Toyota RAV4 Service Manual: Disassembly

1. Fix differential carrier sub-assembly

1. Fix the rear differential carrier in place with the overhaul attachment.

2. Remove stud bolt

1. Remove the 4 stud bolts from the transmission coupling.

3. Remove differential drain plug

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

4. Remove differential filler plug

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

5. Remove differential carrier cover plug

1. Using an 8 mm socket hexagon wrench, remove rear differential carrier cover plug.

6. Remove differential carrier cover breather plug

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

2. Using a screwdriver, lightly pry up and remove the rear differential carrier cover breather plug.

7. Inspect runout of transmission coupling assembly

1. Install a dial gauge so that it is perpendicular to the inner side of the transmission coupling.
2. 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.)

3. Install a dial gauge perpendicularly onto the transmission coupling assembly, as shown in the illustration.
4. 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)

8. Remove electromagnetic coupling

1. 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.

9. Remove 4wd linear solenoid

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

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

10. Remove yoke

1. Using a 5 mm socket hexagon wrench, remove the 3 bolts and yoke from the differential carrier.

11. Remove transmission coupling conical spring washer

1. Remove the spring washer from the differential carrier.

12. Remove transmission coupling shim

1. Remove the shim from the differential carrier.

13. Inspect differential ring gear backlash

1. Insert a dial gauge through the rear differential carrier cover plug hole, and set it perpendicular to the ring gear tooth surface's tip.
2. Using sst, fix the drive pinion in place.

Sst 09556-16011

3. 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.

14. Inspect differential drive pinion preload

1. 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.

15. Inspect total preload

1. 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.

16. Remove differential side gear shaft oil seal

1. Using sst, tap out the 2 rear differential side shaft gear oil seals from the rear differential carrier.

Sst 09308-00010

17. Remove diaphragm oil seal

1. Using sst, remove the diaphragm oil seal from the rear differential carrier.

Sst 09308-10010

18. Remove drive pinion nut

1. 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

2. 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

19. Remove rear drive pinion front tapered roller bearing

1. Using sst, remove the rear drive pinion tapered roller bearing front (inner race) from the rear differential carrier.

Sst 09556-30010

20. Remove differential side bearing retainer

1. Remove the 8 bolts.

2. 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.

21. Remove differential case sub-assembly

1. Remove the rear differential case from the rear differential carrier.

22. Remove differential drive pinion

1. Remove the differential drive pinion from the rear differential carrier.

23. Remove differential drive pinion bearing spacer

1. Remove the rear differential drive pinion bearing spacer from the differential drive pinion.

24. Remove rear drive pinion rear tapered roller bearing

1. 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

2. Remove the rear differential drive pinion washer.

25. Remove rear drive pinion front tapered roller bearing

1. 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)

26. Remove rear drive pinion rear tapered roller bearing

1. 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.

27. Remove differential case bearing

Sst 09950-60010 (09951-00460), 09950-70010 (09951-07100), 09649-17010 (09951-00510)

1. 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)

2. 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

28. Remove differential case bearing

1. 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.

2. 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.

29. Remove differential ring gear

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

30. Remove differential breather plug oil deflector

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

31. Remove straight pin

1. Using pliers, remove the 4 straight pins from the rear differential carrier.

32. Remove elbow tube

33. Remove wiring harness clamp bracket

1. Remove the bolt and bracket.