Toyota RAV4 Service Manual: Disassembly
- Fix differential carrier sub-assembly
- Fix the rear differential carrier in place with the
overhaul attachment.
- Remove stud bolt
- Remove the 4 stud bolts from the transmission
coupling.
- Remove differential drain plug

- Using a 10 mm socket hexagon wrench, remove the
rear differential drain plug and gasket.
- Remove differential filler plug

- Using a 10 mm socket hexagon wrench, remove the
rear differential filler plug and gasket.
- Remove differential carrier cover plug
- Using an 8 mm socket hexagon wrench, remove
rear differential carrier cover plug.
- Remove differential carrier cover breather plug

- Using a chisel and hammer, slightly lift up the rear
differential carrier cover breather plug.

- Using a screwdriver, lightly pry up and remove the
rear differential carrier cover breather plug.
- Inspect runout of transmission coupling assembly

- Install a dial gauge so that it is perpendicular to the
inner side of the transmission coupling.
- Using sst, rotate the transmission coupling
assembly forward and backward and measure the
vertical runout.
Sst 09564-32011
Maximum vertical runout :
0.06 Mm (0.0024 In.)
- Install a dial gauge perpendicularly onto the
transmission coupling assembly, as shown in the
illustration.
- Using sst, rotate the transmission coupling
assembly forward and backward and measure the
lateral runout.
Sst 09564-32011
Maximum lateral runout:
0.07 Mm (0.0028)
- Remove electromagnetic coupling

- Remove the 4 bolts and, using a plastic-faced
hammer, lightly tap the rear differential carrier cover
to remove it from the rear differential carrier.
Notice:
Set the brass bar on the ribbed part of the rear
differential carrier cover.
- Remove 4wd linear solenoid

- Using a snap ring expander, remove the snap ring.

- Remove the solenoid from the yoke.
- Remove the o-ring from the solenoid.
- Remove yoke

- Using a 5 mm socket hexagon wrench, remove the
3 bolts and yoke from the differential carrier.
- Remove transmission coupling conical spring washer

- Remove the spring washer from the differential
carrier.
- Remove transmission coupling shim

- Remove the shim from the differential carrier.
- Inspect differential ring gear backlash

- Insert a dial gauge through the rear differential
carrier cover plug hole, and set it perpendicular to
the ring gear tooth surface's tip.
- Using sst, fix the drive pinion in place.
Sst 09556-16011
- Using sst, rotate the rear differential case forward
and backward, and measure the backlash.
Sst 09564-32011
Standard backlash:
0.09 To 0.16 Mm (0.0034 To 0.0063 In.)
Notice:
Measure at 3 or more areas around the
circumference of the ring gear.
- Inspect differential drive pinion preload

- Using sst and a torque wrench, inspect the preload
(starting torque) within the differential drive pinion
and differential ring gear backlash area.
Sst 09556-16011
Standard drive pinion preload:
0.24 To 0.37 N*m (2 to 4 kgf*cm, 2 to 3 in.*Lbf)
Notice:
For a more accurate measurement, rotate the
case bearing forward and backward before
measuring.
- Inspect total preload

- Using sst and a torque wrench, inspect the preload
(starting torque) with the teeth of the differential
drive pinion and differential ring gear in contact.
Sst 09556-16011
Standard total preload:
standard drive pinion preload plus 0.99 To 1.63
N*m (10 to 17 kgf*cm, 9 to 14 in.*Lbf)
Notice:
For a more accurate measurement, rotate the
case bearing forward and backward before
measuring.
- Remove differential side gear shaft oil seal

- Using sst, tap out the 2 rear differential side shaft
gear oil seals from the rear differential carrier.
Sst 09308-00010
- Remove diaphragm oil seal

- Using sst, remove the diaphragm oil seal from the
rear differential carrier.
Sst 09308-10010
- Remove drive pinion nut

- Using sst and a hammer, unstake the rear drive
pinion nut.
Sst 09930-00010
Notice:
- Use sst with the tapered part against the
shaft side.
- Do not modify the sst tip with a grinder or
equivalent.
- Fully unstake the rear drive pinion nut

- Using sst, fix the differential drive pinion in place
and remove the rear drive pinion nut from the
differential drive pinion.
Sst 09556-16011, 09564-16020
- Remove rear drive pinion front tapered roller bearing

- Using sst, remove the rear drive pinion tapered
roller bearing front (inner race) from the rear
differential carrier.
Sst 09556-30010
- Remove differential side bearing retainer

- Remove the 8 bolts.

- Using a brass bar and hammer, lightly tap out the
differential side bearing retainer.
Notice:
Set the brass bar on the ribbed part of the
differential side bearing retainer.
- Remove differential case sub-assembly

- Remove the rear differential case from the rear
differential carrier.
- Remove differential drive pinion

- Remove the differential drive pinion from the rear differential carrier.
- Remove differential drive pinion bearing spacer

- Remove the rear differential drive pinion bearing
spacer from the differential drive pinion.
- Remove rear drive pinion rear tapered roller bearing

- Using sst and a press, press out the rear drive
pinion tapered roller bearing rear (inner race) from
the differential drive pinion.
Sst 09950-00020
Notice:
If the rear differential drive pinion or differential
ring gear is damaged, replace them both
- Remove the rear differential drive pinion washer.
- Remove rear drive pinion front tapered roller bearing

- Using sst, remove the rear drive pinion tapered
roller bearing front (outer race) from the rear
differential carrier.
Sst 09612-65014 (09612-01020, 09612-01050)
- Remove rear drive pinion rear tapered roller bearing

- Using a brass bar and hammer, lightly and uniformly
tap out the rear drive pinion tapered roller bearing
rear (outer race).
Notice:
Set the brass bar on the notch.
- Remove differential case bearing

Sst 09950-60010 (09951-00460), 09950-70010
(09951-07100), 09649-17010 (09951-00510)
- Using sst and a press, press out the rear
differential case bearing rh (outer race) and rear
differential side gear shaft plate washer from the
rear differential carrier.
Sst 09950-60010, 09950-70010 (09951-07100)

- Using sst and a press, press out the rear
differential case bearing lh (outer race) and rear
differential side gear shaft plate washer from the
differential side bearing retainer.
Sst 09950-60010 (09951-00460), 09950-70010
(09951-07100), 09649-17010
- Remove differential case bearing
- Using sst, remove the rear differential case bearing
rh (inner race) from the rear differential case.

Sst 09950-40011 (09951-04010, 09952-04010,
09953-04020, 09954-04010, 09955-04061,
09957-04010, 09958-04011), 09950-60010
(09951-00320, 09955-04071)
Notice:
Before using sst center bolt (09953-04020),
apply hypoid gear oil to its threads and tip.

- Using sst, remove the rear differential case bearing
lh (inner race) from the rear differential case.
Sst 09950-40011 (09951-04010, 09952-04010,
09953-04020, 09954-04010, 09955-04071,
09957-04010, 09958-04011), 09950-60010
(09951-00320)
Notice:
Before using sst center bolt (09953-04020),
apply hypoid gear oil to its threads and tip.
Hint:
If the race is remains on the rear differential case,
repeat the step above to remove the race.
- Remove differential ring gear

- Place matchmarks on the rear differential case and
differential ring gear.
- Remove the 10 bolts.
- Using a plastic-faced hammer, lightly tap the outer
circumference of the differential ring gear to remove
it from the rear differential case.
- Remove differential breather plug oil deflector

- Using a 5 mm socket hexagon wrench, remove the
2 bolts and rear differential breather plug oil
deflector.
- Remove straight pin

- Using pliers, remove the 4 straight pins from the
rear differential carrier.
- Remove elbow tube
- Remove wiring harness clamp bracket
- Remove the bolt and bracket.
Drain differential oil
Remove rear wheel
Remove tailpipe assembly
Remove the tailpipe (see page ex-2).
Remove center exhaust pipe assembly
Remove the center pipe (see page ex- ...
Install wiring harness clamp bracket
Install the bracket with the bolt.
Install elbow tube
Install straight pin
Using a plastic hammer, install the 4 straight pins to
the ...
Other materials:
Exhaust pipe
Components
Removal
Disconnect cable from negative battery terminal
Caution:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
Remove heated oxygen sensor (for bank 1
sensor 2) (s ...
Run-flat tires
Concept
Run-flat tires permit continued driving under restricted
conditions even in the event of a complete
loss of tire inflation pressure.
General information
The wheels consist of tires that are self-supporting,
to a limited degree, and possibly special
rims.
The support of the sidewall allows t ...
Inspection
Inspect camshaft position sensor
Measure the resistance of the sensor.
Standard resistance
Notice:
Cold and hot mean the temperature of the coils
themselves. Cold is from -10 to 50°c (14 to 122
°f) and hot is from 50 to 100°c (122 to 212°f).
If the result is not as specif ...