1996 TOYOTA RAV4 Cv axle

SA3102
SST
R10778
R10661
SST
R10768
SST
R10641
F03761
SA−82
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
(b) Using SST and a press, install the rear bearing onto the
drive pinion.
SST 09506−30012
8. TEMPORARILY ADJUST DRIVE PINION PRELOAD
(a) Install the drive pinion and front bearing.
HINT:
Assemble the spacer, oil slinger and oil seal after adjusting the
gear contact pattern.
(b) Using SST, install the companion flange.
SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03040, 09956−03020)
(c) Coat the threads of the nut with MP grease.
(d) Adjusting the drive pinion preload by tightening the com-
panion flange nut.
Using SST to hold the flange, torque the nut.
Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf)
SST 09330−00021
NOTICE:
As there is no spacer, torque a little at a time, being careful
not to overtighten it.
(e) Using a torque wrench, measure the preload.
Preload (at starting):
New bearing:
1.0 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing:
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
9. INSTALL DIFFERENTIAL CASE IN CARRIER

F03762
Hold
R10647
F03763
F03762
Hold
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−83
1996 RAV4 (RM447U) 1/17/01
(a) Place the 2 bearing outer races on their respective bear-
ings. Make sure the left and right races are not inter-
changed.
(b) Install the differential case in the carrier.
10. ADJUST RING GEAR BACKLASH
(a) Install only the plate washer on the ring gear back side.
(b) Snug down the washer and bearing by tapping on the ring
gear with a plastic hammer.
(c) Using a dial indicator, hold the side bearing boss on the
teeth surface of the ring gear and measure the ring gear
backlash.
Backlash (reference): 0.13 mm (0.0051 in.)
(d) Select a ring gear back side plate washer so that the back-
lash is 0.13 mm (0.0051 in.).
(e) Select a ring gear teeth side washer with a thickness
which eliminates any clearance between the outer race
and case.
(f) Remove the plate washer and differential case.
(g) Install the plate washer into the ring gear back side.
(h) Place the outer plate washer onto the differential case to-
gether with the outer race, and install the differential case
with the outer race into the carrier.
(i) Using a plastic hammer, snug down the washer and bear-
ing by tapping the ring gear.
(j) Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
If it is not within the specification, adjust it by either increasing
or decreasing the thickness of washers on both sides by an
equal amount.
HINT:
There should be clearance between the plate washer and case.
Ensure that there is ring gear backlash.
11. ADJUST SIDE BEARING PRELOAD
(a) After adjustment with the ring gear backlash as reference,
remove the teeth side plate washer.

RA0090
F03764
F03753
Matchmarks
F03768
Hold
SA−84
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
(b) Using a micrometer, measure the thickness of the re-
moved plate washer.
(c) Install a new washer 0.06 − 0.09 mm (0.0024 − 0.0035 in.)
thicker than the removed washer.
HINT:
Select a washer which can be pressed in 2/3 of the way by fin-
ger.
(d) Using a brass bar and hammer, tap in the plate washer.
(e) Align the matchmarks on the cap and carrier, and install
the 2 bearing caps and 4 bolts.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
(f) Recheck the ring gear backlash.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
If it is not within the specification, adjust it by either increasing
or decreasing the thickness washers on both sides by equal
amount.
HINT:
The backlash will change by about 0.02 mm (0.0008 in.) every
0.03 mm (0.0012 in.) change in the plate washer thickness.
Washer thickness
Thickness mm (in.)Thickness mm (in.)Thickness mm (in.)
2.26 − 2.28 (0.0890 − 0.0898)2.41 − 2.43 (0.0949 − 0.0957)2.56 − 2.58 (0.1008 − 0.1016)
2.29 − 2.31 (0.0902 − 0.0909)2.44 − 2.46 (0.0961 − 0.0969)2.59 − 2.61 (0.1020 − 0.1028)
2.32 − 2.34 (0.0913 − 0.0921)2.47 − 2.49 (0.0972 − 0.0980)2.62 − 2.64 (0.1031 − 0.1039)
2.35 −2.37 (0.0925 − 0.0933)2.50 − 2.52 (0.0984 − 0.0992)2.65 − 2.67 (0.1043 − 0.1051)
2.38 − 2.40 (0.0937 − 0.0945)2.53 − 2.55 (0.0996 − 0.1004)2.68 − 2.70 (0.1055 − 0.1063)

R10641
F03765
SA1653
Proper ContactHeel Contact
Toe ContactSelect an adjusting shim will bring the
drive pinion closer to the ring gear.Face Contact
Flank Contact
Select an adjusting shim that will shift the
drive pinion away from the ring gear.
SA1586
Plate Washer
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−85
1996 RAV4 (RM447U) 1/17/01
12. MEASURE 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)
13. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION
(a) Coat 3 or 4 teeth at 3 different positions on the ring gear
with red lead primer.
(b) Hold the companion flange firmly and rotate the ring gear
in both directions.
(c) Inspect the tooth contact pattern.
If the teeth are not contacting properly, use the following chart
to select a proper washer for correction.

R10649
R10673
R10661
SST SA−86
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
Washer thickness
Thickness mm (in.)Thickness mm (in.)Thickness mm (in.)
2.21 − 2.23 (0.0870 − 0.0878)2.57 − 2.59 (0.1012 − 0.1020)2.93 − 2.95 (0.1154 − 0.1161)
2.24 − 2.26 (0.0882 − 0.0890)2.60 − 2.62 (0.1024 − 0.1031)2.96 − 2.98 (0.1165 − 0.1173)
2.27 − 2.29 (0.0894 − 0.0902)2.63 − 2.65 (0.1035 − 0.1043)2.99 − 3.01 (0.1177 − 0.1185)
2.30 − 2.32 (0.0906 − 0.0913)2.66 − 2.68 (0.1047 − 0.1055)3.02 − 3.04 (0.1189 − 0.1197)
2.33 − 2.35 (0.0917 − 0.0925)2.69 − 2.71 (0.1059 − 0.1067)3.05 − 3.07 (0.1201 − 0.1209)
2.36 −2.38 (0.0929 − 0.0937)2.72 − 2.74 (0.1071 − 0.1079)3.08 − 3.10 (0.1213 − 0.1220)
2.39 − 2.41 (0.0941 − 0.0949)2.75 − 2.77 (0.1083 − 0.1091)3.11 − 3.13 (0.1224 − 0.1232)
2.42 − 2.44 (0.0953 − 0.0961)2.78 − 2.80 (0.1094 − 0.1102)3.14 − 3.16 (0.1236 − 0.1244)
2.45 − 2.47 (0.0965 − 0.0972)2.81 − 2.83 (0.1106 − 0.1114)3.17 − 3.19 (0.1248 − 0.1256)
2.48 − 2.50 (0.0976 − 0.0984)2.84 − 2.86 (0.1118 − 0.1126)3.20 − 3.22 (0.1260 − 0.1268)
2.51 − 2.53 (0.0988 − 0.0996)2.87 − 2.89 (0.1130 − 0.1138)−
2.54 − 2.56 (0.1000 − 0.1008)2.90 − 2.92 (0.1142 − 0.1150)−
14. REMOVE COMPANION FLANGE (See page SA−69)
15. REMOVE FRONT BEARING (See page SA−74)
16. INSTALL NEW BEARING SPACER AND FRONT
BEARING
Install a new bearing spacer and front bearing on the drive pin-
ion.
17. INSTALL OIL SLINGER
18. INSTALL NEW FRONT OIL SEAL
(a) Using SST and hammer, install a new oil seal.
SST 09554−22010
Oil seal drive in depth: 2.0 mm (0.079 in.)
(b) Apply MP grease to the oil seal lip.
19. INSTALL COMPANION FLANGE
(a) Using SST, install the companion flange on the drive pin-
ion.
SST 09950−30010 (09951−03010, 09953−03010,
09954−03010, 09955−03040, 09956−03020)
(b) Coat the threads of a new nut with hypoid gear oil.

R10768
SST
R10641
W01227
SST
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−87
1996 RAV4 (RM447U) 1/17/01
(c) Using SST to hold the flange, torque the nut.
SST 09330−00021
Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf)
20. CHECK DRIVE PINION PRELOAD
(a) Using a torque wrench, measure the preload of the back-
lash between the drive pinion and ring gear.
Preload (at starting):
New bearing:
1.0 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf)
Reused bearing:
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
If preload is larger than the specification, replace the bearing
spacer.
If preload is less than the specification, retorque the nut 13 N·m
(130 kgf·cm, 9 ft·lbf) at a time until the specified preload is
reached.
Torque: 235 N·m (2,400 kgf·cm, 174 ft·lbf) or less
If the maximum torque is exceeded while retighten the nut, re-
place the bearing spacer and repeat the preload procedure. Do
not loosen the pinion nut to reduce the preload.
21. RECHECK TOTAL PRELOAD (See page SA−74)
22. RECHECK RING GEAR BACKLASH
(See page SA−74)
23. RECHECK TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA−79)
24. CHECK COMPANION FLANGE RUNOUT
(See page SA−74)
25. STAKE DRIVE PINION NUT
26. INSTALL SIDE GEAR SHAFT OIL SEALS
(a) Using SST and a hammer, install 2 oil seals until they are
flush with the carrier end surface.
SST 09550−00032, 09950−70010 (09951−07150)
(b) Coat MP grease to the oil seal lip.
27. Torque Sensing LSD:
INSTALL SIDE GEAR SHAFTS

R10664
SST
R10757
Z12363
1 − 2 mm
(0.04 − 0.08 in.) SA−88
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
(a) Install 2 new snap rings to the side gear shafts.
(b) Using SST, install the 2 side gear shafts until it contacts
the pinion shaft.
SST 09520−24010
HINT:
Check that the shaft is fully inserted by confirming the noise it
should make when it is tapped.
28. 2 Pinion Differential:
INSTALL SIDE GEAR SHAFTS
(a) Install the 2 side gear shafts to the differential case.
(b) Install 2 new snap rings to the 2 side gear shafts.
29. INSTALL DIFFERENTIAL CARRIER COVER
(a) Clean contacting surfaces of any residual FIPG material
using gasoline or alcohol.
(b) Apply FIPG to the carrier.
FIPG:
Part No.08826−00090, THREE BOND 1281 or equiva-
lent
HINT:
Install the carrier cover within 3 minutes after applying FIPG.
(c) Torque the 8 bolts.
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)

SA0UN−01
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
SA−89
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page SA−73).
AFTER INSTALLATION, FILL DIFFERENTIAL WITH DIFFERENTIAL OIL (See page SA−69)