1996 TOYOTA RAV4 oil

W01248
SST
F00872
SST
Oil Seal
SR−50
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
14. REMOVE CYLINDER END STOPPER AND STEERING
RACK
(a) Using snap ring pliers, remove the snap ring from the rack
housing.
(b) Using SST, press out the steering rack and end stopper.
SST 09612−10093 (09612−10061)
(c) Remove the oil seal from the steering rack.
15. REMOVE OIL SEAL
Using SST, press out the oil seal.
SST 09950−60010 (09951−00260),
09950−70010 (09951−07360)
NOTICE:
Be careful not to damage the rack housing.

SR0G4−03
R10072
Dial Indicator
W01250
Cylinder Gauge
Bushing
Micrometer
W03557
SST
Bushing SST
R11295
Vinyl Tape
Oil Seal
− STEERINGPOWER STEERING GEAR
SR−51
1996 RAV4 (RM447U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. INSPECT STEERING RACK
(a) Using a dial indicator, check the rack for runout.
Maximum runout: 0.30 mm (0.0118 in.)
(b) Check the rack for teeth wear and damage.
(c) Check the back surface for wear and damage.
2. CHECK CONTROL VALVE ASSEMBLY AND BUSHING
Using a cylinder gauge and a micrometer, measure the inside
diameter of the bushing and outside diameter of the valve as-
sembly.
Maximum inside diameter: 28.20 mm (1.1102 in.)
Minimum outside diameter: 27.75 mm (1.0925 in.)
3. IF NECESSARY, REPLACE BUSHING AND OIL SEAL
(a) Using SST, remove the bushing from the rack housing.
SST 09612−24014 (09613−22011)
NOTICE:
Be careful not to damage the rack housing.
HINT:
Separate the SST as shown in the illustration to use it.
As shown, from the opposite side of SST confirm that its
claw is firmly caught on the bushing.
(b) Using a screwdriver, tap out the oil seal.
NOTICE:
To prevent rack housing damage, wind vinyl tape on the
screwdriver.

W04190
SST
SST Oil Seal
W01253
SST
SST
SSTBushing
R10955
R06172
N00401
SR−52
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
(c) Coat a new oil seal lip with power steering fluid.
(d) Using SST, carefully tap in the oil seal.
SST 09950−60010 (09951−00230, 09951−00330,
09952−06010), 09950−70010 (09951−07150)
NOTICE:
Make sure to install the oil seal facing the correct direction.
(e) Coat a new bushing with molybdenum disulfide lithium
base grease.
(f) Using SST, press in the bushing.
SST 09950−60010 (09951−00270, 09951−00340,
09952−06010),09950−70010 (09951−07150)
4. IF NECESSARY, REPLACE TEFLON RING AND O−
RING
(a) Using a screwdriver, remove the teflon ring and O−ring
from the steering rack.
NOTICE:
Be careful not to damage the groove for the teflon ring.
(b) Coat a new O−ring with power steering fluid and install it.
(c) Expand a new teflon ring with your fingers.
NOTICE:
Be careful not to overexpand the ring.
(d) Coat the ring with power steering fluid.
(e) Install the ring to the steering rack and snug it down with
your fingers.

SR0G8−02
F00873
SST
Oil Seal
SST
W02101
Rack Teeth End
SST
SST Rack Teeth End
W01257
Vinyl Tape
− STEERINGPOWER STEERING GEAR
SR−55
1996 RAV4 (RM447U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH POWER STEERING FLUID OR MOLYBDE-
NUM DISULFIDE LITHIUM BASE GREASE
(See page SR−44)
2. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal.
SST 09950−60010 (09951−00230, 09951−00400,
09952−06010), 09950−70010 (09951−07360)
NOTICE:
Make sure to install the oil seal facing the correct
direction.
Take care that the oil seal does not get reversed as
you install it.
3. INSTALL STEERING RACK
(a) Install SST to the rack.
HINT:
If necessary, scrape the burrs off the rack teeth end and bur-
nish.
SST 09631−16020
(b) Coat SST with power steering fluid.
(c) Install the rack into the rack housing.
(d) Remove the SST.
4. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) To prevent oil seal lip damage, wind vinyl tape on the
steering rack end, and apply power steering fluid.
(c) Install the oil seal by pushing it into the rack housing, with-
out tilting.
NOTICE:
Make sure to install the oil seal facing the correct direction.

W01258
SST
W01259
SST
Bearing
W04191
SST
Oil SealPress SR−56
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
5. INSTALL CYLINDER END STOPPER
(a) Install the stopper into the rack housing.
(b) Using snap ring pliers, install a new snap ring to the rack
housing.
6. AIR TIGHTNESS TEST
(a) Install SST to the union of the rack housing.
SST 09631−22030
(b) Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for
about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil
seals.
7. INSTALL CONTROL VALVE ASSEMBLY
(a) Coat the teflon rings with power steering fluid.
(b) Install the control valve assembly into the rack housing.
NOTICE:
Be careful not to damage the teflon rings and oil seal.
8. INSTALL BEARING
Using SST, press in a new bearing.
SST 09612−22011
9. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST and a press, press in the oil seal.
SST 09612−22011
NOTICE:
Make sure to install the oil seal facing the correct direction.
(c) Using snap ring pliers, install a new snap ring to the rack
housing.
10. INSTALL DUST COVER
11. INSTALL BEARING
Install the spacer and a new bearing into the rack housing.

W01262
SST
W01263
SST
Spacer
Lock NutBC
A
W04192
12°
Hexagon Wrench
W01265
SST
− STEERINGPOWER STEERING GEAR
SR−57
1996 RAV4 (RM447U)
12. INSTALL LOCK NUT
(a) Using SST to stop the control valve shaft rotating, torque
a new nut.
SST 09616−00010
Torque: 12 N·m (125 kgf·cm, 9 ft·lbf)
(b) Turn C of SST to obtain dimension A, then set SST, as
shown.
SST 09613−12020
Dimension A: 16.5 − 17.0 mm (0.65 − 0.67 in.)
(c) Stake the nut by turning B of SST until it touches the
spacer of SST.
13. INSTALL RACK HOUSING CAP
(a) Apply sealant to 2 or 3 threads of the cap.
Sealant: Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Torque the cap.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
14. INSTALL RACK GUIDE SEAT, RACK GUIDE, RACK
GUIDE SPRING AND RACK GUIDE SPRING CAP
(a) Install the seat to the guide.
(b) Apply sealant to 2 or 3 threads of the cap.
Sealant: Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Temporarily install the cap.
15. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH rack ends.
(b) Using a hexagon wrench (21 mm), torque the rack guide
spring cap.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Using a hexagon wrench (21 mm), return the cap 12°.
(d) Using SST, turn the control valve shaft right and left 1 or
2 times.
SST 09616−00010
(e) Using a hexagon wrench (21 mm), loosen the cap until the
rack guide spring is not functioning.

P10584
Ohmmeter
Continuity
ST0N6−01
P10585
Ohmmeter
No Continuity
P10586
P10587
ST0040
− STARTINGSTARTER
ST−7
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT ARMATURE COIL COMMUTATOR FOR
OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
2. INSPECT ARMATURE COIL COMMUTATOR FOR
GROUND
Using an ohmmeter, check that there is no continuity between
the commutator and armature coil core.
If there is continuity, replace the armature.
3. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACES
If the surface is dirty or burnt, correct it with sandpaper (No.400)
or on a lathe.
4. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Place the commutator on V−blocks.
(b) Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
5. INSPECT COMMUTATOR DIAMETER
Using a vernier caliper, measure the commutator diameter.
Standard diameter: 30.0 mm (1.181 in.)
Minimum diameter: 29.0 mm (1.142 in.)
If the diameter is less than minimum, replace the armature.
6. INSPECT UNDERCUT DEPTH
Check that the undercut depth is clean and free of foreign mate-
rials. Smooth out the edge.
Standard undercut depth: 0.6 mm (0.024 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.

P10588
Ohmmeter
Continuity
P10589
Ohmmeter
No Continuity
Z10079
Brush Holder Side
Field Frame Side Length
Length ST−8
− STARTINGSTARTER
1996 RAV4 (RM447U)
7. INSPECT FIELD FRAME (FIELD COIL) FOR OPEN
CIRCUIT
Using an ohmmeter, check that there is continuity between the
lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
8. INSPECT FIELD FRAME (FIELD COIL) FOR GROUND
Using an ohmmeter, check that there is no continuity between
the field coil end and field frame.
If there is continuity, repair or replace the field frame.
9. INSPECT BRUSH LENGTH
Using a vernier caliper, measure the brush length.
Standard length: 15.5 mm (0.610 in.)
Minimum length: 10 mm (0.394 in.)
If the length is less than minimum, replace the brush holder and
field frame.