1996 TOYOTA RAV4 Cv axle

Q06218
Q06219
Q07870
SST MX−60
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
(d) Remove these parts from the front differential case:
2 front differential pinion shafts
No.2 front differential pinion shaft
Front differential pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
Front differential side gear
Front differential side gear thrust washer
6. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the spacer and vehicle speed sensor drive gear.
7. DISASSEMBLE NO.1 DIFFERENTIAL CASE
Remove these parts from the No.1 differential case:
4 differential pinion shafts
Pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
Differential side gear subassembly
Conical spring washer
No.2 differential side gear thrust washer
8. No.2 Differential Case Side:
REMOVE TAPERED ROLLER BEARING
Using SST, remove the tapered roller bearing.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00520)

Q07895
SST
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−61
1996 RAV4 (RM447U)
9. No.1 Differential Case Side:
REMOVE TAPERED ROLLER BEARING
Using SST, remove the tapered roller bearing.
SST 09950−00020, 09950−00030, 09950−60010
(09951−00450)

MX0DX−01
Q06209
A
B
Case No.1 Differential
Case No.2 Differential
Q06210
A B
Z12920
MX−62
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
INSPECTION
1. MEASURE NO.1 AND NO.2 DIFFERENTIAL CASES
Using a cylinder gauge, measure the inner diameter of the No.1
and No.2 differential cases bushing.
Standard diameter:
A: 104.000−104.035 mm (4.0945−4.0959 in.)
B: 97.000−97.035 mm (3.8189−3.8203 in.)
Maximum diameter:
A: 104.060 mm (4.0969 in.)
B: 97.060 mm (3.8213 in.)
2. MEASURE FRONT DIFFERENTIAL CASE
Using a micrometer, measure the outer diameter of the front dif-
ferential case.
Standard diameter:
A: 103.929−103.964 mm (4.0917−4.0931 in.)
B: 96.929−96.964 mm (3.8161−3.8175 in.)
Minimum diameter:
A: 103.850 mm (4.0887 in.)
B: 96.850 mm (3.8130 in.)
3. MEASURE CONICAL SPRING WASHER
Using calipers, measure the height of the conical spring wash-
er.
Standard height:
No.2 differential case side
2.60−2.80 mm (0.102−0.110 in.)
No.1 differential case side
1.70−1.90 mm (0.067−0.075 in.)
Minimum height:
No.2 differential case side
2.50 mm (0.098 in.)
No.1 differential case side
1.60 mm (0.063 in.)

Z12494
MX0DY−01
Z12381
SST
Z12496
Q06288
SST
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−63
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 transmission oil baffle.
(c) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly.
(d) Remove the adjust shim.
(e) Install the adjust shim.
(See page MX−65)
HINT:
First select and install a shim of less thickness than before.
(f) Using SST and a press, install the tapered roller bearing
outer race.
SST 09316−60011 (09316−00011, 09316−00041)
(g) Install the transmission oil baffle.
HINT:
Install the transmission oil baffle projection into the case side
cutout.
(h) Using SST, drive in a new oil seal.
SST 09223−15020, 09950−70010 (09951−07150)
(i) Coat the lip of the oil seal with MP grease.

Z12497
Z12383
SST MX−64
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
2. Transaxle Case Side:
REPLACE TAPERED ROLLER BEARING OUTER
RACE
(a) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly through the cutout portion on the
transaxle case.
(b) Using SST and a press, install the tapered roller bearing
outer race.
SST 09316−60011 (09316−00011, 09316−00041)

Q06211
SST
MX02M−03
Q06212
SST
Q06224
Thrust Washer
Thickness
1.0 mm (0.039 in.)
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−65
1996 RAV4 (RM447U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. No.1 Differential Case Side:
INSTALL TAPERED ROLLER BEARING
Using SST, install a new tapered roller bearing.
SST 09316−20011
2. No.2 Differential Case Side:
INSTALL TAPERED ROLLER BEARING
Using SST, install a new tapered roller bearing.
SST 09316−20011
3. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE
GEAR BACKLASH (DIFFERENTIAL SIDE GEAR SUB-
ASSEMBLY SIDE)
(a) Install these parts to the No.1 differential case:
No.2 differential side gear thrust washer
Temporarily install a 1.0 mm (0.039 in.) thick thrust
washer
Differential side gear subassembly
Pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
4 differential pinion shafts

Q06192
Q06220
Q06193
MX−66
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
1996 RAV4 (RM447U)
(b) Using a dial indicator, measure the backlash of one pinion
gear while holding the differential side gear sub assembly
toward the case.
Standard backlash: 0.05−0.20 mm (0.0020−0.0079 in.)
HINT:
Push the pinion gear of the right side of the differential case.
If the backlash is out of the specification, refer to the table below
and select a thrust washer which will ensure that the backlash
is within the specification.
MarkThickness mm (in.)MarkThickness mm (in.)
−0.80 (0.0315)−1.15 (0.0453)
−0.85 (0.0335)−1.20 (0.0472)
−0.90 (0.0354)−1.25 (0.0492)
−0.95 (0.0374)−1.30 (0.0512)
−1.00 (0.0394)−1.35 (0.0531)
−1.05 (0.0413)−1.40 (0.0551)
−1.10 (0.0433)−−
(c) Disassemble the No.1 differential case.
4. ASSEMBLE NO.1 DIFFERENTIAL CASE
Install these parts to the No.1 differential case:
No.2 side gear thrust washer (previously selected)
Conical spring washer
Differential side gear subassembly
Pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
4 differential pinion shafts
HINT:
Ensure that the conical spring washer is installed correctly.
5. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR
(a) Install the vehicle speed sensor drive gear and spacer.
(b) Using a snap ring expander, install the snap ring.

Q06218
Q06194
Q06195
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−67
1996 RAV4 (RM447U)
6. CHECK AND ADJUST FRONT SIDE GEAR BACK-
LASH (FRONT DIFFERENTIAL CASE SIDE)
(a) Install these parts to the front differential case:
Front differential side gear thrust washer
Front differential side gear
Front differential pinion shaft holder
4 differential pinions
4 differential pinion thrust washers
No.2 front differential pinion shaft
2 front differential pinion shafts
(b) Using a dial indicator, measure the backlash of one pinion
gear while holding the front differential side gear toward
the case.
Standard backlash: 0.05−0.20 mm (0.0020−0.0079 in.)
NOTICE:
Do not mount the surface of front differential case which
contacts with bushing in a vise.
If the backlash is out of the specification, refer to the table below
and select a thrust washer which will ensure that the backlash
is within the specification.
MarkThickness mm (in.)
B1.00 (0.0394)
C1.05 (0.0413)
D1.10 (0.0433)
E1.15 (0.0453)
F1.20 (0.0472)
G1.25 (0.0492)
7. INSTALL SNAP RING
(a) Install the spacer.
(b) Using a snap ring expander, install the shaft snap ring, as
shown.
HINT:
Before installing the shaft snap ring, wrap vinyl tape around the
case to avoid damaging the case.