1996 TOYOTA RAV4 Cv axle

SA0UK−01
R10640
R10650
F03752
Hold
R10645
SA−74
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE DIFFERENTIAL CARRIER COVER
(a) Remove the 8 bolts from the carrier cover.
(b) Using a brass bar and hammer, separate the cover and
carrier.
2. CHECK RUNOUT OF COMPANION FLANGE
Using a dial indicator, measure the runout of the companion
flange vortically and horizontally.
Maximum runout: 0.10 mm (0.0039 in.)
3. CHECK RING GEAR RUNOUT
Using a dial indicator, check the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 in.)
If the runout is greater than the maximum, replace with a new
ring gear.
4. CHECK RING GEAR BACKLASH
Using a dial indicator, check the backlash of the ring gear.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
If the backlash is not within the specification, adjust the side
bearing preload or repair as necessary.
5. CHECK TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA−79)
6. 2 PINION DIFFERENTIAL:
CHECK SIDE GEAR BACKLASH
Using a dial indicator, check the backlash of the side gear with
holding 1 pinion gear toward the differential case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within the specification, install the 2 side
gear thrust washers of different thickness (See page SA−79).

R10641
R10660
SST
R10788
SST
R10662
SST
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−75
1996 RAV4 (RM447U)
7. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of the backlash
between the drive pinion and ring gear.
Preload (at starting):
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
8. CHECK TOTAL PRELOAD
Using a torque wrench, measure the preload.
Total preload (at starting):
Drive pinion preload plus
0.3 − 0.5 N·m (3 − 5 kgf·cm, 2.6 − 4.3 in.·lbf)
If necessary, disassemble and inspect the differential.
9. REMOVE COMPANION FLANGE
(a) Using a chisel and hammer, unstake the staked part of the
nut.
(b) Using SST to hold the flange, remove the nut.
SST 09330−00021
(c) Using SST, remove the companion flange.
SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03040, 09956−03020)
10. REMOVE FRONT OIL SEAL AND OIL SLINGER
(a) Using SST, remove the oil seal from the housing.
SST 09308−10010
(b) Remove the oil slinger.

R10663
SST
R10664
SST
R10757
R10665
SST
F03753
Matchmarks
SA−76
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
11. REMOVE FRONT BEARING AND BEARING SPACER
(a) Using SST, remove the front bearing from the drive pinion.
SST 09556−22010
(b) Remove the bearing spacer.
12. Torque Sensing LSD:
REMOVE SIDE GEAR SHAFTS
(a) Using SST, remove the 2 side gear shafts from the differ-
ential.
SST 09520−24010
(b) Using a screwdriver, remove the 2 snap rings from the 2
side gear shafts.
13. 2 Pinion Differential:
REMOVE SIDE GEAR SHAFTS
(a) Using needle nose pliers, remove the 2 snap rings from
the 2 side gear shafts.
(b) Remove the 2 side gear shafts.
14. REMOVE SIDE GEAR SHAFT OIL SEALS
Using SST, remove the 2 oil seals from the housing.
SST 09308−00010
15. REMOVE DIFFERENTIAL CASE
(a) Place matchmarks on the bearing cap and differential car-
rier.
(b) Remove the 4 bolts and 2 bearing caps.

F03754
SST
R10668
SST
R10669
Front Rear
F03755
Matchmarks
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−77
1996 RAV4 (RM447U)
(c) Using SST and a hammer, remove the 2 plate washers.
SST 09504−22011
HINT:
Measure the plate washer and note down the thickness.
(d) Remove the differential case and 2 bearing outer races
from the carrier.
HINT:
Tag the 2 bearing outer races to show the location for reassem-
bling.
16. REMOVE DRIVE PINION FROM DIFFERENTIAL CAR-
RIER
17. REMOVE DRIVE PINION REAR BEARING
(a) Using SST and a press, remove the bearing from the drive
pinion.
SST 09950−00020
HINT:
If the drive pinion or ring gear are damaged, replace them a set.
(b) Remove the plate washer.
18. REMOVE FRONT AND REAR BEARING OUTER
RACES
Using a brass bar and hammer, remove the 2 outer races from
the carrier.
19. REMOVE RING GEAR
(a) Place matchmarks on the ring gear and differential case.
(b) Using a screwdriver and hammer, unstake the 4 lock
plates.
(c) Remove the 8 ring gear set bolts and 4 lock plates.
(d) Using a plastic hammer, tap on the ring gear to separate
it from the differential case.

F03756
SST
R07223
Z13195
SA−78
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
20. REMOVE SIDE BEARINGS
Using SST and a press, remove the 2 side bearings from the
differential case.
SST 09950−00020
NOTICE:
Be careful not to drop the differential case.
21. 2 Pinion Differential Only:
DISASSEMBLE DIFFERENTIAL CASE
NOTICE:
If equipped with Torque Sensing LSD, do not disassemble
the differential case.
(a) Using a pin punch and hammer, remove the straight pin.
(b) Remove these parts from the differential case:
Pinion shaft
2 pinion gears
2 pinion gear thrust washers
2 side gears
2 side gear thrust washers

SA0UM−01
FA1121
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−79
1996 RAV4 (RM447U) 1/17/01
REASSEMBLY
1. 2 Pinion Differential:
ADJUST DIFFERENTIAL SIDE GEAR BACKLASH
(a) Install the 2 proper thrust washers on the 2 side gears.
HINT:
Refer to the table below to table, select 2 thrust washers which
will ensure that the backlash is within the specification.
Thrust washer thickness
Thickness mm (in.)Thickness mm (in.)
0.93 − 0.97 (0.0366 − 0.0382)1.08 − 1.12 (0.0425 − 0.0441)
0.98 − 1.02 (0.0386 − 0.0402)1.13 − 1.17 (0.0445 − 0.0461)
1.03 − 1.07 (0.0406 − 0.0421)1.18 − 1.22 (0.0465 − 0.0480)
(b) Install the 2 side gears, 2 pinion gears, 2 pinion gear
thrust washers and pinion shaft in the differential case.
HINT:
Align the holes of the differential case and pinion shaft.

F14547
FA1124
SA1143
Boiling Water
F03758
Matchmarks
SA−80
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
(c) Measure the side gear backlash.
(1) Install the 2 side gear shafts.
(2) Measure the side gear backlash with holding 1 pin-
ion gear toward the differential case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within the specification, install the 2 side
gear thrust washers with different thicknesses.
(3) Remove the 2 side gear shafts.
2. 2 PINION DIFFERENTIAL:
INSTALL STRAIGHT PIN AND STAKE DIFFERENTIAL
CASE
(a) Using a pin punch and hammer, install the straight pin
through the differential case and hole of the pinion shaft.
(b) Using a chisel and hammer, stake the outside of the differ-
ential case pin hole.
3. INSTALL RING GEAR ON DIFFERENTIAL CASE
(a) Clean the contact surfaces of the differential case and
ring gear.
(b) Heat the ring gear in boiling water.
(c) Carefully remove the ring gear from the boiling water.
(d) After the moisture on the ring gear has completely evapo-
rated, quickly install the ring gear to the differential case.
(e) Align the matchmarks on the ring gear and differential
case.
(f) Temporarily install the 4 lock plates and 8 bolts.
(g) After the ring gear cools down enough, torque the 8 bolts
uniformly at a time.
Torque: 97 N·m (985 kgf·cm, 71 ft·lbf)
(h) Using a chisel and hammer, stake the 4 lock plates.
HINT:
Stake one claw flush with the flat surface of the bolt. For the
claw contacting the protruding portion of the bolt, stake only the
half of it on the tightening side.

F03759
SST
F03760
W01226
SST SST FrontRear
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−81
1996 RAV4 (RM447U) 1/17/01
4. INSTALL SIDE BEARINGS
Using SST and a press, install the 2 side bearings into the differ-
ential case.
SST 09710−22021 (09710−01031)
5. INSPECT RING GEAR RUNOUT
(a) Install the differential case on the carrier, and install the
2 plate washers to fill the no play in the bearing.
(b) Install the bearing caps (See page SA−79).
(c) Using a dial indicator, measure the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 in.)
(d) Remove the 2 bearing caps, 2 plate washers and differen-
tial carrier (See page SA−74).
6. INSTALL FRONT AND REAR BEARING OUTER
RACES
(a) Front side:
Using SST and a press, install the 2 outer races to the car-
rier.
SST 09950−60020 (09951−00790),
09950−70010 (09951−07150)
(b) Rear side:
Using SST and a press, install the 2 outer races to the car-
rier.
SST 09950−60020 (09951−00710),
09950−70010 (09951−07150)
7. INSTALL DRIVE PINION REAR BEARING
(a) Install the reused washer on the drive pinion.