2006 TOYOTA RAV4 Front bar

SEAT – FRONT POWER SEAT CONTROL SYSTEMSE–3
SE
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help determine the cause of the
problem symptom. The potential causes of the symptoms are
listed in order of probability in the "Suspected Area" column
of the table. Check each symptom by checking the suspected
areas in the order they are listed. Replace parts as
necessary.
Front power seat control system
ON-VEHICLE INSPECTION
1. CHECK POWER SEAT FUNCTION
(a) Check the basic functions.
(1) Operate the power seat switches and check to
make sure each seat function works:
• Sliding
•Front vertical
•Lifter
• Reclining
• Lumbar support
2. CHECK FRONT SEAT FRAME WITH ADJUSTER
(SLIDING, FRONT VERTICAL, LIFTER AND
RECLINING FUNCTIONS)
(a) Check the PTC operation inside the power seat
motor.
HINT:
The PTC thermistor's resistance increases when the
power seat switch is held down even after the power
seat has been moved to the maximum in one
direction. If the resistance increases beyond a
specified level, current is cut to prevent a short
circuit.
Symptom Suspected area See page
All functions do not operate (except lumbar support)1. P/SEAT fuseSE-1
2. Front power seat switchSE-124
3. Wire harness -
Only slide operation function does not operate1. Front power seat switchSE-124
2. Front seat frame with adjuster (slide motor)SE-125
3. Wire harness -
Only front vertical operation function does not operate1. Front power seat switchSE-124
2. Front seat frame with adjuster (front vertical motor)SE-125
3. Wire harness -
Only lifter operation function does not operate1. Front power seat switchSE-124
2. Front seat frame with adjuster (lifter motor)SE-125
3. Wire harness -
Only reclining operation function does not operate1. Front power seat switchSE-124
2. Front seat frame with adjuster (reclining motor)SE-125
3. Wire harness -
Only lumbar support operation function does not
operate1. Front power seat lumbar switchSE-127
2. Lumbar support adjuster (lumbar support motor)SE-127
3. Wire harness -
B131377E01

SE–4SEAT – FRONT POWER SEAT CONTROL SYSTEM
SE
NOTICE:
• The inspection should be performed with the
seat installed in the vehicle.
• Perform the 4 steps below for the full range of
motion for each power seat function.
(1) Choose a power seat function. Operate the
power seat switch and move the seat as much
as possible in one direction. Keep the seat in
that position for approximately 60 seconds.
(2) Operate the power seat switch again and
continue to try to move the seat in the same
direction as in the previous step. Measure the
amount of time elapsed before current is
automatically cut (the sound of the motor has
stopped).
Standard:
4 to 90 seconds
(3) After current has been cut, release the power
seat switch and wait for approximately 60
seconds.
(4) Operate the same power seat switch and move
the seat in the opposite direction. Check that
the motor operates.
3. CHECK LUMBAR SUPPORT ADJUSTER ASSEMBLY
(a) Check the PTC operation inside the power seat
motor.
NOTICE:
The inspection should be performed with the
seat installed in the vehicle.
(1) Operate the lumbar support switch and move
the lumbar support to either the foremost or
rearmost position. Keep the seat in that
position for approximately 60 seconds.
(2) Operate the lumbar support switch again and
continue to try to move the lumbar support in
the same direction as in the previous step.
Measure the amount of time elapsed before
current is automatically cut (the sound of the
motor has stopped).
Standard:
4 to 90 seconds
(3) After current has been cut, release the lumbar
support switch and wait for approximately 60
seconds.
(4) Operate the lumbar support switch and move
the seat in the opposite direction. Check that
the motor operates.

DS–12DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)
DS
(d) Using a snap ring expander, remove the shaft snap
ring.
(e) Put matchmarks on the outboard joint shaft and
tripod joint.
NOTICE:
Do not punch the marks.
(f) Using a brass bar and hammer, tap out the tripod
joint from the outboard joint shaft.
NOTICE:
Do not tap the rollers.
(g) Remove the inboard joint boot.
7. REMOVE FRONT DRIVE SHAFT DAMPER CLAMP LH
(a) One touch type:
(1) Using a screwdriver, remove the drive shaft
damper clamp, as shown in the illustration.
(b) Claw engagement type:
(1) Using needle-nose pliers, remove the drive
shaft damper clamp, as shown in the
illustration.
8. REMOVE FRONT DRIVE SHAFT DAMPER LH
(a) Remove the front drive shaft damper from the
outboard joint shaft.
9. REMOVE FRONT AXLE OUTBOARD JOINT BOOT
NO. 2 CLAMP LH
(a) Using a screwdriver, remove the outboard joint boot
clamp, as shown in the illustration.
C127648
C127649E01
C127651E01
C127653

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)DS–15
DS
2. REMOVE FRONT AXLE INBOARD JOINT BOOT
CLAMP
(a) One touch type:
Using a screwdriver, remove the inboard joint boot
clamp, as shown in the illustration.
(b) Claw engagement type:
Using needle-nose pliers, remove the inboard joint
boot clamp, as shown in the illustration.
3. REMOVE FRONT AXLE INBOARD JOINT BOOT
(a) Remove the boot from the inboard joint.
4. REMOVE FRONT DRIVE INBOARD JOINT
ASSEMBLY LH
(a) Remove any old grease from the inboard joint.
(b) Put matchmarks on the inboard joint and outboard
joint shaft.
NOTICE:
Do not punch the marks.
(c) Remove the inboard joint from the outboard joint
shaft.
(d) Using a snap ring expander, remove the shaft snap
ring.
(e) Put matchmarks on the outboard joint shaft and
tripod joint.
NOTICE:
Do not punch the marks.
(f) Using a brass bar and hammer, tap out the tripod
joint from the outboard joint shaft.
NOTICE:
Do not tap the rollers.
(g) Remove the inboard joint boot.
C127645E01
C127646E02
C127648
C127649E01

DS–22DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)
DS
11. INSTALL FRONT DRIVE SHAFT DAMPER LH
HINT:
Install the damper clamp to outboard joint side.
(a) Install a new drive shaft damper clamp and the drive
shaft damper to the drive shaft.
(b) Make sure that the damper is on the shaft groove.
(c) Set the distance, as described below.
Standard distance:
161 to 165 mm (6.339 to 6.496 in.)
12. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP LH
(a) Hold the front drive shaft lightly in a soft vise.
(b) Install the drive shaft damper clamp to the damper.
NOTICE:
Be sure to install the clamp in the correct
position.
(c) One touch type:
(1) Using a screwdriver, install the drive shaft
damper clamp, as shown in the illustration.
(d) Claw engagement type:
(1) Using needle-nose pliers, install the drive shaft
damper clamp, as shown in the illustration.
13. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY
LH
(a) Wrap the spline of the outboard joint shaft with vinyl
tape to prevent the boots from being damaged.
(b) Install new parts to the outboard joint shaft in the
following order.
(1) Inboard joint boot clamp
(2) No. 2 inboard joint boot clamp
(3) Inboard joint boot
(c) Place the beveled side of the tripod axial spline
toward the outboard joint.
(d) Align the matchmarks placed before removal.
(e) Using a brass bar and hammer, tap the tripod joint
onto the drive shaft.
NOTICE:
• Do not tap the rollers.
• Be sure to install the tripod joint in the correct
direction.
C127690E01
C127651E01
C127694E02

DS–30DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)
DS
(c) Place the beveled side of the tripod axial spline
toward the outboard joint.
(d) Align the matchmarks placed before removal.
(e) Using a brass bar and hammer, tap the tripod joint
onto the drive shaft.
NOTICE:
• Do not tap the rollers.
• Be sure to install the tripod joint in the correct
direction.
(f) Pack the inboard joint shaft and boot with grease
from the boot kit.
Standard grease capacity:
175 to 185 g (6.2 to 6.5 oz.)
(g) Using a snap ring expander, install a new shaft snap
ring.
(h) Align the matchmarks, and install the inboard joint to
the outboard joint shaft.
12. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY
RH
HINT:
Use the same procedures described for the LH side.
13. INSTALL FRONT AXLE INBOARD JOINT BOOT
(a) Install the inboard joint boot to the inboard joint.
14. INSTALL FRONT AXLE INBOARD JOINT BOOT
CLAMP
(a) One touch type:
Using a screwdriver, install the inboard joint boot
clamp, as shown in the illustration.
NOTICE:
Be careful not to damage the boot.
(b) Claw engagement type:
Using needle-nose pliers, install the inboard joint
boot clamp, as shown in the illustration.
NOTICE:
Be careful not to damage the boot.
C127694E02
C127695
C127696E01

DS–32DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)
DS
INSTALLATION
(2005/11-2006/01)
1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
(a) Coat the spline of the inboard joint shaft with gear
oil.
(b) Using a brass bar and hammer, align the shaft
splines in the drive shaft.
NOTICE:
• Set the snap ring with the opening side facing
downwards.
• Be careful not to damage the oil seal, boot
and dust cover.
2. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
(a) Coat the spline of the inboard joint shaft with gear
oil.
(b) Align the shaft spline and install the drive shaft with
2 bolts.
Torque: 63.7 N*m (650 kgf*cm, 47 ft.*lbf)
NOTICE:
Do not damage the oil seal, boot and dust cover.
3. CONNECT STEERING KNUCKLE WITH AXLE HUB
LH
(a) Align the shaft splines in the drive shaft to the
steering knuckle with axle hub.
4. CONNECT STEERING KNUCKLE WITH AXLE HUB
RH
HINT:
Use the same procedures described for the LH side.
5. CONNECT FRONT SUSPENSION NO. 1 LOWER ARM
SUB-ASSEMBLY LH (See page AH-10)
6. CONNECT FRONT SUSPENSION NO. 1 LOWER ARM
SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
7. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
(See page SP-31)
8. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
9. CONNECT TIE ROD END SUB-ASSEMBLY LH (See
page PS-45)
10. CONNECT TIE ROD END SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
11. CONNECT FRONT SPEED SENSOR LH
(a) Connect the speed sensor (see page BC-191).
C127700
C127638

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)DS–33
DS
12. CONNECT FRONT SPEED SENSOR RH
HINT:
Use the same procedures described for the LH side.
13. INSTALL FRONT AXLE HUB NUT (See page AH-10)
14. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
15. ADD AUTOMATIC TRANSAXLE FLUID
(a) Add automatic transaxle fluid for U140F (see page
AX-152).
(b) Add automatic transaxle fluid for U241E (see page
AX-151).
16. CHECK FOR AUTOMATIC TRANSAXLE OIL
LEAKAGE
17. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (see
page SP-3).
INSTALLATION
(2006/01- )
1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
(a) Coat the spline of the inboard joint shaft with gear
oil.
(b) Align the shaft splines and tap in the drive shaft with
a brass bar and hammer.
NOTICE:
• Set the snap ring with the opening side facing
downwards.
• Be careful not to damage the oil seal, boot
and dust cover.
2. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
(a) Coat the spline of the inboard joint shaft with gear
oil.
(b) Align the shaft splines and securely insert the drive
shaft.
(c) Install the 2 bearing bracket bolts.
Torque: 63.7 N*m (650 kgf*cm, 47 ft.*lbf)
NOTICE:
Do not damage the oil seal, boot and dust cover.
C127700
C127638