Toyota RAV4 2000-05

Overhaul

Print

Front Shaft



2wd With A/T
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the inboard and outboard joint boot clamps.
  4.  
  5. Disassemble the inboard joint tulip, as follows:

    Matchmark the tri-pot, inboard joint tulip or center driveshaft to the driveshaft
     

  6.  


WARNING
Do not use punch marks.



Inboard joint tulip from the driveshaft
 

  1. Remove the inboard and outboard joint clamps.
  2.  
  3. Remove the tri-pot joint, as follows:

    Snapring
     
    Matchmark the tri-pot joint to the driveshaft
     
    Tri-pot joint, using a brass bar and hammer
     

  4.  


WARNING
Do not tap the roller.

  1. Remove or disconnect the following:

    Inboard and outboard joint boots
     

  2.  


NOTE
Do not disassemble the outboard joint.



Dust cover from the center driveshaft, using a press, for 2WD on the right side
 
Dust cover from the inboard joint tulip, using tool 09950-00020 and a press, for 2WD on the left side and 4WD
 

  1. Disassemble the center driveshaft, as follows:

    Snapring
     
    Bearing case, using a press
     
    Straight pin from the bearing case, using a pin punch and hammer
     
    Dust cover, using tool 09950-00020 and a press
     
    Snapring
     
    Bearing, using a press
     

  2.  
  3. Remove the No. 2 dust deflector, using a screwdriver and hammer.
  4.  

To assemble:



Click image to see an enlarged view

Fig. View of the bearing-to-dust cover clearance-2WD A/T and 4WD



Click image to see an enlarged view

Fig. View of the dust cover-to-center drive distance-2WD A/T and 4WD



Click image to see an enlarged view

Fig. Measuring the front halfshaft lengths-2WD A/T and 4WD

  1. Install a new No. 2 dust deflector, using a press.
  2.  
  3. Assemble the center driveshaft, as follows:

    Straight pin into the bearing case, using a pin punch and hammer
     
    New bearing, using tools 09959-60010, 09950-70010 and a press
     
    New snapring
     
    Bearing with the bearing case assembly to the center driveshaft, using tool 09710-30021 and a press
     
    New snapring
     
    New dust cover, until the clearance between the dust cover and the bearing is 0.039 in. (1.0mm)
     

  4.  
  5. Install or connect the following:

    Right dust cover (2WD), until the distance from the tip of the center drive is 3.39-3.34 in. (86-87mm) to the inner edge of the dust cover
     
    Left side dust cover (2WD and 4WD), using a press
     

  6.  
  7. Temporarily install new outboard/inboard joint boots using new clamps, as follows:
    1. Warp tape around the driveshaft splines.
    2.  
    3. Install the new outboard joint boot onto the driveshaft.
    4.  
    5. Install the new inboard joint boot onto the driveshaft.
    6.  

  8.  
  9. Install the tri-pot joint, as follows:

    Tri-pot joint, face the beveled side toward the outboard joint and align the matchmarks
     
    Tri-pot joint onto the driveshaft, using a press
     

  10.  


WARNING
Be careful not to tap the roller.



New snapring
 

  1. Install the outboard joint boot packed with grease from the boot kit.
  2.  
  3. Install the inboard joint tulip, as follows:

    Pack the inboard joint boot with grease from the boot kit
     
    Inboard joint tulip, by aligning the matchmarks
     
    Temporarily, install the inboard joint boot packed with grease from the kit
     

  4.  
  5. Install the boot clamps to both boots, as follows:

    Both boots to the shaft grooves
     
    Halfshaft length should be 33.055-33.449 in. (839.6-849.6mm) for the right side on 2WD with A/T, 21.397-21.791 in. (543.5-553.5mm) for the left side on 2WD with A/T, 19.929-20.323 in. (506.2-516.2mm) for the right side on 4WD or 19.803-20.197 in. (503-511mm) for the left side on 4WD
     
    Both new boot clamps boot
     
    Bend the band and lock it using a screwdriver
     

  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the inboard and outboard joint boot clamps.
  4.  
  5. Disassemble the inboard joint tulip, as follows:
    WARNING
    Do not use punch marks.



    Matchmark the tri-pot, inboard joint tulip or center driveshaft to the driveshaft
     



    Inboard joint tulip from the driveshaft
     

  6.  
  7. Remove the inboard and outboard joint clamps.
  8.  
  9. Remove the tri-pot joint, as follows:
    WARNING
    Do not tap the roller.



    Snapring
     
    Matchmark the tri-pot joint to the driveshaft
     
    Tri-pot joint, using a brass bar and hammer
     

  10.  
  11. Remove or disconnect the following:
    NOTE
    Do not disassemble the outboard joint.



    Inboard and outboard joint boots
     



    Dust cover from the center driveshaft, using a press, for 2WD on the right side
     
    Dust cover from the inboard joint tulip, using tool 09950-00020 and a press, for 2WD on the left side and 4WD
     

  12.  
  13. Disassemble the center driveshaft, as follows:

    Snapring
     
    Bearing case, using a press
     
    Straight pin from the bearing case, using a pin punch and hammer
     
    Dust cover, using tool 09950-00020 and a press
     
    Snapring
     
    Bearing, using a press
     

  14.  
  15. Remove the No. 2 dust deflector, using a screwdriver and hammer.
  16.  

To assemble:

Click image to see an enlarged view

Fig. View of the bearing-to-dust cover clearance-RAV4 with 2WD A/T and 4WD



Click image to see an enlarged view

Fig. View of the dust cover-to-center drive distance-RAV4 with 2WD A/T and 4WD



Click image to see an enlarged view

Fig. Measuring the front halfshaft lengths-RAV4 with 2WD A/T and 4WD

  1. Install a new No. 2 dust deflector, using a press.
  2.  
  3. Assemble the center driveshaft, as follows:

    Straight pin into the bearing case, using a pin punch and hammer
     
    New bearing, using tools 09959-60010, 09950-70010 and a press
     
    New snapring
     
    Bearing with the bearing case assembly to the center driveshaft, using tool 09710-30021 and a press
     
    New snapring
     
    New dust cover, until the clearance between the dust cover and the bearing is 0.039 in. (1.0mm)
     

  4.  
  5. Install or connect the following:

    Right dust cover (2WD), until the distance from the tip of the center drive is 3.39-3.34 in. (86-87mm) to the inner edge of the dust cover
     
    Left side dust cover (2WD and 4WD), using a press
     

  6.  
  7. Temporarily install new outboard/inboard joint boots using new clamps, as follows:
    1. Warp tape around the driveshaft splines.
    2.  
    3. Install the new outboard joint boot onto the driveshaft.
    4.  
    5. Install the new inboard joint boot onto the driveshaft.
    6.  

  8.  
  9. Install the tri-pot joint, as follows:
    WARNING
    Be careful not to tap the roller.



    Tri-pot joint, face the beveled side toward the outboard joint and align the matchmarks
     
    Tri-pot joint onto the driveshaft, using a press
     



    New snapring
     

  10.  
  11. Install the outboard joint boot packed with grease from the boot kit.
  12.  
  13. Install the inboard joint tulip, as follows:

    Pack the inboard joint boot with grease from the boot kit
     
    Inboard joint tulip, by aligning the matchmarks
     
    Temporarily, install the inboard joint boot packed with grease from the kit
     

  14.  
  15. Install the boot clamps to both boots, as follows:

    Both boots to the shaft grooves
     
    Halfshaft length should be 33.055-33.449 in. (839.6-849.6mm) for the right side on 2WD with A/T, 21.397-21.791 in. (543.5-553.5mm) for the left side on 2WD with A/T, 19.929-20.323 in. (506.2-516.2mm) for the right side on 4WD or 19.803-20.197 in. (503-511mm) for the left side on 4WD
     
    Both new boot clamps boot
     
    Bend the band and lock it using a screwdriver
     

  16.  

2wd With M/T
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the inboard and outboard joint boot clamps.
  4.  
  5. Disassemble the inboard joint tulip, as follows:

    Snapring from the inboard joint tulip (center driveshaft)
     
    Inboard joint tulip (center driveshaft), by matchmarking it to the shaft
     

  6.  
  7. Disassemble the inboard joint, as follows:

    Matchmark the inner race and cage to the driveshaft
     
    6 balls and cage
     
    Snapring
     
    Inner race, using a brass bar and a hammer
     
    Snapring
     

  8.  
  9. Remove the inboard and outboard joint boots and inboard joint clamps.
  10.  


WARNING
Do not disassemble the outboard joint.

  1. Remove or disconnect the following:

    Dust cover from the center driveshaft, using a press
     
    Dust cover from the inboard joint tulip, using tool 09950-00020 and a press
     

  2.  
  3. Remove the bearing, as follows:

    Dust cover from the inboard joint tulip, using tool 09950-00020 and a press
     
    Snapring
     
    Bearing, using a press
     
    Snapring
     

  4.  
  5. Remove the No. 2 dust deflector, using a screwdriver and a hammer.
  6.  

To assemble:



Click image to see an enlarged view

Fig. View of the bearing-to-dust cover clearance-2WD with M/T



Click image to see an enlarged view

Fig. View of the dust cover-to-center drive distance-2WD with M/T



Click image to see an enlarged view

Fig. Measuring the front halfshaft lengths-2WD with M/T

  1. Install a new No. 2 dust deflector, using tools 09309-36010, 09316-20011 and a press.
  2.  
  3. Install the bearing, as follows:

    New snapring
     
    Bearing, using a press
     
    New snapring
     
    Dust cover, until the clearance between the dust cover and the bearing is 0.039 in. (1.0mm)
     

  4.  
  5. Install or connect the following:

    Right dust cover, until the distance from the tip of the center drive is 4.134-4.173 in. (105.0-106.0mm) to the inner edge of the dust cover
     
    Left side dust cover, using a press
     

  6.  
  7. Temporarily install new outboard/inboard joint boots using new clamps, as follows:
    1. Warp tape around the driveshaft splines.
    2.  
    3. Install the new outboard joint boot onto the driveshaft with both new clamps.
    4.  
    5. Install the new inboard joint boot onto the driveshaft.
    6.  

  8.  
  9. Assemble the inboard joint onto the driveshaft, as follows:

    New snapring
     
    Cage
     

  10.  


NOTE
The smaller diameter side must face outboard.



Inner race, using a brass bar and hammer by aligning the matchmarks
 


WARNING
Be careful not to damage the inner race.



New snapring
 

  1. Install the outboard joint boot packed with grease from the boot kit.
  2.  
  3. Install the inboard joint tulip, as follows:

    Cage to the inner race by aligning the matchmarks
     
    6 cage balls
     

  4.  


NOTE
Lubricate the balls with grease to keep them from falling.



Inboard joint tulip, by aligning the matchmarks
 
New snapring
 
Temporarily, install the inboard joint boot packed with grease from the kit
 

  1. Install the boot clamps to both boots, as follows:

    Both boots to the shaft grooves
     
    Halfshaft length should be 32.988-33.382 in. (837.9-847.9mm) for the right side or 21.165-21.559 in. (537.6-547.6mm) for the left side
     
    Both new clamps on the inboard joint boot
     
    Crimp the new clamps using tool 09521-24010
     
    Adjust the crimp clearance to 0.047-0.157 in. (1.2-4.0mm)
     

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the inboard and outboard joint boot clamps.
  4.  
  5. Disassemble the inboard joint tulip, as follows:

    Snapring from the inboard joint tulip (center driveshaft)
     
    Inboard joint tulip (center driveshaft), by matchmarking it to the shaft
     

  6.  
  7. Disassemble the inboard joint, as follows:

    Matchmark the inner race and cage to the driveshaft
     
    6 balls and cage
     
    Snapring
     
    Inner race, using a brass bar and a hammer
     
    Snapring
     

  8.  
  9. Remove the inboard and outboard joint boots and inboard joint clamps.
    WARNING
    Do not disassemble the outboard joint.

  10.  
  11. Remove or disconnect the following:

    Dust cover from the center driveshaft, using a press
     
    Dust cover from the inboard joint tulip, using tool 09950-00020 and a press
     

  12.  
  13. Remove the bearing, as follows:

    Dust cover from the inboard joint tulip, using tool 09950-00020 and a press
     
    Snapring
     
    Bearing, using a press
     
    Snapring
     

  14.  
  15. Remove the No. 2 dust deflector, using a screwdriver and a hammer.
  16.  

To assemble:

Click image to see an enlarged view

Fig. View of the bearing-to-dust cover clearance-2WD RAV4 With M/T



Click image to see an enlarged view

Fig. View of the dust cover-to-center drive distance-2WD RAV4 With M/T



Click image to see an enlarged view

Fig. Measuring the front halfshaft lengths-2WD RAV4 with M/T

  1. Install a new No. 2 dust deflector, using tools 09309-36010, 09316-20011 and a press.
  2.  
  3. Install the bearing, as follows:

    New snapring
     
    Bearing, using a press
     
    New snapring
     
    Dust cover, until the clearance between the dust cover and the bearing is 0.039 in. (1.0mm)
     

  4.  
  5. Install or connect the following:

    Right dust cover, until the distance from the tip of the center drive is 4.134-4.173 in. (105.0-106.0mm) to the inner edge of the dust cover
     
    Left side dust cover, using a press
     

  6.  
  7. Temporarily install new outboard/inboard joint boots using new clamps, as follows:
    1. Warp tape around the driveshaft splines.
    2.  
    3. Install the new outboard joint boot onto the driveshaft with both new clamps.
    4.  
    5. Install the new inboard joint boot onto the driveshaft.
    6.  

  8.  
  9. Assemble the inboard joint onto the driveshaft, as follows:
    NOTE
    The smaller diameter side must face outboard.


    WARNING
    Be careful not to damage the inner race.



    New snapring
     
    Cage
     



    Inner race, using a brass bar and hammer by aligning the matchmarks
     



    New snapring
     

  10.  
  11. Install the outboard joint boot packed with grease from the boot kit.
  12.  
  13. Install the inboard joint tulip, as follows:
    NOTE
    Lubricate the balls with grease to keep them from falling.



    Cage to the inner race by aligning the matchmarks
     
    6 cage balls
     



    Inboard joint tulip, by aligning the matchmarks
     
    New snapring
     
    Temporarily, install the inboard joint boot packed with grease from the kit
     

  14.  
  15. Install the boot clamps to both boots, as follows:

    Both boots to the shaft grooves
     
    Halfshaft length should be 32.988-33.382 in. (837.9-847.9mm) for the right side or 21.165-21.559 in. (537.6-547.6mm) for the left side
     
    Both new clamps on the inboard joint boot
     
    Crimp the new clamps using tool 09521-24010
     
    Adjust the crimp clearance to 0.047-0.157 in. (1.2-4.0mm)
     

  16.  

Rear Halfshaft



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the inboard and outboard joint boot clamps.
  4.  
  5. Disassemble the inboard joint tulip, as follows:

    Matchmark the tri-pot, inboard joint tulip or center driveshaft to the driveshaft
     

  6.  


WARNING
Do not use punch marks.



Inboard joint tulip from the driveshaft
 

  1. Remove the tri-pot joint, as follows:

    Snapring
     
    Matchmark the tri-pot joint to the driveshaft
     

  2.  


WARNING
Do not use punch marks.



Tri-pot joint, using a brass bar and hammer
 


WARNING
Do not tap the roller.

  1. Remove or disconnect the following:

    Inboard and outboard joint boots
     

  2.  


NOTE
Do not disassemble the outboard joint.



No. 2 dust deflector from the center driveshaft, using a screwdriver and hammer
 

To assemble:



Click image to see an enlarged view

Fig. Measuring the rear halfshaft lengths

  1. Install a new No. 2 dust deflector, using tools 09309-36010, 09316-20011 and a press.
  2.  
  3. Temporarily install new outboard/inboard joint boots using new clamps, as follows:
    1. Warp tape around the driveshaft splines.
    2.  
    3. Install the new outboard joint boot onto the driveshaft.
    4.  
    5. Install the new inboard joint boot onto the driveshaft.
    6.  

  4.  
  5. Install the tri-pot joint, as follows:

    Tri-pot joint, face the beveled side toward the outboard joint and align the matchmarks
     
    Tri-pot joint onto the driveshaft, using a brass bar and hammer
     

  6.  


WARNING
Be careful not to tap the roller.



New snapring
 

  1. Install the outboard joint boot packed with grease from the boot kit.
  2.  
  3. Install the inboard joint tulip, as follows:

    Pack the inboard joint boot with grease from the boot kit
     
    Inboard joint tulip, by aligning the matchmarks
     
    Inboard joint boot packed with grease from the kit
     

  4.  
  5. Install the boot clamps to both boots, as follows:

    Both boots to the shaft grooves
     
    Halfshaft length should be 23.392-23.795 in. (594.4-604.4mm) for the right side or 21.590-21.984 (548.4-558.4mm) for the left side
     
    New boot clamps boot
     
    Bend the band and lock it using a screwdriver
     

  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the inboard and outboard joint boot clamps.
  4.  
  5. Disassemble the inboard joint tulip, as follows:
    WARNING
    Do not use punch marks.



    Matchmark the tri-pot, inboard joint tulip or center driveshaft to the driveshaft
     



    Inboard joint tulip from the driveshaft
     

  6.  
  7. Remove the tri-pot joint, as follows:
    WARNING
    Do not use punch marks.


    WARNING
    Do not tap the roller.



    Snapring
     
    Matchmark the tri-pot joint to the driveshaft
     



    Tri-pot joint, using a brass bar and hammer
     

  8.  
  9. Remove or disconnect the following:
    NOTE
    Do not disassemble the outboard joint.



    Inboard and outboard joint boots
     



    No. 2 dust deflector from the center driveshaft, using a screwdriver and hammer
     

  10.  

To assemble:

Click image to see an enlarged view

Fig. Measuring the rear halfshaft lengths-RAV4

  1. Install a new No. 2 dust deflector, using tools 09309-36010, 09316-20011 and a press.
  2.  
  3. Temporarily install new outboard/inboard joint boots using new clamps, as follows:
    1. Warp tape around the driveshaft splines.
    2.  
    3. Install the new outboard joint boot onto the driveshaft.
    4.  
    5. Install the new inboard joint boot onto the driveshaft.
    6.  

  4.  
  5. Install the tri-pot joint, as follows:
    WARNING
    Be careful not to tap the roller.



    Tri-pot joint, face the beveled side toward the outboard joint and align the matchmarks
     
    Tri-pot joint onto the driveshaft, using a brass bar and hammer
     



    New snapring
     

  6.  
  7. Install the outboard joint boot packed with grease from the boot kit.
  8.  
  9. Install the inboard joint tulip, as follows:

    Pack the inboard joint boot with grease from the boot kit
     
    Inboard joint tulip, by aligning the matchmarks
     
    Inboard joint boot packed with grease from the kit
     

  10.  
  11. Install the boot clamps to both boots, as follows:

    Both boots to the shaft grooves
     
    Halfshaft length should be 23.392-23.795 in. (594.4-604.4mm) for the right side or 21.590-21.984 (548.4-558.4mm) for the left side
     
    New boot clamps boot
     
    Bend the band and lock it using a screwdriver
     

  12.  

 
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