Toyota RAV4 2000-05

Removal & Installation

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Fig. Rear halfshaft removal and installation (4WD only)-2001-03



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Fig. Rear halfshaft and related parts-2004

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Rear wheels
     
    Anti-lock Brake System (ABS) speed sensor from the axle assembly by removing the bolt, if equipped
     
    Cotter pin, lock cap and the nut holding the halfshaft to the axle carrier
     

  4.  
  5. Place matchmarks on the halfshaft and side gear shaft.
  6.  
  7. Remove or disconnect the following:

    Halfshaft from the differential side gear shaft, by removing the 4 nuts and washers
     
    Halfshaft from the axle carrier, using a plastic hammer
     

  8.  

To install:

  1. Install or connect the following:

    Halfshaft to the axle carrier
     
    Halfshaft to the differential side gear shaft, by aligning the marks. Tighten the 4 nuts to 41 ft. lbs. (56 Nm).
     
    Nut, lock cap and the cotter pin to hold the halfshaft to the axle carrier. Tighten the nut to 152 ft. lbs. (206 Nm) for 2001-03; 159 ft. lbs. (216 Nm) for 2004.
     
    ABS sensor. Tighten the bolt to 69 inch lbs. (8 Nm).
     
    Rear wheels
     
    Negative battery cable
     

  2.  
  3. Check the ABS sensor signal.
  4.  

Front





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Fig. Front halfshaft exploded view (2WD with manual transmission only)-2001-03



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Fig. Front halfshaft exploded view (2WD with automatic transmission and 4WD)-2001-03

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     

  4.  
  5. Drain the transaxle.
  6.  
  7. Remove or disconnect the following:

    Anti-lock Brake System (ABS) sensor by removing the bolt, if equipped
     
    Cotter pin, lock cap and the locknut holding the halfshaft to the steering knuckle
     
    Tie rod ends, from the steering knuckle
     
    Sway bar link, from the lower control arm
     
    Lower ball joint, from the lower control arm
     
    Halfshaft from the axle hub, using a plastic hammer
     

  8.  
  9. If working on a 2WD right-hand halfshaft and the vehicle is equipped with a manual transaxle, perform the following to remove the halfshaft:

    Snapring from the center bearing bracket, using a brass bar and hammer
     
    Bolt and the center bearing bracket
     
    Halfshaft with the center halfshaft
     
    2 bolts and the center bearing bracket
     

  10.  
  11. If working on a 2WD right-hand halfshaft and the vehicle is equipped with an automatic transaxle, perform the following to remove the halfshaft:

    2 bolts of the center bearing bracket and pull out the halfshaft together with the center bearing case and center halfshaft
     
    3 bolts and the center bearing bracket
     

  12.  
  13. If working on a 2WD left-hand, perform the following:

    Halfshaft, using a brass bar and hammer
     
    Snapring from the transaxle
     

  14.  
  15. If working of a 4WD right-hand halfshaft, perform the following:

    Halfshaft, using a brass bar and hammer
     
    Snapring from the transaxle
     
    O-ring
     

  16.  
  17. If working on a 4WD left-hand side, perform the following:

    Air cleaner
     
    Transaxle case protector
     
    Halfshaft, by prying it out using a hub wrench
     
    Snapring
     

  18.  

To install:

  1. If working on a 4WD left-hand side, perform the following:

    Snapring
     
    Halfshaft to the transaxle
     
    Transaxle case protector
     
    Air cleaner
     

  2.  
  3. If working of a 4WD right-hand halfshaft, perform the following:

    Snapring to the transaxle
     
    New O-ring
     
    Halfshaft to the transaxle
     

  4.  
  5. If working on a 2WD left-hand, perform the following:

    Snapring
     
    Halfshaft to the transaxle
     

  6.  
  7. If working on a 2WD right-hand halfshaft and the vehicle is equipped with an automatic transaxle, perform the following to remove the halfshaft:

    Center bearing bracket. Tighten the 3 bolts to 47 ft. lbs. (64 Nm).
     
    Halfshaft together with the center bearing case and center halfshaft. Tighten both bolts to 47 ft. lbs. (64 Nm).
     

  8.  
  9. If working on a 2WD right-hand halfshaft and the vehicle is equipped with a manual transaxle, perform the following to remove the halfshaft:

    Center bearing bracket
     
    Halfshaft with the center halfshaft
     
    Center bearing bracket. Tighten the bolt to 24 ft. lbs. (32 Nm).
     
    Snapring to the center bearing bracket
     

  10.  
  11. Install or connect the following:

    Halfshaft to the axle hub
     
    Lower ball joint to the lower control arm. Tighten the nuts/bolt to 94 ft. lbs. (127 Nm).
     
    Sway bar link to the lower control arm. Tighten the nut to 47 ft. lbs. (64 Nm) for 3-door or to 83 ft. lbs. (113 Nm) for 5-door.
     
    Tie rod end to the steering knuckle. Tighten the nut to 36 ft. lbs. (49 Nm).
     
    New tie rod end cotter pin
     
    Halfshaft to the axle hub. Tighten the locknut to 159 ft. lbs. (216 Nm).
     
    Lock cap and cotter pin
     
    ABS speed sensor with the bolt, if equipped
     

  12.  
  13. Fill the transaxle with gear oil (manual transmission) or ATF (automatic transmission).
  14.  
  15. Install or connect the following:

    Engine undercover
     
    Wheels
     
    Negative battery cable
     

  16.  
  17. Check the ABS sensor signal.
  18.  



Click image to see an enlarged view

Fig. Front halfshafts-2004

  1. Remove the wheel.
  2.  
  3. Drain the transaxle. With 4WD, drain the transfer case.
  4.  
  5. Unstake and remove the locknut.
  6.  
  7. Unbolt the lower arm from the ball joint.
  8.  
  9. Remove the halfshaft from the hub, using a plastic hammer.
  10.  
  11. Remove the halfshaft. On 2wd vehicle, the right side shaft is retained by 2 bolts. All others are removed with a slidehammer and special tool 09520-01010, or equivalent.
  12.  
  13. Remove the snapring.
  14.  
  15. Installation is the reverse of removal. The new snapring is installed with the split facing downward. After installation, check that there is 2-3mm of axial play. Observe the following torques:

    Right halfshaft bolts: 47 ft. lbs. (64 Nm)
     
    Lower arm-to-ball joint: 94 ft. lbs. (128 Nm)
     
    Hub nut: 159 ft. lbs. (216 Nm)
     

  16.  



Click image to see an enlarged view

Fig. Front halfshaft exploded view (2WD with manual transmission only)-RAV4



Click image to see an enlarged view

Fig. Front halfshaft exploded view (2WD with automatic transmission and 4WD)-RAV4

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     

  4.  
  5. Drain the transaxle.
  6.  
  7. Remove or disconnect the following:

    Anti-lock Brake System (ABS) sensor by removing the bolt, if equipped
     
    Cotter pin, lock cap and the locknut holding the halfshaft to the steering knuckle
     
    Tie rod ends, from the steering knuckle
     
    Sway bar link, from the lower control arm
     
    Lower ball joint, from the lower control arm
     
    Halfshaft from the axle hub, using a plastic hammer
     

  8.  
  9. If working on a 2WD right-hand halfshaft and the vehicle is equipped with a manual transaxle, perform the following to remove the halfshaft:

    Snapring from the center bearing bracket, using a brass bar and hammer
     
    Bolt and the center bearing bracket
     
    Halfshaft with the center halfshaft
     
    2 bolts and the center bearing bracket
     

  10.  
  11. If working on a 2WD right-hand halfshaft and the vehicle is equipped with an automatic transaxle, perform the following to remove the halfshaft:

    2 bolts of the center bearing bracket and pull out the halfshaft together with the center bearing case and center halfshaft
     
    3 bolts and the center bearing bracket
     

  12.  
  13. If working on a 2WD left-hand, perform the following:

    Halfshaft, using a brass bar and hammer
     
    Snapring from the transaxle
     

  14.  
  15. If working of a 4WD right-hand halfshaft, perform the following:

    Halfshaft, using a brass bar and hammer
     
    Snapring from the transaxle
     
    O-ring
     

  16.  
  17. If working on a 4WD left-hand side, perform the following:

    Air cleaner
     
    Transaxle case protector
     
    Halfshaft, by prying it out using a hub wrench
     
    Snapring
     

  18.  

To install:

  1. If working on a 4WD left-hand side, perform the following:

    Snapring
     
    Halfshaft to the transaxle
     
    Transaxle case protector
     
    Air cleaner
     

  2.  
  3. If working of a 4WD right-hand halfshaft, perform the following:

    Snapring to the transaxle
     
    New O-ring
     
    Halfshaft to the transaxle
     

  4.  
  5. If working on a 2WD left-hand, perform the following:

    Snapring
     
    Halfshaft to the transaxle
     

  6.  
  7. If working on a 2WD right-hand halfshaft and the vehicle is equipped with an automatic transaxle, perform the following to remove the halfshaft:

    Center bearing bracket. Tighten the 3 bolts to 47 ft. lbs. (64 Nm).
     
    Halfshaft together with the center bearing case and center halfshaft. Tighten both bolts to 47 ft. lbs. (64 Nm).
     

  8.  
  9. If working on a 2WD right-hand halfshaft and the vehicle is equipped with a manual transaxle, perform the following to remove the halfshaft:

    Center bearing bracket
     
    Halfshaft with the center halfshaft
     
    Center bearing bracket. Tighten the bolt to 24 ft. lbs. (32 Nm).
     
    Snapring to the center bearing bracket
     

  10.  
  11. Install or connect the following:

    Halfshaft to the axle hub
     
    Lower ball joint to the lower control arm. Tighten the nuts/bolt to 94 ft. lbs. (127 Nm).
     
    Sway bar link to the lower control arm. Tighten the nut to 47 ft. lbs. (64 Nm) for 3-door or to 83 ft. lbs. (113 Nm) for 5-door.
     
    Tie rod end to the steering knuckle. Tighten the nut to 36 ft. lbs. (49 Nm).
     
    New tie rod end cotter pin
     
    Halfshaft to the axle hub. Tighten the locknut to 159 ft. lbs. (216 Nm).
     
    Lock cap and cotter pin
     
    ABS speed sensor with the bolt, if equipped
     

  12.  
  13. Fill the transaxle with gear oil (manual transmission) or ATF (automatic transmission).
  14.  
  15. Install or connect the following:

    Engine undercover
     
    Wheels
     
    Negative battery cable
     

  16.  
  17. Check the ABS sensor signal.
  18.  

Rear





Click image to see an enlarged view

Fig. Rear halfshaft removal and installation (4WD only)-RAV4

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Rear wheels
     
    Anti-lock Brake System (ABS) speed sensor from the axle assembly by removing the bolt, if equipped
     
    Cotter pin, lock cap and the nut holding the halfshaft to the axle carrier
     

  4.  
  5. Place matchmarks on the halfshaft and side gear shaft.
  6.  
  7. Remove or disconnect the following:

    Halfshaft from the differential side gear shaft, by removing the 4 nuts and washers
     
    Halfshaft from the axle carrier, using a plastic hammer
     

  8.  

To install:

  1. Install or connect the following:

    Halfshaft to the axle carrier
     
    Halfshaft to the differential side gear shaft, by aligning the marks. Tighten the 4 nuts to 41 ft. lbs. (56 Nm).
     
    Nut, lock cap and the cotter pin to hold the halfshaft to the axle carrier. Tighten the nut to 152 ft. lbs. (206 Nm).
     
    ABS sensor. Tighten the bolt to 69 inch lbs. (8 Nm).
     
    Rear wheels
     
    Negative battery cable
     

  2.  
  3. Check the ABS sensor signal.
  4.  

 
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