Toyota RAV4 Service Manual: Differential case
Components

Disassembly
- Remove front differential ring gear

- Place the matchmarks on the ring gear and
differential case.

- Remove the 14 bolts.

- Using a plastic-faced hammer, tap on the ring gear
to remove it from the case.
- Remove front differential case front tapered
roller bearing

- Using sst, tap out the front differential case front
tapered roller bearing from the differential case.
Sst 09950-00020, 09950-00030, 09950-60010
(09951-00500)

- Using sst, remove the front differential case front
tapered roller bearing outer race.
Sst 09308-00010
- Remove front differential case rear tapered
roller bearing

- Using sst, remove the front differential case rear
tapered roller bearing from the differential case.
Sst 09950-00020, 09950-00030, 09950-60010
(09951-00500)
- Using sst, tap out the front differential case front
tapered roller bearing outer race.

Sst 09308-00010
- Remove front differential pinion shaft
straight pin

- Using a pin punch and hammer, tap in the straight
pin.
Notice:
Before removing the straight pin, unstake it with
a pin punch.
- Remove no. 1 Front differential pinion shaft

- Remove the front differential pinion shaft from the
differential case.
- Remove front differential side gear

- Remove the 2 front differential pinions, 2 pinion
thrust washers, 2 front differential side gears and 2
side gear thrust washers from the differential case.
- Remove transaxle housing oil seal

- Using sst and hammer, tap out the oil seal.
Sst 09950-70010 (09951-07100), 09215-00013
(09215-00471)
- Remove differential side bearing retainer oil seal

- Using sst and hammer, tap out the oil seal.
Sst 09950-70010 (09951-07100), 09608-10010
Inspection
- Inspect differential side gear backlash

- Using a dial indicator, measure the backlash of the
side gear.
Standard backlash:
0.05 To 0.20 Mm (0.0020 To 0.0070 In.)
Standard thrust washer thickness

Reassembly
- Install front differential side gear

- Coat the 2 front differential side gears, 2 side gear
thrust washers, 2 font differential pinions and 2
pinion thrust washers with atf and install them to
the differential case.
- Install no. 1 Front differential pinion shaft

- Coat the no. 1 Front differential pinion shaft with
atf, and install it to the differential case.
- Install transaxle case straight pin

- Using a pin punch and a hammer, tap in the pinion
shaft straight pin.

- Using a chisel and a hammer, stake the differential
case.
Notice:
Stake it after adjusting the backlash.
- Install front differential case rear tapered
roller bearing

- Using sst and a press, press in the front differential
case rear tapered roller bearing to the differential
case.
Sst 09550-60010, 09950-60020 (09951-00680),
09950-70010 (09951-07100)

- Using sst and a hammer, tap in the front
differential case tapered roller bearing front outer
race to the transaxle housing.
Sst 09550-60010, 09950-60020 (09951-00680),
09950-70010 (09951-07100, 09951-00890)
- Install front differential case front tapered
roller bearing

- Using sst and a press, press in the front differential
case rear tapered roller bearing to the differential
case.
Sst 09550-60010, 09950-60020 (09951-00680),
09950-70010 (09951-07100, 09951-00890)

- Using sst and a hammer, tap in the front
differential case tapered roller bearing front outer
race to the transaxle housing.
Sst 09550-60010, 09950-60020 (09951-00680),
09950-70010 (09951-07100, 09951-00890)
Notice:
Clearance is not allowed between the bearing
and transaxle housing.
- Adjust differential side bearing preload

- Install the differential assembly to the transaxle
case.

- Clean the matching surfaces of the transaxle case
and transaxle housing.
- Install the transaxle housing to the transaxle case
and tighten them with the 16 bolts
Torque: 22 n*m (224 kgf*cm, 16 ft.*Lbf) for bolt a
29 n*m (296 kgf*cm, 21 ft.*Lbf) for bolts
b and c
Hint:
Each bolt length is indicated below.
Bolt length:
50 Mm (1.969 In.) For bolt a
50 M (1.969 In.) For bolt b
42 Mm (1.654 In.) For bolt c
Notice:
Usually, bolt a is non-reusable bolt. In this case,
however, it can be used after cleaning it.

- Using sst, return the differential assembly right and
left 2 or 3 times to allow the bearing settle.
Sst 09564-32011
- Using sst and torque wrench, measure the turning
torque of the differential.
Sst 09564-32011
Torque: standard turning torque at 60 rpm
0.20 To 0.69 N*m (2.0 To 7.0 Kgf*cm, 1.8
To 6.1 In.*Lbf)
Hint:
If the turning torque is not within the specified value,
refer to the table below and select a thrust washer
which turning torque is within the specified value.
Standard flange thickness

- Remove the 16 bolts and the transaxle housing.

- Remove the differential assembly.
- Install front differential ring gear

- Using atf and a heater, heat the front differential
ring gear to 90 to 110 °c (194.0 To 230.0 °F)
Notice:
Do not overheat the ring gear to 110°c (230.0°F)
or more.
- Clean the contract surface of the front differential
case.

- Align the matchmarks, and install the front
differential ring gear case quickly.
Notice:
Do not install the bolts while the ring gear is hot.

- Tighten the 14 bolts.
Torque: 95 n*m (969 kgf*cm, 70 ft.*Lbf)
Notice:
Tighten the bolts a little at a time in diagonal
order.
- Install differential side bearing retainer oil
seal

- Coat the lip of a new oil seal with a little amount of
mp grease.
- Using sst and a hammer, tap in the oil seal.
Sst 09223-15020, 09950-70010 (09951-07100)
- Remove transaxle housing oil seal

- Coat the lip of a new oil seal with a little amount of
mp grease.
- Using sst and a hammer, tap in the oil seal.
Sst 09710-30050, 09950-70010 (09951-07100)
Components
Disassembly
Remove shift solenoid valve slt
Remove the bolt, plate and shift solenoid valve slt
from the valve body.
Remove shift solenoid valve sl1
Rem ...
Other materials:
Dtc check / clear
Check dtc
When using intelligent tester:
Connect the intelligent tester (with can vim) to
the dlc3.
Turn the ignition switch on and press the
intelligent tester main switch on.
Read the dtcs by following the prompts on the
intelligent tester.
Hint:
Refer to the intel ...
Compressor solenoid circuit (2005/11-2006/01)
Description
In this circuit, the compressor receives a refrigerant compression demand
signal from the air conditioning
amplifier. Based on this signal, the compressor changes the degree of
refrigerant compression.
Wiring diagram
Inspection procedure
Read value of intelligent ...
Installation (2006/01- )
Install abs and traction actuator assembly with bracket
Notice:
do not remove the hole plug before connecting the
brake tube. new actuators are filled with brake fluid.
Install the actuator with bracket with the 3 nuts.
Torque: 19 n*m (194 kgf*cm, 14 ft.*Lbf)
Hint:
The nuts should b ...