1996 TOYOTA RAV4 rear suspension

AX0T8−01
Z18886
RH Drive Shaft
LH Drive Shaft  Snap Ring
64 (650, 47)
 Cotter Pin
Lock Cap
216 (2,200, 159)
 Gasket
49 (500, 36)
7.0 (75, 65 in.·lbf)
62 (630, 46)
48 (490, 35)
Front Exhaust PipeEngine Mounting
Center MemberPS Gear Assembly
Front Suspension Crossmember
Assembly with Stabilizer Bar
RH Engine Under Cover
LH Engine Under Cover
137 (1,400, 101)
206 (2,100, 152)
127 (1,300, 94)
72 (730, 53)

73 (740, 54)
N·m (kgf·cm, ft·lbf)
: Specified torque
 Non−reusable part
113 (1,150 83)
 Cotter Pin
 Gasket
35 (360, 26)
64 (650, 47)
64 (650, 47)
19 (194, 14)
25 (250, 18)
46 (470, 34)
27 (280, 20)
25 (250, 18)
9.0 (95, 78 in.·lbf)
64 (650, 47)
9.0 (95, 78 in.·lbf)
37 (380, 27)
13 (135, 10)
39 (400, 29)64 (650, 47)
 GasketStarterEngine Wire
Clamp Plug for Line
Pressure Test
Shift Control
Cable ClipRear End Plate Stiffener Platex 6 Torque Converter
ClutchEngine Coolant Reservoir TankABS RelayAir Intake Connector
Air Cleaner
Case Assembly AX−14
− AUTOMATIC TRANSAXLE (A241E)AUTOMATIC TRANSAXLE UNIT
1996 RAV4 (RM447U)
AUTOMATIC TRANSAXLE UNIT
COMPONENTS

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

GENERAL INFORMATION
1. BASIC DIMENSIONS
(a) There are two types of dimensions in the diagram.
(Three-dimensional distance)

Straight-line distance between the centers of two
measuring points.
(Two-dimensional distance)

Horizontal distance in forward/rearward between
the centers of two measuring points.

The height from an imaginary standard line.
(b) In cases in which only one dimension is given, left
and right are symmetrical.
(c) The dimensions in the following drawing indicate
actual distance. Therefore, please use the dimenœ
sions as a reference.
2. MEASURING
(a) Basically, all measurements are to be done with a
tracking gauge. For portions where it is not possible
to use a tracking gauge, a tape measure should be
used.
(b) Use only a tracking gauge that has no looseness in
the body, measuring plate, or pointers.
HINT:
1. The height of the left and right pointers must be equal.
2. Always calibrate the tracking gauge before measuring or
after adjusting the pointer height.
3. Take care not to drop the tracking gauge or otherwise
shock it.
4. Confirm that the pointers are securely in the holes.
(c) When using a tape measure, avoid twists and
bends in the tape.
(d) When tracking a diagonal measurement from the
front spring support inner hole to the suspension
member upper rear installation hole, measure
along the front spring support panel surface.
Center-to-center
straight-line
distance Three-dimensional
distance
Front Spring Support Inner Hole
Tape Measure
Along Body
Surface
Front Suspension Member Rear Side
Upper Installation HoleMaster Gauge PointerPointer LoosenessBody LoosenessPlate Looseness Two-dimensional
distanceCenter-to-center
Horizontal distance in
forward/rearward
Vertical distance
in lower surface Vertical distance
in center
Imaginary Standard Line
WrongCorrect
Pointer
BODY DIMENSIONSDIœ2

HINT: For symbols, capital letters indicate right side of vehicle,
small letters indicate left side of vehicle (Seen from rear).
(Two-Dimensional Distance)
mm (in.)
Hole dia.
18 (0.71)
18 (0.71)
34y17.5 (1.34y0.689)12.5 (0.492)
12.5 (4.492)
10 (0.39)
18 (0.71) Name
Front floor under reinforcement standard hole
Rear floor side member standard hole
Strut bar installation hole-inner
Rear suspension member installation nut
Rear floor crossmember working hole No. 3
Rear floor crossmember standard hole
Rear side member standard hole Symbol
G, g
H, h
I, i
J, j
K, k
L, l
M, m Hole dia.
8 (0.31) nut
18 (0.71)
10 (0.39) nut
12 (0.47) nut
14 (0.55) nut
12 (0.47) nut
18 (0.71) Name
Engine mounting member installation nut
Front side member standard hole
Engine mount installation nut-front
Engine mount installation nut
Front suspension crossmember installation nut
Front suspension crossmember installation nut-outer
Front floor under reinforcement standard hole Symbol
A, a
B, b
C
c
D, d
E, e
F, f
UNDER BODY
BODY DIMENSIONSDIœ7

Wheel Base2,410 (94.88)
Imaginary
Standard
Line
mm (in.)
(Two-Dimensional Distance)
Hole dia.
10 (0.39) nut
18 (0.71)
18 (0.71)
39y17.5 (1.34y0.689)12.5 (0.492)
12.5 (0.492)
10 (0.39)
18 (0.71) Name
Propeller shaft center support bearing installation nut
Front floor under reinforcement standard hole
Rear floor side member standard hole
Strut bar installation hole-inner
Rear suspension member installation nut
Rear floor crossmember working hole No. 3
Rear floor crossmember standard hole
Rear side member standard hole Symbol
H, h
I, i
J, j
K, k
L, l
M, rn
N, n
O, o Hole dia.
8 (0.31) nut
18 (0.71)
10 (0.39) nut
12 (0.47) nut
11 (0.43)
14 (0.55) nut
12 (0.47) nut
18 (0.71) Name
Engine mounting member installation nut
Front side member standard hole
Engine mount installation nut-front
Engine mount installation nut
Front spring support hole-outer
Front suspension crossmember installation nut
Front suspension crossmember installation nut-outer
Front floor under reinforcement standard hole Symbol
A, a
B, b
C
c
D, d
E, e
F, f
UNDER BODY (Cont'd)
G, g
BODY DIMENSIONSDIœ8

S01362
S01364
S01434
Z17304BB A EM−76
− ENGINE MECHANICALENGINE UNIT
1996 RAV4 (RM447U)
7. INSTALL FRONT SUSPENSION CROSSMEMBER
(a) Support the front suspension crossmember with a jack.
(b) Attach the front suspension crossmember to the body,
and temporarily install the 6 bolts.
(c) Temporarily install the engine mounting center member
with the 2 nuts.
(d) Temporarily install the PS gear assembly with the 2 bolts
and 2 nuts.
(e) Tighten the 6 bolts holding the front suspension cross-
member to the body.
Torque:
206 N·m (2,100 kgf·cm, 152 ft·lbf) for bolt A
137 N·m (1,400 kgf·cm, 101 ft·lbf) for bolt B
(f) Tighten the 2 bolts and 2 nuts holding the PS gear assem-
bly to the front suspension crossmember.
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
(g) Tighten the 2 nuts holding the front suspension cross-
member, engine mounting center member to the rear en-
gine mounting insulator.
Torque: 112 N·m (1,140 kgf·cm, 82 ft·lbf)
(h) Tighten the 2 bolts holding the engine mounting center
member to the front engine mounting insulator.
Torque: 80 N·m (820 kgf·cm, 59 ft·lbf)
(i) Tighten the 2 bolts holding the engine mounting center
member to the body.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
8. INSTALL STABILIZER (See page SA−50)
9. INSTALL FRONT DRIVE SHAFT (See page SA−31)

MX05N−02
Q10400
Air Intake Connector
Engine Coolant
Reservoir Tank Clutch Release Cylinder
and Line
Vehicle Speed
Sensor Connector
Back−Up Light Switch
Connector
Control Cable
Clip
Ground Cable
Transaxle Case Protector
Tie Rod End RH Drive Shaft
Stiffener PlateNo.2 Rear
End Plate
 Snap Ring
 Cotter Pin LH Drive
Shaft
PS Gear Assembly
Engine Mounting
Center Member
RH Engine
Under Cover
LH Engine Under CoverFront Suspension Crossmember
Assembly with Stabilizer BarClipAir Cleaner Case
Assembly
with Air Hose
Snap Ring
Engine
Wire
Clamp
 Cotter Pin
Lock Cap Starter
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
 
4.9 (50, 43 in.·lbf)
12 (120, 9)
29 (300, 22)
35 (360, 26)32 (330, 24)46 (470, 34)
64 (650, 47)
35 (360, 26)
64 (650, 47)
12 (120, 9)
64 (650, 47)
25 (250, 18)
25 (250, 18)
9.0 (95, 78 in.·lbf)
37 (380, 27)
39 (400, 29)
9.0 (95, 78 in.·lbf)
29 (300, 22)
37 (380, 27)49 (500, 36)
113 (1,150, 83)
137 (1,400, 101)
206 (2,100, 152)
216 (2,200, 159)
113 (1,150, 83)
64 (650, 47)
48 (490, 35)
80 (820, 59)
115 (1,170, 85)
127 (1,300, 94)
62 (630, 46)
Front Exhaust Pipe
 GasketClip
Washer
MX−2
− MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT (2WD)
1996 RAV4 (RM447U)
MANUAL TRANSAXLE UNIT (2WD)
COMPONENTS