1996 TOYOTA RAV4 Cv axle

CL04S−02
Q06030
Matchmarks
Q06031
CL−16
− CLUTCHCLUTCH UNIT
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE TRANSAXLE FROM ENGINE
(2WD: See page MX−2)
(4WD: See page MX−8)
2. REMOVE CLUTCH COVER AND DISC
(a) Place matchmarks on the flywheel and clutch cover.
(b) Loosen each set bolt one turn at a time until spring tension
is released.
(c) Remove the set bolts, and pull off the clutch cover with the
clutch disc.
NOTICE:
Do not drop the clutch disc.
3. REMOVE RELEASE BEARING AND FORK FROM
TRANSAXLE
(a) Remove the release bearing together with the fork and
then separate them.
(b) Remove the boot.

CL04U−02
Q06037
Flywheel
Side
SST
Q06038
Matchmarks8 2, 5
6
SST
3
7 1, 4
Q06039SST
Q06245
CL−18
− CLUTCHCLUTCH UNIT
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON
FLYWHEEL
(a) Insert SST in the clutch disc, and then set them and the
clutch cover in position.
SST 09301−00220
(b) Align the matchmarks on the clutch cover and flywheel.
(c) Temporarily tighten the topmost bolt from the 3 near the
knock pins.
HINT:
Temporarily tighten the No.3 bolt.
(d) Torque the bolts on the clutch cover in the order shown.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non−alignment: 0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the dia-
phragm spring tip alignment.
SST 09333−00013
3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO.2)
(a) Apply release hub grease to the following parts.
Release fork and hub contact point
Release fork and push rod contact point
Release fork pivot point
(b) Apply clutch spline grease.
Clutch disc spline
HINT:
Recommended grease part number 08887−01706 (100g).
4. INSTALL RELEASE BEARING AND FORK TO TRANS-
AXLE
Install the bearing to the release fork, and then install them to
the transaxle.
5. INSTALL TRANSAXLE TO ENGINE
(2WD: See page MX−2)
(4WD: See page MX−8)

Q00515
4−pulse 4−pluse
ECM Combination
Meter No.1 Vehicle
Speed Sensor
Transaxle DI−94
− DIAGNOSTICSENGINE
1996 RAV4 (RM447U)
DTC P0500 Vehicle Speed Sensor Malfunction
CIRCUIT DESCRIPTION
The No.1 vehicle speed sensor outputs a 4−pulse signal for every revolution of the rotor shaft, which is ro-
tated by the transmission output shaft via the driven gear. After this signal is converted into a more precise
rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted
to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals.
DTC No.DTC Detecting ConditionTrouble Area
P0500
No vehicle speed sensor signal to ECM under the following
conditions:
(2 trip detection logic)
For A/T:
(a) Park / neutral position switch is OFF
(b) Vehicle is being driven
For M/T:
(a) Engine speed is between 2,000 rpm and 5,000 rpm
(b) Vehicle is being driven at 88 km/h (54 mph) or more
Open or short in vehicle speed sensor circuit
Vehicle speed sensor
Combination meter
ECM
DI3ZZ−01

DI409−02
Vehicle Brought to Workshop
P.DI−126
Connect the OBD ll Scan Tool or TOYOTA Hand−Held Tester to DLC3
If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have
connected the scan tool/TOYOTA hand−held tester, inspect DLC3 P. DI−127
Check DTC and Freeze Frame Data (Pre−check)
Record or Print DTC and Freeze Frame Data P. DI−127
Clear DTC and Freeze Frame Data P. DI−127 Customer Problem Analysis
Visual Inspection
DTC CheckSymptom Simulation Setting the Check Mode Diagnosis P. DI−127
Problem Symptom Confirmation
P. IN−20 Symptom does
not occur
OK Codethe page number indicated in the bottom portion. See the
indicated pages for detailed explanations.
Preliminary Checkare titles of pages in the manual, with Item inside
Mechanical System Tests DTC Chart
Chapter 1
(Electronic)Manual Shifting Test
Matrix Chart of Symptoms Problems − P. DI−140
(On−vehicle)
 Pattern Select Signal Check  O/D Signal Check
InspectionCircuit(Off−vehicle) Chapter 2 Chapter 3
END Repair
Confirmation Test
Identification of ProblemParts Inspection P. DI−127
P. DI−127P. DI−127
P. DI−127
P. DI−127
P. DI−145 − DI−168 P. DI−141 1
2
P. DI−141P. DI−141 3
4
5
6
78
9
1011
12
13
14
16
18 15
17
Symptom occurs
OKNG
OKNG
NG
OK
OK OK
NG
NGNG
Step 2, 3, 4, 6, 9, 15, 18:
Diagnostic steps permitting the use of the TOYOTA
hand−held tester or TOYOTA brake−out−box.
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−125
1996 RAV4 (RM447U)
AUTOMATIC TRANSAXLE (A241E)
HOW TO PROCEED WITH TROUBLESHOOTING
Trobleshoot in accordance with the procedure on the follwoing pages.

Brought InInspector ’s
System Check Sheet
Name
Customer ’s NameTransaxle Control
Registration No.
Frame No.
Date VehicleRegistration Year:
Date Problem
Frequency
Problem Occurs Occurred/ /
Odometer Reading
SymptomsIntermittent ( times a day)
Vehicle does not move Any positionContinuous
Particular position) / /km
mile
/ /
Shift point too high or too low No up−shift 1st → 2nd
Lock−up malfunction
Harsh engagement No down−shift
(
3rd → O/D) (
N → D (
2nd → 1st) 2nd → 3rd
3rd → 2nd O/D → 3rd
Slip or shudder
No kick−down
Malfunction code (Code )Any drive position) Lock−up
Others
1st Time
2nd Time(
Indicator LampRemains ON Check ItemMalfunction
Normal
DTC Check
Normal
NormalMalfunction code (Code )
DI40A−01
DI−126
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
CUSTOMER PROBLEM ANALYSIS CHECK

DI40B−02
Q08848
Q08736
TOYOTA Hand−held Tester
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−127
1996 RAV4 (RM447U)
PRE−CHECK
1. DIAGNOSIS SYSTEM
(a) Description
When troubleshooting OBDII vehicles, the only dif-
ference from the usual troubleshooting procedure
is that you connect the OBDII scan tool complying
with SAE J1978 or TOYOTA hand−held tester to the
vehicle, and read off various data output from the
vehicle’s ECM.
OBD ll regulations require that the vehicle’s on−
board computer lights up the Malfunction Indicator
Lamp (MIL) on the instrument panel when the com-
puter detects a malfunction in the computer itself or
in drive system components which affect the vehicle
emissions. In addition to the MIL lighting up when
a malfunction is detected, the applicable DTCs pre-
scribed by SAE J2012 are recorded in the ECM
memory (See page DI−14).
If the malfunction does not reoccur in 3 trips, the MIL goes off
but the DTCs remain recorded in the ECM memory.
To check the DTCs, connect the OBDII scan tool or
TOYOTA hand−held tester to the DLC3 on the ve-
hicle. The OBDII scan tool or TOYOTA hand−held
tester also enables you to erase the DTCs and
check freezed frame data and various forms of en-
gine data. (For operating instructions, see the OBD
II scan tool’s instruction book.)
DTCs include SAE controlled codes and Manufac-
turer controlled codes.
SAE controlled codes must be set as prescribed by
the SAE, while Manufacturer controlled codes can
be set freely by the manufacturer within the pre-
scribed limits (See page DI−138).

Q08848
DI−128
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
The diagnosis system operates in normal mode
during normal vehicle use, and also has a check
mode for technicians to simulate malfunction symp-
toms and perform troubleshooting. Most DTCs use
2 trip detection logic (*) to prevent erroneous detec-
tion. By switching the ECM to check mode when
troubleshooting, the technician can cause the MIL
to light up for a malfunction that is only detected
once or momentarily (TOYOTA hand−held tester)
(See page DI−127).
*2 trip detection logic:
When a logic malfunction is first detected, the mal-
function is temporarily stored in the ECM memory.
If the same malfunction is detected again during the second test
drive, this second detection causes the MIL to light up.
2. Normal Mode:
INSPECT DIAGNOSIS
(a) Check the MIL.
(1) The MIL lights up when the ignition switch is turned
ON and the engine is not running.
HINT:
If the MIL does not light up, troubleshoot the combination meter
(See page BE−2).
(2) When the engine starts, the MIL should go off. If the
lamp remains on, the diagnosis system has de-
tected a malfunction or abnormality in the system.
(b) Check the DTC.
NOTICE:
TOYOTA hand−held tester only:
When the diagnostic system is switched from the normal
mode to the check mode, it erases all DTCs and freezed
frame data recorded in the normal mode. So before switch-
ing modes, always check the DTCs and freezed frame data,
and note them down.
(1) Prepare the OBD II scan tool (complying with SAE
J1978) or TOYOTA hand−held tester.
(2) Connect the OBD II scan tool or TOYOTA hand−
held tester to the DLC3.
(3) Turn the ignition switch ON and turn the OBD II scan
tool or TOYOTA hand−held tester switch ON.
(4) Use the OBD II scan tool or TOYOTA hand−held
tester to check the DTCs and freezed frame data.
Note them down (For operating instructions, see
the OBDII scan tool’s instruction book.).

FI3605
013 sec. ON
OFF
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−129
1996 RAV4 (RM447U)
(5) See page DI−138 to confirm the details of the
DTCs.
NOTICE:
When simulating symptoms with an OBD II scan tool (ex-
cluding TOYOTA hand−held tester) to check the DTCs, use
the normal mode. For codes on the DTC chart subject to ”2
trip detection logic”, turn the ignition switch off after the
symptoms have been simulated for the first time. Then re-
peat the simulation process again. When the program has
been simulated twice, the MIL lights up and the DTCs are
recorded in the ECM.
3. Check Mode:
INSPECT DIAGNOSIS
HINT:
TOYOTA hand−held tester only:
Compared to the normal mode, the check mode has high sens-
ing ability to detect malfunctions.
Furthermore, the same diagnostic items which are detected in
the normal mode can also be detected in the check mode.
(a) Check the DTC.
(1) Initial conditions.
Battery positive voltage 11 V or more
Throttle valve fully closed
Transaxle in the PARK position
Air conditioning switched off
(2) Prepare the TOYOTA hand−held tester.
(3) Connect the TOYOTA hand−held tester to the
DLC3.
(4) Turn the ignition switch ON and switch the TOYOTA
hand−held tester ON.
(5) Switch the TOYOTA hand−held tester from the nor-
mal mode to the check mode (Check that the MIL
flashes.).
(6) Start the engine (The MIL goes off after the engine
start.).
(7) Simulate the conditions of the malfunction de-
scribed by the customer.
NOTICE:
Leave the ignition switch ON until you have checked the
DTCs, etc.
(8) After simulating the malfunction conditions, use the
TOYOTA hand−held tester diagnosis selector to
check the DTCs and freezed frame data, etc.
HINT:
Take care not to turn the ignition switch OFF.
Turning the ignition switch off switches the diagnosis system
from check mode to normal mode, so all DTCs, etc. are erased.
(9) After checking the DTC, inspect the applicable cir-
cuit.