1996 TOYOTA RAV4 replacement

Z12494
MX0DY−01
Z12381
SST
Z12496
Q06288
SST
− MANUAL TRANSAXLEDIFFERENTIAL CASE (4WD)
MX−63
1996 RAV4 (RM447U)
REPLACEMENT
1. Transmission Case Side:
REPLACE OIL SEAL AND TAPERED ROLLER BEAR-
ING OUTER RACE
(a) Using a screwdriver, remove the oil seal.
(b) Remove the transmission oil baffle.
(c) Using a brass bar and hammer, drive out the bearing out-
er race lightly and evenly.
(d) Remove the adjust shim.
(e) Install the adjust shim.
(See page MX−65)
HINT:
First select and install a shim of less thickness than before.
(f) Using SST and a press, install the tapered roller bearing
outer race.
SST 09316−60011 (09316−00011, 09316−00041)
(g) Install the transmission oil baffle.
HINT:
Install the transmission oil baffle projection into the case side
cutout.
(h) Using SST, drive in a new oil seal.
SST 09223−15020, 09950−70010 (09951−07150)
(i) Coat the lip of the oil seal with MP grease.

Q05709
SST
MX0E0−01
Z12397
SST
Z12546
Q08760
SST SST
Z16232
Socket Wrench MX−86
− MANUAL TRANSAXLETRANSFER (4WD)
1996 RAV4 (RM447U)
REPLACEMENT
1. REPLACE DRIVEN PINION FRONT BEARING
(a) Using SST and a press, remove the front bearing.
SST 09950−00020
(b) Using SST and a press, install a new front bearing.
SST 09316−60011 (09316−00051)
2. REPLACE FRONT AND REAR BEARING OUTER
RACE
(a) Using a brass bar and hammer, drive out the front and
rear bearing outer race lightly and evenly.
(b) Using SST and a press, install a new front bearing outer
race.
SST 09950−60020 (09951−00780), 09950−70010
(09951−07150)
(c) Using SST and a press, install a new rear bearing outer
race.
SST 09950−60010 (09951−00590), 09950−70010
(09951−07150)
3. REPLACE SHIFT FORK SHAFT OIL SEAL
(a) Using a screwdriver, remove the oil seal from the transfer
right case.
(b) Using a socket wrench and hammer, install a new oil seal.

PR02T−01
Q08048
Q08119
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY
PR−7
1996 RAV4 (RM447U)
REPLACEMENT
REPLACE DUST COVER
(a) Using a screwdriver and hammer, remove the dust cover.
(b) Using 2 screwdrivers and hammers, install a new dust
cover.
NOTICE:
Be careful not to damage the dust cover.

RS031−08
RS−18
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 RAV4 (RM447U)
REPLACEMENT
REPLACEMENT REQUIREMENTS
In the following cases, replace the steering wheel pad, steering wheel or spiral cable.
CaseReplacing part
If the airbag has been deployed.Steering wheel pad
If the steering wheel pad has been found to be faulty in troubleshooting.Steering wheel pad
If the spiral cable has been found to be faulty in troubleshooting.Spiral cable
If the steering wheel pad has been found to be faulty during checking items.
(See page RS−9)Steering wheel pad
If the steering wheel has been found to be faulty during checking items.
(See page RS−9)Steering wheel
If the spiral cable has been found to be faulty during checking items.
(See page RS−9)Spiral cable
If the steering wheel pad has been dropped.Steering wheel pad
CAUTION:
For replacement of the steering wheel pad, see page SR−12 and SR−19, and be sure to follow the
correct procedure.

SA0TE−01
R10733
SST
R10759
− SUSPENSION AND AXLEFRONT WHEEL HUB BOLT
SA−17
1996 RAV4 (RM447U)
FRONT WHEEL HUB BOLT
REPLACEMENT
1. REMOVE FRONT WHEEL
2. REMOVE FRONT BRAKE CALIPER AND DISC
(a) Remove the 2 bolts and brake caliper from the steering
knuckle.
(b) Support the brake caliper securely and remove the disc.
3. REMOVE HUB BOLT
Using SST, remove the hub bolt.
SST 09628−10011
4. INSTALL HUB BOLT
(a) Install a washer and nut to the hub bolt, as shown in the
illustration.
(b) Install the hub bolt with torquing the nut.
5. INSTALL FRONT BRAKE DISC AND CALIPER
Install the disc and brake caliper with the 2 bolts.
Torque: 107 N·m (1,090 kgf·cm, 79 ft·lbf)
HINT:
Check the disc runout (See page BR−26).
6. INSTALL FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm 76 ft·lbf)

SA0UA−01
R10741
SST
R10751
SA−60
− SUSPENSION AND AXLEREAR WHEEL HUB BOLT
1996 RAV4 (RM447U)
REAR WHEEL HUB BOLT
REPLACEMENT
1. REMOVE REAR WHEEL
2. REMOVE BRAKE DRUM
3. REMOVE HUB BOLT
Using SST, remove the hub bolt.
SST 09628−10011
4. INSTALL HUB BOLT
Install a washer and nut to the hub bolt, as shown in the illustra-
tion, and install the hub bolt by tightening the nut.
5. INSTALL BRAKE DRUM
6. INSTALL REAR WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)

SA0UH−01
R10762
SST
R10742
SST
R10743
SST
R10744
SST
− SUSPENSION AND AXLEREAR DIFFERENTIAL FRONT OIL SEAL
SA−69
1996 RAV4 (RM447U)
REPLACEMENT
1. REMOVE PROPELLER SHAFT (See page PR−3)
2. 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)
3. REMOVE FRONT OIL SEAL AND OIL SLINGER
(a) Using SST, remove the oil seal.
SST 09308−10010
(b) Remove the oil slinger.
4. REMOVE FRONT BEARING AND BEARING SPACER
(a) Using SST, remove the front bearing.
SST 09556−22010
(b) Remove the bearing spacer.
5. INSTALL NEW BEARING SPACER AND FRONT
BEARING
(a) Install a new bearing spacer on the shaft.
(b) Install the front bearing on the shaft.
6. INSTALL OIL SLINGER AND NEW OIL SEAL
(a) Install the oil slinger.

SA0UW−01
W01228
R11091
SST
R11092
5°
5°SST
Horizontal Line
Press Line
Position Mark
− SUSPENSION AND AXLEREAR SUSPENSION ARM AND COIL SPRING
SA−99
1996 RAV4 (RM447U)
REPLACEMENT
1. REMOVE SHOCK ABSORBER LOWER PIVOT PIN
(a) Mount No.1 suspension arm in a vise.
(b) Remove the nut.
(c) Using a plastic hammer, remove the pivot pin.
2. INSTALL SHOCK ABSORBER LOWER PIVOT PIN
(a) Install the pivot pin.
(b) Install the nut.
Torque: 140 N·m (1,430 kgf·cm, 103 ft·lbf)
3. REMOVE REAR NO.1 SUSPENSION ARM BUSHING
Using SST and a press, remove the bushing.
SST 09649−17010, 09710−30050
4. INSTALL NEW BUSHING
(a) Place position mark on to a new bushing, as shown.
(b) Using SST and a press, install the bushing.
SST 09710−30050
HINT:
At the time of installation, please refer to the following items.
Before installing the bushing, align the position mark and
press line.
When assembling the bushing, assemble it so that its pro-
jections are horizontal.
Do not let grease or oil get on the bushing.