.08 − 0.15 mm (0.0031 − 0.0059 in.)
Maximum clearance:
0.30 mm (0.0118 in.)
3. CHECK SIDE CLEARANCE
Using a precision straight edge and feeler gauge, measure the
side clearance of both rotors.
Standard clearance:
0.03 − 0.08 mm (0.0012 − 0.0031 in.)
Maximum clearance:
0.15 mm (0.0059 in.)

MX05Y−01
Z17559
GasketO−Ring
Oil Strainer
Oil Pump Driven Rotor
Oil Pump Drive Gear Oil Pump Drive Rotor
Oil Pump Cover
Spring Holder Spring
Ball Relief Valve Transmission Oil Pump Case
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable partOil Line Case
No.3 Oil Pipe
10 (105, 8)
10 (105, 8)
 MX−46
− MANUAL TRANSAXLEOIL PUMP (4WD)
1996 RAV4 (RM447U)
OIL PUMP (4WD)
COMPONENTS

MX05Z−01
− MANUAL TRANSAXLEOIL PUMP (4WD)
MX−47
1996 RAV4 (RM447U)
INSPECTION
(See page MX−45)

MX02I−02
Q06217
Shift Interlock Plate
Transmission Oil Baffle Shift Interlock Plate
No.1 Compression SpringControl Shaft Cover
Oil Seal
Snap Ring
No.1 Select Spring Seat
Slotted Spring Pin
No.1 Shift Inner Lever
Shift and Select Lever Shaft Snap Ring
Non−reusable part No.2 Select Spring SeatNo.2 Compression SpringNo.2 Shift Inner LeverSlotted Spring Pin
Apply MP grease 
Dust Boot
 MX−48
− MANUAL TRANSAXLESHIFT AND SELECT LEVER SHAFT
1996 RAV4 (RM447U)
SHIFT AND SELECT LEVER SHAFT
COMPONENTS

MX060−01
Z17560
Transaxle Case Cover
Differential Spider
Differential Pinion
Differential Side Gear
Side Gear Thrust
Washer
Pinion Thrust Washer
 Tapered Roller Bearing
and Outer Race
Differential Right Case
Vehicle Speed Sensor Drive Gear
Differential Left Case
 Tapered Roller Bearing
and Outer Race Ring Gear
Oil Baffle
 Oil Seal x16
Shim  Oil Seal
54 (550, 40)
63 (640, 46)
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part 

x16
 Precoated partStud Bolt
54 (550, 40)
124 (1,260, 91)
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
MX−49
1996 RAV4 (RM447U)
DIFFERENTIAL CASE (2WD)
COMPONENTS

Q05166
SST
MX0DV−01
Z00281
Matchmarks
Z00284
MX−50
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE TAPERED ROLLER BEARING
Using SST, remove the left and right bearings.
SST 09950−40010
2. REMOVE RING GEAR
(a) Place matchmarks on both the differential case and ring
gear.
(b) Remove the 16 bolts.
(c) Using a plastic hammer, tap the ring gear and remove it.
3. DISASSEMBLE DIFFERENTIAL CASE
(a) Place matchmarks on the differential right and left cases.
(b) Using a torx wrench (T50), remove the 16 torx screws.
(c) Using a plastic hammer, tap the differential left case.
(d) Remove the vehicle speed sensor drive gear from the dif-
ferential right case.
(e) Remove the 2 differential side gears, side gear thrust
washers, 4 differential pinions and pinion thrust washers
from the differential left case.

Z00286
MX0DW−01
Z00288
SST
Z00289
Q06288
SST
− MANUAL TRANSAXLEDIFFERENTIAL CASE (2WD)
MX−51
1996 RAV4 (RM447U)
REPLACEMENT
1. Transmission Case Side:
REPLACE OIL SEAL AND TAPERED ROLLER BEAR-
ING OUTER RACE
(a) Using a screwdriver, remove the oil seal.
(b) Remove the oil baffle.
(c) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly.
(d) Remove the shim.
(e) Install the shim (See page MX−49).
HINT:
First select and install a shim of lesser thickness than before.
(f) Using SST and a press, install a new tapered roller bear-
ing outer race.
SST 09316−60011 (09316−00011, 09316−00041)
(g) Install the oil baffle.
HINT:
Install the oil baffle projection into the case side cutout.
(h) Using SST and a hammer, drive in a new oil seal.
SST 09223−15020, 09950−70010 (09951−07150)
(i) Coat the lip of oil seal with MP grease.