SA0UE−05
F01439
w/o ABS w/ ABS
SST
RA1310
Vinyl Tape
− SUSPENSION AND AXLEREAR DRIVE SHAFT
SA−65
1996 RAV4 (RM447U)
REASSEMBLY
1. INSTALL NEW NO.2 DUST DEFLECTOR
Using SST and a press, install a new No.2 dust deflector.
SST 09309−36010, 09316−20011
NOTICE:
Be careful not to damage the ABS speed sensor rotor.
2. TEMPORARILY INSTALL NEW OUTBOARD AND IN-
BOARD JOINT BOOTS
HINT:
Before installing the 2 boots, wrap vinyl tape around the spline
of the drive shaft to prevent damaging the boots.
(a) Temporarily install a new outboard joint boot to the drive
shaft.
(b) Temporarily install a new inboard joint boot to the drive
shaft.
3. INSTALL TRIPOD
(a) Place the beveled side of the tripod axial spline toward the
outboard joint.
(b) Align the matchmarks placed before removal.
(c) Using a brass bar and hammer, tap in the tripod to the
drive shaft.
NOTICE:
Do not tap the roller.
(d) Using a snap ring expander, install a new snap ring.
4. INSTALL INBOARD JOINT TULIP
(a) Pack the inboard joint and boot with grease in the boot kit.
HINT:
Use the grease supplied in the boot kit.
Grease capacity (Color = Yellow ocher):
180 − 190 g (6.3 − 6.7 oz.)
(b) Align the matchmarks placed before removal, and install
the inboard joint tulip to the drive shaft.
5. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS
(a) Before assembling the boot, pack the outboard joint and
boot with grease in the boot kit.
Use the grease supplied in the boot kit.
Grease capacity (Color = Black):
100 − 110 g (3.5 − 3.9 oz.)
(b) Make sure that the 2 boots are on the shaft groove.
SA0UK−01
R10640
R10650
F03752
Hold
R10645
SA−74
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 RAV4 (RM447U)
DISASSEMBLY
1. REMOVE DIFFERENTIAL CARRIER COVER
(a) Remove the 8 bolts from the carrier cover.
(b) Using a brass bar and hammer, separate the cover and
carrier.
2. CHECK RUNOUT OF COMPANION FLANGE
Using a dial indicator, measure the runout of the companion
flange vortically and horizontally.
Maximum runout: 0.10 mm (0.0039 in.)
3. CHECK RING GEAR RUNOUT
Using a dial indicator, check the runout of the ring gear.
Maximum runout: 0.07 mm (0.0028 in.)
If the runout is greater than the maximum, replace with a new
ring gear.
4. CHECK RING GEAR BACKLASH
Using a dial indicator, check the backlash of the ring gear.
Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
If the backlash is not within the specification, adjust the side
bearing preload or repair as necessary.
5. CHECK TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA−79)
6. 2 PINION DIFFERENTIAL:
CHECK SIDE GEAR BACKLASH
Using a dial indicator, check the backlash of the side gear with
holding 1 pinion gear toward the differential case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within the specification, install the 2 side
gear thrust washers of different thickness (See page SA−79).
