1996 TOYOTA RAV4 Cv axle

Q08839
Q06112
Z17589
AX−20
− AUTOMATIC TRANSAXLE (A540H)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
7. REMOVE CENTER STIFFENER PLATE
Remove the 4 bolts and stiffener plate.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
8. REMOVE TRANSAXLE WITH TRANSFER ASSEMBLY
(a) Remove the 2 bolts.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(b) Remove the 5 transaxle mounting bolts.
Torque:
14 mm head bolt: 64 N·m (650 kgf·cm, 47 ft·lbf)
12 mm head bolt: 46 N·m (470 kgf·cm, 34 ft·lbf)
(c) Separate the transaxle assembly.

AT3412
AX04V−01
− AUTOMATIC TRANSAXLE (A540H)AUTOMATIC TRANSAXLE UNIT
AX−21
1996 RAV4 (RM447U)
INSTALLATION
1. CHECK TORQUE CONVERTER CLUTCH INSTALLA-
TION
Using calipers and a straight edge, measure the distance from
the installed surface to front surface of the transaxle housing.
Correct distance: More than 13.7 mm (0.539 in.)
2. TRANSAXLE INSTALLATION
Installation is in the reverse order of removal (See page
AX−19).
HINT:
After installation, check and inspect the following items.
Fluid level (See page DI−173)
Front wheel alignment (See page SA−4)
Do the road test

AT0952
SST
AX04W−01
AT0953
SST
AT3306
Hold
Lock
Free
Turn
AT2821
AX−22
− AUTOMATIC TRANSAXLE (A540H)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
1996 RAV4 (RM447U)
TORQUE CONVERTER CLUTCH
AND DRIVE PLATE
INSPECTION
1. INSPECT ONE−WAY CLUTCH
(a) Install SST into the inner race of the one−way clutch.
SST 09350−32014 (09351−32010)
(b) Install SST so that it fits in the notch of the converter clutch
hub and outer race of the one−way clutch.
SST 09350−32014 (09351−32020)
(c) With the torque converter clutch standing on its side, the
clutch locks when turned counterclockwise, and rotates
freely and smoothly clockwise.
If necessary, clean the converter clutch and retest the clutch.
Replace the converter clutch if the clutch still fails the test.
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
(a) Set up a dial indicator and measure the drive plate runout.
(b) Check the damage of the ring gear.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification, or ring gear is dam-
aged replace the drive plate.
Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)

AT4184
− AUTOMATIC TRANSAXLE (A540H)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
AX−23
1996 RAV4 (RM447U)
3. MEASURE TORQUE CLUTCH CONVERTER SLEEVE
RUNOUT
(a) Temporarily mount the torque converter clutch to the drive
plate. Set up a dial indicator and measure the torque con-
verter clutch sleeve runout.
Maximum runout: 0.30 mm (0.0118 in.)
If the runout is not within the specification, try to correct by reori-
enting the installation of the converter clutch.
HINT:
Mark the position of the converter clutch to ensure correct
installation.
(b) Remove the torque converter clutch.

BR035−02
W01808
R10635
R10636
R10637
BR−26
− BRAKEFRONT BRAKE CALIPER
1996 RAV4 (RM447U)
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 12.0 mm (0.472 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the pad’s thickness is at the minimum thick-
ness or less, or if the pad has severe and uneven wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 18.0 mm (0.709 in.)
Minimum thickness: 16.0 mm (0.630 in.)
Replace the disc if the thickness of the disc is at the minimum
thickness or less. Replace the disc or grind it on a lathe if it is
scored or is worn unevenly.
3. MEASURE DISC RUNOUT
Using a dial indicator, measure the disc runout at a position 10
mm (0.39 in.) from the outside edge.
Maximum disc runout: 0.05 mm (0.0020 in.)
If the disc’s runout is at the maximum value or greater, check the
bearing play in the axial direction and check the axle hub runout
(See page SA−10). If the bearing play and axle hub runout are
not abnormal, adjust the disc runout or grind it on a ”On−Car”
brake lathe.
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the 2 bolts and torque plate from the knuckle.
(b) Remove the hub nuts and the disc. Reinstall the disc in
the position turned 1/5 from its original position on the
hub. Install and torque the hub nuts.
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
(c) Remeasure the disc runout. Make a note of the runout
and the disc’s position on the hub.
(d) Repeat (b) and (c) until the disc is installed on the 3 re-
maining hub positions.
If the minimum runout recorded in (b) and (c) is less
than 0.05 mm (0.0020 in.), install the disc in that
position.
If the minimum runout recorded in (b) and (c) is
greater than 0.05 mm (0.0020 in.), replace the disc
and repeat step 3.
(e) Install the torque plate and torque the mounting bolts.
Torque: 107 N·m (1,090 kgf·cm, 79 ft·lbf)

BR03Z−02
R10729
R10704
BR−46
− BRAKEREAR SPEED SENSOR
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT SPEED SENSOR CONNECTOR
(a) Remove the seat cushion and rear side trim.
(b) Disconnect the speed sensor connector, and pull out the
sensor wire harness with grommet.
(c) Disconnect the parking brake cable from the suspension
arm.
(d) Remove the 3 clamp bolts holding the sensor wire har-
ness to the body and suspension arm.
Torque:
To body: 5.0 N·m (55 kgf·cm, 49 in.·lbf)
To suspension arm: 13 N·m (130 kgf·cm, 9 ft·lbf)
2. 2WD:
REMOVE SPEED SENSOR WITH AXLE HUB
(See page SA−52)
3. 4WD:
REMOVE SPEED SENSOR
Remove the speed sensor from the axle carrier.
Torque: 8.0 N·m (80 kgf·cm, 69 in.·lbf)

Component to be alignedSection of repair manual
for relevant model
Front Wheels
Suspension and Axle (SA) section
Rear Wheels
Suspension and Axle (SA) section
1. Never disassemble the steering wheel pad assembly.
2. Do not subject the steering wheel pad to shocks or bring magnets close to it.
3. Do not expose the steering wheel pad to high temperatures or fire.
4. If grease, cleaner, oil or water gets on the steering wheel pad, promptly wipe it off with a dry cloth.
5. Do not drop the steering wheel pad. Never use a steering wheel pad which has been dropped.
6. Never install the steering wheel and pad in another vehicle.
7. When the steering wheel pad is removed, store it on a stable, flat place with the pad surface facing upœ
wards. Never place anything on top of the pad.
8. When work on the vehicle will produce too strong a shock, first loosen the sensor lock release bolt until
it turns freely and perform the work after sensor lock occurs.
9. Even in cases where the vehicle is in a low-impact accident where the airbag is not activated, always
check the pad surface and airbag sensor part. If dents, cracks or deformation is visible, replace the airœ
bag with a new assembly.
10. When disposing of the vehicle or steering wheel, always deploy the airbag first.
11. The deployed inflator inside the steering wheel pad is hot, so dispose of it after it has been cooled by
atmospheric air. Never apply water to cool it down.
2. BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and
notes given in section BR of the repair manual for the relevant model year when handling brake system
parts.
3. DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance
and vibration resistance of the vehicle. After installing components in the sections listed in the table
below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate
repair of the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions
given in the repair manual for the relevant model during alignment and section DI of this manual.
INTRODUCTIONINœ7

SUPPORT POSITIONPANTOGRAPH JACK POSITION
CAUTION: Before jacking-up the rear and front, make sure the car is
not carrying any extra weight.
Front Front crossmember. . . . . . . .
Rear Rear axle beam. . . . . . . .
JACK POSITION
Front
VEHICLE LIFT AND SUPPORT LOCATIONS
Safety stand and swing arm type lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTIONINœ14