HỆ THỐNG PHUỘC NHÚN VÀ CẦU XE TRÊN XE TOYOTA RAV4 ĐỜI 1994-2000
SA0T5−01 −SUSPENSION AND AXLE TROUBLESHOOTING SA−1 1996 RAV4 (RM447U) TROUBLESHOOTING PROBLEM SYMPTOMS TABLE Use the table below th 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. Symptom Suspect Area See page Wander/pulls 1. Tires (Worn or improperly inflated) 2. Wheel alignment (Incorrect) 3. Steering linkage (Loosen or worn) 4. Hub bearings (Loosen or worn) 5. Steering gear (Out of adjustment or broken) 6. Suspension parts (Worn out) SA−2 SA−4 − SA−10 SA−52 SA−56 − − Bottoming 1. Vehicle (Overloaded) 2. Spring (Weak) 3. Shock absorber (Worn out) − SA−32 SA−95 SA−35 SA−92 Sways/pitches 1. Tires (Worn or improperly inflated) 2. Stabilizer bar (Bent or broken) 3. Shock absorber (Worn out) SA−2 SA−49 SA−35 SA−92 Front wheel shimmy 1. Tires (Worn or improperly inflated) 2. Wheels (Out of balance) 3. Shock absorber (Worn out) 4. Wheel alignment (Incorrect) 5. Ball joints (Worn) 6. Hub bearings (Loosen or worn) 7. Steering linkage (Loosen or worn) 8. Steering gear (Out of adjustment or broken) SA−2 SA−2 SA−35 SA−2 SA−45 SA−10 − − Abnormal tire wear 1. Tires (Improperly inflated) 2. Wheel alignment (Incorrect) 3. Suspension parts (Worn out) 4. Shock absorber (Worn out) SA−2 SA−4 − SA−35 SA−92 Noise in rear differential 1. Oil level (Low or wrong grade) 2. Excessive backlash between pinion and ring gear 3. Ring, pinion or side gears (Worn or chipped) 4. Pinion shaft bearing (Worn) 5. Side bearing (Worn) 6. Differential bearing (Loosen or worn) SA−69 SA−79 SA−79 SA−79 SA−79 SA−79 Oil leak from rear differential 1. Oil level (Too high or wrong grade) 2. Drive pinion oil seal (Worn or damaged) 3. Side gear oil seal (Worn or damaged) 4. Companion flange (Loose or damaged) 5. Side gear shaft (Damaged) SA−69 SA−79 SA−79 SA−74 SA−79 SA0T6−02 R03031 R14869 R07928 SA−2 −SUSPENSION AND AXLE TIRE AND WHEEL 1996 RAV4 (RM447U) TIRE AND WHEEL INSPECTION 1. INSPECT TIRE (a) Check the tires for wear and proper inflation pressure. Cold tire inflation pressure Tire size Front kPa (kgf/cm 2 or bar, psi) Rear kPa (kgf/cm 2 or bar, psi) 3 Door vehicle 215/70R16 99S 180 (1.8, 26) 180 (1.8, 26) 5 Door vehicle 215/70R16 99S 190 (1.9, 28) 180 (1.8, 26) (b) Check the tire runout. Tire runout: 1.0 mm (0.039 in.) or less 2. ROTATING TIRES HINT: See the illustration for where to rotate each tire. 3. INSPECT WHEEL BALANCE (a) Check and adjust the Off−the−car balance. (b) If necessary, check and adjust the On−the−car−balance. Imbalance after adjustment: 13.0 g (0.029 lb) or less R10657 −SUSPENSION AND AXLE TIRE AND WHEEL SA−3 1996 RAV4 (RM447U) 4. CHECK WHEEL BEARING LOOSENESS (a) Check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 in.) (b) Check the axle hub deviation. Maximum: 0.07 mm (0.0028 in.) 5. CHECK FRONT SUSPENSION FOR LOOSENESS 6. CHECK STEERING LINKAGE FOR LOOSENESS 7. CHECK BALL JOINT FOR LOOSENESS 8. CHECK SHOCK ABSORBER WORKS PROPERLY S Check for oil leak S Check mounting bushings for wear S Check bounce for front and rear of the vehicle R10734 R10735 F02020 Front: Rear: SA0T7−05 Z03382 SA3213 A C B Front D SA−4 −SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT 1996 RAV4 (RM447U) FRONT WHEEL ALIGNMENT INSPECTION 1. MEASURE VEHICLE HEIGHT Tire size Front* 1 mm (in.) Rear* 2 mm (in.) 215/70R16 (2WD) 227 (8.94) 353 (13.90) 215/70R16 (4WD) 227 (8.94) 360 (14.17) * 1 : Front measuring point: Measure from the ground to the center of the lower suspension arm front mounting bolt. * 2 : Rear measuring point: Measure from the ground to the center of the body side No.1 suspension arm mounting bolt. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specification. If the vehicle height is not to specification, try to adjust it by pushing down on or lifting the body. 2. INSTALL CAMBER−CASTER−KINGPIN GAUGE ONTO VEHICLE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION Tire size: 215/70R16 2WD 4WD Camber Left−right error −0°20’ ± 45’ (−0.33°± 0.75°) 45’ (0.75°) or less −0°15’± 45’ (−0.25° ± 0.75°) 45’ (0.75°) or less Caster Left−right error 1°25’ ± 45’ (1.42° ± 0.75°) 45’ (0.75°) or less 1°20 ± 45’ (1.33° ± 0.75°) 45’ (0.75°) or less Steering axis inclination Left−right error 11°00’ ± 45’ (11° ± 0.75°) 45’ (0.75°) or less 10°45’ ± 45’ (10.75° ± 0.75°) 45’ (0.75°) or less If the caster and steering axis inclination are not within the spec- ification, after the camber has correctly adjusted, recheck the suspension parts for damaged and/or worn out parts. 4. INSPECT TOE−IN To e−in (total) A + B: 0° ± 0’10’ (0° ± 0.17°) C − D: 0 ± 2 mm (0 ± 0.08 in.) If the toe−in is not within the specification, adjust it by the tie rod end. R10850 W01204 F01195 Bolt Set Bolt Adjusting Bolt 1 Dot 2 Dots 3 Dots 30’ 45’ 1°15’ 1°30’ Adjusting Value OD=13.9 mm OD=13.3 mm OD=12.4 mm Original 15’ 1°00’ −SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT SA−5 1996 RAV4 (RM447U) 5. ADJUST CAMBER NOTICE: After the camber has been adjusted, inspect the toe−in. (a) Remove the front wheels. (b) Remove the 2 nuts on the lower side of the shock absorb- er. (c) Coat the threads of the nuts with engine oil. (d) Temporarily install the 2 nuts. (e) Adjust the camber by pushing or pulling the lower side of the shock adjustment is required. (f) Tighten the 2nuts. Torque: 158 N·m (1,610 kgf·cm, 117 ft.lbf) (g) Install the front wheels. Torque: 103 N·m (1,050 kgf·cm, 76 ft.lbf) (h) Check the camber. HINT: S Try to adjust the camber to the center value. S Adjusting value for the set bolts is 6’ − 30’ (0.1° − 0.5°). If the camber is not within the specification, using the table be- low, estimate for how much additional camber adjustment will be required, and select the camber adjusting bolt. W01205 1 2 R10746 R10747 SA0028 AB Front AB A: Inside B: Outside SA−6 −SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT 1996 RAV4 (RM447U) (i) Follow the above mentioned steps again. Between the step (b) and (c), exchange 1 or 2 selected bolts. HINT: When exchanging the 2 bolts, exchange 1 bolt for each time. 6. ADJUST TOE−IN (a) Remove the boot clamps. (b) Loosen the tie rod end lock nuts. (c) Turn the left and right rack ends an equal amount to adjust the toe−in. HINT: S Try to adjust the toe−in to the center value. S Make sure that the length of the left and right rack ends is the same. Tie rod end length difference: 1.5 mm (0.059 in.) or less (d) Torque the tie rod end lock nuts. Torque: 56 N·m (570 kgf·cm, 41 ft·lbf) (e) Place the boot on the seat and install the clamp. HINT: Make sure that the boots are not twisted. 7. INSPECT WHEEL ANGLE Turn the steering wheel fully, and measure the turning angle. Inside wheel 33°15’ ± 2.0° (33.25° ± 2.0°) Outside wheel: Reference 28°05’ (28.08°) If the wheel angles differ from the standard specification, adjust the toe−in. SA0T8−05 SA3213 AB D Front C W01763 −SUSPENSION AND AXLE REAR WHEEL ALIGNMENT SA−7 1996 RAV4 (RM447U) REAR WHEEL ALIGNMENT INSPECTION 1. MEASURE VEHICLE HEIGHT (See page SA−4) NOTICE: Before inspect the wheel alignment, adjust the vehicle height to specification. 2. INSTALL CAMBER−CASTER−KINGPIN GAUGE OR ONTO WHEEL ALIGNMENT TESTER Follow the specifications of the equipment manufacturer. 3. INSPECT CAMBER 2WD 4WD Camber Left−right error −1°20’ ± 45’ (−1.33° ± 0.75°) 45’ (0.75°) or less −1°05’ ± 45’ (−1.08° ± 0.75°) 45’ (0.75°) or less If the camber is not within the specification, adjust it by the cam- ber adjust cam. 4. INSPECT TOE−IN 2WD To e−in (total) A + B: 0°20’ ± 0’10’ (0.33° ± 0.17°) C − D: 4 ± 2 mm (0.16 ± 0.08 in.) 4WD To e−in (total) A + B: 0°15’ ± 0’10’ (0.25° ± 0.17°) C − D: 3 ± 2 mm (0.12 ± 0.08 in.) If the toe−in is not within the specification, adjust it by the toe− adjust cam. If the toe−in is not within the specification, adjust it by the toe− adjust cam. 5. ADJUST CAMBER (a) Loosen the camber adjust cam lock bolt. (b) Turn the camber adjust cam to adjust camber. HINT: S Try to adjust the camber to the center value. S The camber will change about 16’ (0.27°) with each grad- uation of the cam. (c) Torque the lock bolt. Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf) R10782 W01761 SA−8 −SUSPENSION AND AXLE REAR WHEEL ALIGNMENT 1996 RAV4 (RM447U) 6. ADJUST TOE−IN (a) Measure the distance between each wheel disc and cor- ner of the cam bracket, then confirm that both are the same. Left−right difference: 1 mm (0.04 in.) or less If the left−right difference is larger than 1 mm (0.04 in.), adjust it by following the procedures below. (b) Loosen the toe−adjust cam lock bolt. (c) Turn the toe−adjust cam an equal amount to adjust toe− in. HINT: S Try it adjust the tie−in to the center value. S The toe−in will change about 2.5 mm (0.10 in.) with each graduation of the cam (both side). (d) Torque the lock bolts. Torque: 132 N·m (1,350 kgf·cm, 97 ft·lbf) SA0T9−03 Z19327 49 ABS Speed Sensor 158 (1,610, 117) 49 (500, 36) 8.3 (85, 74 in.·lbf) 127 (1,300, 94) 107 (1,090, 79) Steering Knuckle with Axle Hub Axle Hub Snap Ring Oil Seal Lower Ball Joint Steering Knuckle Front Shock Absorber Lower Suspension Arm Lock Cap Cotter Pin z 5 (55, 48 in.·lbf) Front Drive Shaft Tie Rod End Hub Bolt Disc Cotter Pin z Brake Caliper Dust Deflectorz Dust Cover z Bearingz Cotter Pinz Oil Seal z N·m (kgf·cm, ft·lbf) Non−reusable part : Specified torque z 216 (2,200, 159) 127 (1,300, 94) z 8 (80, 69 in.·lbf) −SUSPENSION AND AXLE FRONT AXLE HUB SA−9 1996 RAV4 (RM447U) FRONT AXLE HUB COMPONENTS SA0TA−03 R10657 R10655 SA−10 −SUSPENSION AND AXLE FRONT AXLE HUB 1996 RAV4 (RM447U) REMOVAL 1. REMOVE FRONT WHEEL Torque: 103 N·m (1,050kgf·cm, 76 ft·lbf) 2. CHECK BEARING BACKLASH AND AXLE HUB DEVI- ATION (a) Remove the 2 bolts and brake caliper from the steering knuckle. (b) Support the brake caliper securely. (c) Remove the disc. (d) Using a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the bearing. (e) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.07 mm (0.0028 in.) If the deviation exceeds the maximum, replace the axle hub and bearing. 3. REMOVE DRIVE SHAFT LOCK NUT (a) Install the disc and brake caliper. Torque: 107 N·m (1,090 kgf·cm, 79 ft·lbf) (b) Remove the cotter pin and lock cap. (c) With applying the brakes, remove the nut. Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf) (d) Remove the brake caliper and disc. 4. w/ ABS: REMOVE ABS SPEED SENSOR AND WIRE HARNESS FROM STEERING KNUCKLE Remove the 2 bolts, ABS speed sensor and wire harness. Torque: ABS speed sensor x Steering knuckle: 8 N·m (80 kgf·cm, 69 in.·lbf) ABS speed sensor wire x Steering knuckle: 5 N·m (55 kgf·cm, 48 in.·lbf) 5. LOOSEN 2 NUTS ON LOWER SIDE ON SHOCK AB- SORBER Torque: 158 N·m (1,610 kgf·cm, 117 ft·lbf) HINT: Do not remove the 2 nuts and bolts. 6. DISCONNECT TIE ROD END FROM STEERING KNUCKLE (a) Remove the cotter pin and nut. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) [...]... SSTR10771 1996 RAV4 (RM447U) SA0TC−02 6 INSTALL DUST DEFLECTOR Using SST and a hammer, install a new dust deflector SST 09316−20011, 09608−32010, 09950−70010 (09951−07150) HINT: Align the holes for the ABS speed sensor in the dust deflector and steering knuckle SA−15 SUSPENSION AND AXLE 7 (a) (b) 1996 RAV4 (RM447U) − FRONT AXLE HUB INSTALL LOWER BALL JOINT Install the lower ball joint and torque the... 127 N·m (1,300 kgf·cm, 94 ft·lbf) Install a new cotter pin SA−16 SUSPENSION AND AXLE INSTALLATION − FRONT AXLE HUB SA0TD−04 Installation is in the reverse order of removal (See page SA−10) AFTER INSTALLATION, CHECK ABS SPEED SENSOR SIGNAL (See page DI−257) AND FRONT WHEEL ALIGNMENT (See page SA−4) 1996 RAV4 (RM447U) SA−17 SUSPENSION AND AXLE − FRONT WHEEL HUB BOLT FRONT WHEEL HUB BOLT REPLACEMENT 1 2... Lower Suspension Arm Stabilizer Bar Link Cage Ball z No.2 Dust Deflector 127 (1,300, 94) Outboard Joint Shaft LH z Dust Cover Inner Race Center Drive Shaft z Snap Ring Center Bearing Inboard Joint Tulip N·m (kgf·cm, ft·lbf) : Specified torque z Non−reusable part 1996 RAV4 (RM447U) z Snap Ring z Dust Cover W04172 SA−19 SUSPENSION AND AXLE 1996 RAV4 (RM447U) − FRONT DRIVE SHAFT SA−20 SUSPENSION AND AXLE. .. 1996 RAV4 (RM447U) SA0TM−01 (e) Using SST to hold the spring upper seat, remove the nut SST 09729−22031 Remove these parts from the shock absorber: S Suspension support S Dust seal S Spring upper seat S Upper insulator and coil spring S Spring bumper and lower insulator SA−35 SUSPENSION AND AXLE − FRONT SHOCK ABSORBER INSPECTION N00203 1996 RAV4 (RM447U) SA0TN−01 INSPECT SHOCK ABSORBER Compress and. .. 1996 RAV4 (RM447U) Disassemble the inboard joint (1) Place matchmarks on the drive shaft, inner race and cage (2) Remove the 6 balls and cage (3) Using a snap ring expander, remove the snap ring (4) Using a brass bar and hammer, remove the inner race NOTICE: Be careful not to damage the inner race (5) Using a snap ring expander, remove the snap ring (e) Remove inboard and outboard joint boots and inboard... in.) W01212 W01765 1996 RAV4 (RM447U) SA−27 SUSPENSION AND AXLE (e) Vinyl Tape W01994 1996 RAV4 (RM447U) − FRONT DRIVE SHAFT Temporarily the install new outboard and inboard joint boots and new boot clamps HINT: Before installing the 2 boots, wrap vinyl tape around the spline of the drive shaft to prevent damaging the boots (1) Place 2 new clamps on a new outboard joint boot and install the boot to... ABSORBER WITH COIL SPRING Remove the 3 nuts, suspension support No.2 and shock absorber with the coil spring Torque: 80 N·m (820 kgf·cm, 59 ft·lbf) R10823 1996 RAV4 (RM447U) SA−34 SUSPENSION AND AXLE − FRONT SHOCK ABSORBER DISASSEMBLY Vinyl Tape SST R10824 REMOVE COIL SPRING (a) Install 2 nuts and a bolt to the bracket at the lower portion of the shock absorber and secure it in a vise (b) Using SST, compress... careful not to damage the oil seal, boot and ABS speed sensor rotor SA−12 SUSPENSION AND AXLE − FRONT AXLE HUB DISASSEMBLY SA0TB−01 1 REMOVE DUST DEFLECTOR Using a screwdriver, remove the dust deflector 2 REMOVE LOWER BALL JOINT (a) Remove the cotter pin and nut (b) Using SST, remove the lower ball joint SST 09628−62011 3 (a) REMOVE AXLE HUB Using SST, remove the axle hub SST 09520−00031 SST R10677 SST... W01207 2WD LH and 4WD RH W01208 (a) (b) (c) (d) 1996 RAV4 (RM447U) FRONT DRIVE SHAFT 9 DISCONNECT DRIVE SHAFT FROM AXLE HUB Using a plastic hammer, disconnect the drive shaft from the axle hub NOTICE: Be careful not to damage the inner oil seal and ABS speed sensor rotor 10 2WD (M/T) RH: REMOVE DRIVE SHAFT NOTICE: Be careful not to damage the dust cover and oil seal (a) Using a screwdriver and hammer,...SA−11 SUSPENSION AND AXLE (b) SST R10678 1996 RAV4 (RM447U) − FRONT AXLE HUB Using SST, disconnect the tie rod end from the steering knuckle SST 09610−20012 7 DISCONNECT LOWER BALL JOINT FROM LOWER ARM Remove the bolt and 2 nuts Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf) 8 REMOVE STEERING KNUCKLE WITH AXLE HUB HINT: At the time of installation, please refer . (80, 69 in.·lbf) SUSPENSION AND AXLE FRONT AXLE HUB SA−9 1996 RAV4 (RM447U) FRONT AXLE HUB COMPONENTS SA0TA−03 R10657 R10655 SA−10 SUSPENSION AND AXLE FRONT AXLE HUB 1996 RAV4 (RM447U) REMOVAL 1 part LH SA−18 SUSPENSION AND AXLE FRONT DRIVE SHAFT 1996 RAV4 (RM447U) FRONT DRIVE SHAFT COMPONENTS SUSPENSION AND AXLE FRONT DRIVE SHAFT SA−19 1996 RAV4 (RM447U) SA1YB−02 FA1535 SST R10849 SA−20 SUSPENSION. sensor in the dust deflector and steering knuckle. SUSPENSION AND AXLE FRONT AXLE HUB SA−15 1996 RAV4 (RM447U) 7. INSTALL LOWER BALL JOINT (a) Install the lower ball joint and torque the nut. Torque: