1996 TOYOTA RAV4 runout

AT0953
SST
AX05A−02
AT3306
Hold
Lock
Free
Turn
D00776
AT4184
AX−20
− AUTOMATIC TRANSAXLE (A241E)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
Set up a dial indicator, measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification or if the ring gear is
damaged, replace the drive plate. If installing a new drive plate,
note the orientation of spacers and tighten the bolts.
Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)
3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE
RUNOUT
Temporarily mount the torque converter clutch to the drive
plate. Set up a dial indicator, measure the torque converter
clutch sleeve runout.
Maximum runout: 0.30 mm (0.0118 in.)
If the runout is not within the specification, try to correcting by
reorienting the installation of the converter clutch.

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.

BR0M4−01
R10627
R10628
− BRAKEFRONT BRAKE PAD
BR−21
1996 RAV4 (RM447U)
REPLACEMENT
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with the hub
nuts.
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace the pads if they are not within the specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. LIFT UP CALIPER
(a) Remove the flexible hose from the shock absorber brack-
et.
(b) Hold the sliding pin on the bottom and loosen the installa-
tion bolt.
(c) Remove the installation bolt.
(d) Lift up the caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose from the caliper.
4. REMOVE THESE PARTS:
2 brake pads
4 anti−squeal shims
4 pad support plates
NOTICE:
The support plates can be used again provided that they
have sufficient rebound, no deformation, cracks or wear,
and have had all rust, dirt and foreign particles cleaned off.
5. CHECK DISC THICKNESS AND RUNOUT
(See page BR−26)
6. INSTALL 4 PAD SUPPORT PLATES

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)

CL04F−03
− CLUTCHTROUBLESHOOTING
CL−1
1996 RAV4 (RM447U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Clutch grabs/chatters
3. Engine mounting (Loosen)
4. Clutch disc (Runout is excessive)
5. Clutch disc (Oily)
6. Clutch disc (Worn out)
7. Clutch disc torsion rubber (Damaged)
8. Clutch disc (Glazed)
9. Diaphragm spring (Out of tip alignment)−
CL−15
CL−15
CL−15
CL−15
CL−15
CL−15
Clutch pedal spongy
1. Clutch line (Air in line)
2. Master cylinder cup (Damaged)
3. Release cylinder cup (Damaged)−
CL−5
CL−10
Clutch noisy1. Release bearing (Worn, dirty, or damaged)
2. Clutch disc torsion rubber (Damaged)CL−15
CL−15
Clutch slips
1. Clutch pedal (Free play out of adjustment)
2. Clutch disc (Oily)
3. Clutch disc (Worn out)
4. Diaphragm spring (Damaged)
5. Pressure plate (Distortion)
6. Flywheel (Distortion)CL−2
CL−15
CL−15
CL−15
CL−15
−
Clutch does not disengage
1. Clutch pedal (Free play out of adjustment)
2. Clutch line (Air in line)
3. Master cylinder cup (Damaged)
4. Release cylinder cup (Damaged)
5. Clutch disc (Out of true)
6. Clutch disc (Runout is excessive)
7. Clutch disc (Lining broken)
8. Clutch disc (Dirty or burned)
9. Clutch disc (Oily)
10.Clutch disc (Lack of spline grease)
11. Diaphragm spring (Damaged)
12.Diaphragm spring (Out of tip alignment)
13.Pressure plate (Distortion)CL−2
−
CL−5
CL−10
CL−15
CL−15
CL−15
CL−15
CL−15
CL−18
CL−15
CL−18
CL−15

CL04T−01
Q06032
Q06033
Q06034
Q06035
AB
Q06036
− CLUTCHCLUTCH UNIT
CL−17
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012in.)
If a problem is found, replace the clutch disc.
2. INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc runout.
Maximum runout: 0.8 mm (0.031 in.)
If runout is excessive, replace the clutch disc.
3. INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.
Maximum runout: 0.1 mm (0.004 in.)
If runout is excessive, replace the flywheel.
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
4. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum:
A (Depth): 0.5 mm (0.020 in.)
B (Width): 6.0 mm (0.236 in.)
If necessary, replace the clutch cover.
5. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direc-
tion.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
If a problem is found, replace the bearing.

EM0281
EM1628
EM2011
EM2538
EM3322
Free Distance
− ENGINE MECHANICALCYLINDER HEAD
EM−49
1996 RAV4 (RM447U)
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
164 − 189 N (16.7 − 19.3 kgf, 36.8 − 42.5 lbf)
at 34.7 mm (1.366 in.)
If the installed tension is not as specified, replace the valve
spring.
9. INSPECT CAMSHAFTS
(a) Inspect the circle runout.
(1) Place the camshaft on V−blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.04 mm (0.0016 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake42.01 − 42.11 mm (1.6539 − 1.6579 in.)
Exhaust40.06 − 40.16 mm (1.5772 − 1.5811 in.)
Minimum cam lobe height:
Intake41.90 mm (1.6496 in.)
Exhaust39.95 mm (1.5728 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
(c) Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 − 26.975 mm (1.0614 − 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
(d) Using vernier calipers, measure the free distance be-
tween the gear spring ends.
Free distance: 22.5 − 22.9 mm (0.886 − 0.902 in.)
If the free distance is not as specified, replace the gear spring.