1996 TOYOTA RAV4 4WD

4WD
− BRAKEABS ACTUATOR
BR−39
1996 RAV4 (RM447U)

BR0MA−03
BR−40
− BRAKEABS ACTUATOR
1996 RAV4 (RM447U)
REMOVAL
1. DISCONNECT BRAKE LINES
Using SST, disconnect the 6 brake lines from the ABS actuator.
SST 09023−00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
2. DISCONNECT POWER STEERING FLUID RES-
ERVOIR
(a) Remove the bolt and disconnect the PS hose from the ac-
tuator bracket.
(b) Disconnect the PS fluid reservoir.
3. REMOVE ABS ACTUATOR ASSEMBLY
(a) Disconnect the 2 connectors.
(b) Remove the 3 bolts and ABS actuator assembly.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
4. 2WD
REMOVE ABS ACTUATOR
Remove the 2 nuts and actuator from the actuator bracket.
Torque: 5 N·m (55 kgf·cm, 48 in.·lbf)
5. 4WD
REMOVE ABS ACTUATOR
Remove the 3 nuts and actuator from the actuator bracket.
Torque: 5 N·m (55 kgf·cm, 48 in.·lbf)
6. 2WD
REMOVE 2 CUSHION BOLTS AND 3 CUSHIONS
7. 4WD
REMOVE 3 HOLDERS AND 3 CUSHIONS

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)

ABS Antilock Brake System
A/C Air Conditioner
assy assembly
ECT Electronic Controlled Transmission
ECU Electronic Control Unit
e.g. Exempli Gratia (for Example)
Ex. Except
FWD Front Wheel Drive Vehicles
4WD Four Wheel Drive Vehicles
in. inch
LH Left-hand
LHD Left-hand Drive
MIG Metal Inert Gas
M/Y Model Year
PPS Progressive Power Steering
RH Right-hand
RHD Right-hand Drive
SRS Supplemental Restraint System
w/ with
w/o without
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual.
INTRODUCTIONINœ15

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)

S07292
1K1D 49
EA1IG1
1211
22
2 225
23
1
22
6
5 21
20
AA
BR 1D1F1E
1B
1H
1D3718
8
13 34 Fuse Block
B
R−L
R−LECM
E6
E6
E6
E6 19 188 22
IG17
16
IG2
IG2 15 3B 5
53A
IG2 2 IG1 10 EA17
EA113S3 1 B
B
*1: 2WD
*2: 4WD
J1
Junction
Connector Fusible
Link
BlockMAIN
Battery
To Terminal STA of ECMEAB
StarterPark/Neutral
Position
Switch
R−B5 B−W W
B−R
J/B No.1
B−RB−R
724
8B−W B−Y IG Switch
W
ST Relay
ALT
AM2
MAIN No.1
B
R−L
B−W J/B No.1
LG−R
LG
LG R−B
LG−R
W−BW−BB+
R
2
LE1
E1
E1 NSW
8
9
3
4
4
6 3 5 2 6
R
AM1
1
2
GAUGE
R/B No.2
W
W2 6*
1
*2
*12 *1
*1
*2
*1
*2
*1
*2
*2
*1
R−L
S02502S02496A07403
2WD:
4WD:4
6
2
10
− DIAGNOSTICSENGINE
DI−111
1996 RAV4 (RM447U)
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Check park / neutral position switch.
PREPARATION:
Disconnect park / neutral position switch connector.
CHECK:
Check continuity between each terminal shown below when the
shift lever is positioned to each range.
OK:
Shift PositionTerminal No. to continuity
P6 − 1 *1 : 2 − 7 *22 − 3 *1 : 5 − 6 *2
R6 − 5 *1 : 2 − 8 *2
N6 − 7 *1 : 2 − 9 *22 − 3 *1 : 5 − 6 *2
D6 − 8 *1 : 2 − 10 *2
26 − 9 *1 : 2 − 3 *2
L6 − 4 *1 : 2 − 4 *2
*1: 2WD
*
2: 4WD
NG Replace park / neutral position switch.

S07291
ECM
E1 FC 14
E6 G−R
ID1 4 R/B No.5
5
5 5
53
12 5
Circuit Opening
Relay
Fuse Block
10 11
L−B
B−O 11 17 2
1J
1E1
9 8
3
131E
1D
1D
1H
Fuel
Pump
L−B
W−BBH
IB111
B−R
6 5
1 3
2
EFI Main RelayR/B No.6
B−R
B−R
B−W
B−W
B−W (M/T) B−R
B
B R
IG1
IG12
1
Clutch Start
Switch10 IG111
EA
12 2 17
16
20
21
6 6 6
10 B−R A
W−BW−B
J1
Junction
Connector
W−BA A
EA1 B
BB
WEA1
810
652 3 B (A/T)
Starter S31
Battery
Fusible
Link
Block 252
2
2
2 2 21
3ST Relay MAIN
No.1AM2EFI
56
MAINR−W
B−R
*
1
*1*2
*2
EA1
*1: 2WD
*2: 4WDJ/B
No.1B−O
IGN B−O
IG Switch
8 76 R/B No.2
54 B−O
Park/Neutral
Position Switch
− DIAGNOSTICSENGINE
DI−11 7
1996 RAV4 (RM447U)
WIRING DIAGRAM