1996 TOYOTA RAV4 key

K OVERALL ELECTRICAL WIRING DIAGRAM
1
234
10 RAV4
2 1D 9
2 1K 4100A ALT2
1
IG 16 II1 31 L1 UL2
10 131
16 4 3EACT+ACT-
4 IC 1 1 4 IC1 4 II1 14 II1
2BM1 1BM1 7ID2 8ID2
54 54 21
MMM
4C 14C 9
W-B W-B W-B
L-WL- Y
L- W L- Y
W L-WL- Y W-R
IG
D 5
DOOR LOCK CONTROL RELAY
W-B L-WD14
DOOR KEY LOCK AND
UNLOCK SW
(
Front Passenger' s
Side)W-B
D13
DOOR LOCK MOTOR
(
Driver' s Side)D14
DOOR LOCK MOTOR
(
Front Passenger' s
Side)D12
DOOR LOCK MOTOR
(
Rear RH)
L RL RL R
L RL R
R
L
R
L L R
W-B
Right kick panel
Power
SourceDoor Lock ControlBATTERYF 7
FU SIB LE LIN K
BLO CK
40A
AM1
LO C K UNLOCKLOCK UNLOCK
6
2 1 1 II1 1 0 II1
3
47 BK1 8 BK1
31
M
B 7
BACK DOOR
LO C K MO T O R
L R
2BN1 1BN1
21
M
D11
DOOR LOCK MOTOR
(
Rear LH)
L R
W
6 4 3 2 1
7 8 9 10 11 12 145
13 B (
*2)
P 4 A (
*1)
P 4
(
*2) (
*2) (
*2) (
*2)
L RL R
(
*2)
(
*2)R
LLR
(
*2)
(
*2)(
*2)
(
*2) DOOR LOCK CONTROL SW
[PO W ER W IND O W M ASTER SW ]
L-Y
A, B2
1
ID 16 IC1 31
W-B W-B W-B
L-WL-R
L-WL-Y
W-B L- W
D13
DOOR KEY LOCK AND
UNLOCK SW
(
Driver' s Side)
Left kick panel
LOCK UNLOCKLO CK UNLOCK
2 11 IC 1 10 IC1
4B 2A
2B 6A(
*1)
(
*2)P 4
DOOR LOCK
CO NTRO L SW
[P O W E R W IND OW
M ASTER SW ] A(
*1)
(
*2)
B 3
D10
DOOR LOCK CONTROL SW
(
Front Passenger' s
Side)
L-W
L-W L-Y
L-Y
15
AB
B A B A B AJ 6
JUNCTION
CONNECTORR- L
To Power M ain R elay
<14-1
12
534
678910* 1 : 2- D oor
* 2 : 4- D oor
IC1 UL3
9
L-R L-R
8RLY
To Door Courtesy SW
(
F ront P assenger' s Side)
<6-3R- G14
DSWP 1E 8
1B 83
4 F 8
10A GAUGE
[FUSE BLOCK] 2AC C
IG 1 AM1 421K
1
230A
POWER
11C 1
1F 7
1D B-Y B
8
B
R-L R-L
WW
WW
I1 0
IG N ITION S W

K
1
234
15 RAV4
ACC
IG 1
IG 2
ST2 AM1
AM2
1D 9
1K 4
3A
2A 6A 1A 5A 2B 6B
5ID2 6ID2 IC 1 1 7 IC1 1 II1 II172
2
4A
1B 3B 7A
3ID2 4ID2
IG I1 0
IG N ITION S W
6
80A M A IN
L-R
F 8
7. 5A E C U- IG
[FUSE BLOCK] 24
BATTERY+B
FL- FR + FR- R L+ R L- FL+ACC
1122
F 9
FRONT SPEAKER
LHF10
FRONT SPEAKER
RH15A
DOME
RR+ RR- GND R 3 B , R 4 A RADIO AND PLAYER12 34
567891012
3456
A R 4B R 3 RADIO AND PLAYER
100A ALTP V LGL BB
L
LG
V
P
W W2
26
1D 5
1FL- R
12
131D 7
1F 4
B-Y GR GRY RR
Y W W BR
L-Y
W
19 18
W
R ight kick panel
Power SourceRadio and Player2
F 7
FU SIBLE
LIN K B LO CK
40A
AM1
1* 1 : 2- Door
* 2 : 4- Door
(
*1) (
*2)(
*2)
(
*1)REAR SPEAKER LH, RH
12
1 2
R12 A , B
REAR SPEAKER LHR13 A , B
REAR SPEAKER RH 1
B 2
A1
B 2
A 2
B1
A2
B1
AA (
*2)
R12, R13
B (
*1)
R12, R13W
1J 5
1I 22L-Y L-YD
6CD
J 3
JUNCTION
CONNECTOR J 3
JUNCTION
CON NECTOR 1H 101E 66
7F 8
15A
CIG & RAD
[FUSE BLOCK]
4C 3
4C 15
1
2P2
P1
P 3G-W
G- R
G 12
SLS+
SLS- L L-R SH IFT LO CK
SO LENO ID
SH IFT LO CK
CONTROL SW
Instrument panel
brace R HIF 1 2
10
4C1H 31E 4 B- Y 3
GR
B-Y B-YG-WGR
212
F rom S top Light S W
<9-3
IG ST P A CC
W-B
L-B
W-B
C
4EKLS+
W-B
S 4
SHIFT LOCK ECU
Shift Lock
K 2
KEY INTERLOCK
SOLENO ID

MX01Z−08
− MANUAL TRANSAXLETROUBLESHOOTING
MX−1
1996 RAV4 (RM447U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Noise
14.Oil (Level low) 2WD
4WD
15. Oil (Wrong) 2WD
4WD
16.Gear (Worn or damaged)
17.Bearing (Worn or damaged)MX−3
MX−9
MX−3
MX−9
MX−12
MX−79
MX−12
MX−79
Oil leakage
1. Oil (Level too high) 2WD
4WD
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O−Ring (Worn or damaged)MX−3
MX−9
MX−12
MX−79
MX−12
MX−79
MX−12
MX−78
MX−79
Hard to shift or will not shift
1. Control cable (Faulty)
2. Synchronizer ring (Worn or damaged)
3. Shift key spring (Damaged)MX−77
MX−12
MX−29
MX−36
MX−12
MX−29
MX−36
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MX−12
MX−12
MX−79
MX−12
MX−79
MX−12
MX−79
Tight corner braking1. Differential, Center differential (Faulty)MX−58
MX−72

Z17555
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 Precoated partOutput Shaft AssemblyInput Shaft Assembly
 Tapered Roller Bearing
Outer Race
Reverse Idler Gear ShaftReverse Idler Gear
Thrust Washer
Rear Bearing Retainer
Needle Roller Bearing 5th Driven Gear
Synchronizer Pull RingKey Spring
Middle Synchronizer
Ring
Snap Ring Output Shaft
Lock Nut5th Gear
No.3 Clutch Hub
No.3 Hub Sleeve Key Spring Outer Synchronizer RingInner Synchronizer RingSnap Ring
Spacer x7Shim
 Lock Bolt
29 (300, 22)
42 (430, 31)
123 (1,250, 90)
Snap Ring 
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX−15
1996 RAV4 (RM447U)

MT0781
MX−22
− MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 RAV4 (RM447U)
38. REMOVE NO.5 SYNCHRONIZER RING WITH KEY
SPRING FROM NO.3 CLUTCH HUB
(a) Remove the No.5 synchronizer ring with the key spring
from the No.3 clutch hub.
(b) Using a screwdriver, remove the snap ring.
HINT:
Wrap vinyl tape on the screwdriver to prevent damaging the
synchronizer ring.
(c) Remove the synchronizer rings.

MX028−02
MT0791
Rear Bearing4th GearSpacer
Synchronizer Ring
Snap Ring
Needle Roller Bearing3rd GearNeedle Roller Bearing
 Input Shaft Front Bearing Inner Race
Input Shaft Synchronizer Ring
No.2 Hub Sleeve
No.2 Clutch Hub
Shifting KeySpring
Snap Ring
 Non−reusable part
− MANUAL TRANSAXLEINPUT SHAFT
MX−29
1996 RAV4 (RM447U)
INPUT SHAFT
COMPONENTS

MX02B−04
Q00383
Front
MT0790
Q00183SST
Q00116
MX−34
− MANUAL TRANSAXLEINPUT SHAFT
1996 RAV4 (RM447U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
(a) Install the 3 springs and shifting keys to the clutch hub.
(b) Install the hub sleeve to the clutch hub.
HINT:
Direct identification groove of the hub sleeve to front of the
transmission.
2. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-
SEMBLY TO INPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Assemble the needle roller bearings into the 3rd gear.
(c) Place the synchronizer rings on the gear and align the
ring slots with the shifting keys.
(d) Using SST and a press, install the 3rd gear and No.2 hub
sleeve.
SST 09506−35010
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
H2.30 (0.0906)M2.50 (0.0984)
J2.35 (0.0925)N2.55 (0.1004)
K2.40 (0.0945)P2.60 (0.1024)
L2.45 (0.0965)−−
(b) Using a screwdriver and hammer, tap in the snap ring.

N00494
SST
Q00118
− MANUAL TRANSAXLEINPUT SHAFT
MX−35
1996 RAV4 (RM447U)
4. MEASURE 3RD GEAR THRUST CLEARANCE
(See page MX−30)
5. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE
ROLLER BEARING, 4TH GEAR AND REAR BALL
BEARING
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearings.
(c) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(d) Install the 4th gear.
(e) Using SST and a press, install the rear ball bearing.
SST 09506−35010
6. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
12.35 (0.0925)52.55 (0.1004)
22.40 (0.0945)62.60 (0.1024)
32.45 (0.0965)72.65 (0.1043)
42.50 (0.0984)82.70 (0.1063)
(b) Using a screwdriver and hammer, tap in the snap ring.
7. MEASURE 4TH GEAR THRUST CLEARANCE
(See page MX−30)