1996 TOYOTA RAV4 transfer

Z17564
Left Side Bearing
Right Side Bearing
Ring Gear Mounting Case
Transfer Ring Gear
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable partx12
 
97 (985, 71)
− MANUAL TRANSAXLETRANSFER (4WD)
MX−81
1996 RAV4 (RM447U)

MX0DZ−01
Q06131
Q06157
SST
Q06158
MX−82
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE DUST BOOT
2. REMOVE DYNAMIC DAMPER
Remove the 4 bolts and dynamic damper.
3. REMOVE EXTENSION HOUSING
(a) Remove the 4 bolts, tap the extension housing with a
plastic hammer and remove it.
(b) Remove the O−ring from the extension housing.
4. REMOVE PLUG AND DIFFERENTIAL LOCK INDICA-
TOR SWITCH
(a) Using a hexagon wrench (6 mm), remove the plug.
(b) Using a hexagon wrench (10 mm), remove the plug and
gasket.
(c) Remove the differential lock indicator switch and gasket.
5. REMOVE TRANSFER RIGHT CASE OIL SEAL
Using a screwdriver and hammer, remove the oil seal.
6. CHECK PRELOAD
(a) Using SST and a spring tension gauge, measure the driv-
en pinion preload of the backlash between the driven pin-
ion and ring gear.
SST 09326−20011
Preload (at starting):
9−14 N (0.9−1.4 kgf, 2−3 lbf)
(b) Using SST and a spring tension gauge, measure the total
preload.
SST 09326−20011
Total preload (at starting):
Driven pinion preload plus
5−9 N (0.5−0.9 kgf, 1−2 lbf)
7. REMOVE TRANSFER INSPECTION HOLE COVER
(a) Remove the 3 bolts.
(b) Using a screwdriver and hammer, remove the transfer in-
spection hole cover.
8. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13−0.18 mm (0.0051−0.0071 in.)
9. CHECK TOOTH CONTACT (See page MX−89)

Z12395
SST
Z12545
Q06133
Q06142
SST
− MANUAL TRANSAXLETRANSFER (4WD)
MX−83
1996 RAV4 (RM447U)
10. REMOVE TRANSFER PINION BEARING CAGE AS-
SEMBLY
(a) Remove the 6 bolts, tap the transfer pinion bearing cage
assembly with a plastic hammer and remove it.
(b) Remove the O−ring and 2 adjusting shims from the trans-
fer pinion bearing cage.
(c) Remove the lock nut.
(1) Unstake the lock nut.
(2) Using SST, remove the lock nut.
SST 09326−20011
(d) Remove the transfer driven pinion.
Using a press, remove the transfer driven pinion, rear
bearing and spacer.
11. REMOVE DIFFERENTIAL LOCK SHIFT FORK, LOCK
SLEEVE AND SHIFT FORK SHAFT
Remove the bolt, shift fork, shift fork shaft and lock sleeve.
12. REMOVE TRANSFER RIGHT CASE
Remove the 10 bolts, tap the transfer right case with a plastic
hammer and remove it.
13. REMOVE RING GEAR MOUNTING CASE ASSEMBLY
(a) Remove the mounting case right side bearing.
Using SST, remove the right side bearing.
SST 09950−40010, 09950−60010 (09951−00500)

Q06143
SST
Q06144
Q06161
Q06148
Q06134
SST MX−84
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
(b) Remove the mounting case left side bearing.
Using SST, remove the left side bearing.
SST 09950−40010, 09950−60010 (09951−00500)
(c) Check the ring gear runout.
Using a dial indicator, check the ring gear runout.
Maximum runout: 0.1 mm (0.004 in.)
(d) Remove the transfer ring gear.
(1) Place matchmarks on both the ring gear mounting
case and transfer ring gear.
(2) Remove the 12 bolts.
(3) Using a pin punch and hammer, tap out the transfer
ring gear.
14. REMOVE DIFFERENTIAL SIDE GEAR SHAFT HOLD-
ER
(a) Using snap ring pliers, remove the snap ring from the
transfer right case.
(b) Using SST and a press, remove the differential side gear
shaft holder.
SST 09527−17011

Q06135
− MANUAL TRANSAXLETRANSFER (4WD)
MX−85
1996 RAV4 (RM447U)
15. REMOVE ADJUSTING NUT LOCK PLATE
Using snap ring pliers, remove the adjusting nut lock plate from
the transfer right case.

Q05709
SST
MX0E0−01
Z12397
SST
Z12546
Q08760
SST SST
Z16232
Socket Wrench MX−86
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
REPLACEMENT
1. REPLACE DRIVEN PINION FRONT BEARING
(a) Using SST and a press, remove the front bearing.
SST 09950−00020
(b) Using SST and a press, install a new front bearing.
SST 09316−60011 (09316−00051)
2. REPLACE FRONT AND REAR BEARING OUTER
RACE
(a) Using a brass bar and hammer, drive out the front and
rear bearing outer race lightly and evenly.
(b) Using SST and a press, install a new front bearing outer
race.
SST 09950−60020 (09951−00780), 09950−70010
(09951−07150)
(c) Using SST and a press, install a new rear bearing outer
race.
SST 09950−60010 (09951−00590), 09950−70010
(09951−07150)
3. REPLACE SHIFT FORK SHAFT OIL SEAL
(a) Using a screwdriver, remove the oil seal from the transfer
right case.
(b) Using a socket wrench and hammer, install a new oil seal.

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)

Z12393
SST
Q06159
SST
Q06177
Q06160
SST MX−88
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
7. Transfer Right Case Side:
REPLACE RING GEAR MOUNTING CASE SIDE BEAR-
ING OUTER RACE
(a) Using SST, turn the bearing adjusting nut, and remove the
outer race and bearing adjusting nut.
SST 09318−20010
(b) Using SST, turn the bearing adjusting nut until it touches
the lip of the case.
SST 09318−20010
(c) Using SST and a press, install a new bearing outer race
until it almost touches the bearing adjusting nut.
SST 09950−60020 (09951−00890), 09950−70010
(09951−07150)
8. Transfer Left Case Side:
REPLACE RING GEAR MOUNTING CASE SIDE BEAR-
ING OUTER RACE
(a) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly.
(b) Remove the plate washer.
(c) Install the plate washer.
HINT:
First install a washer of the same thickness as before.
(d) Using SST and a press, install a new bearing outer race.
SST 09316−60011 (09316−00011, 09316−00061)