TOYOTA RAV4 2006 Service Repair Manual

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)DS–67
DS
3. CONNECT STEERING KNUCKLE WITH AXLE HUB
LH
(a) Align the shaft splines in the drive shaft to the
steering knuckle with axle hub, and connect the
steering knuckle with axle hub.
4. CONNECT STEERING KNUCKLE WITH AXLE HUB
RH
HINT:
Use the same procedures described for the LH side.
5. CONNECT FRONT SUSPENSION LOWER NO. 1 ARM
SUB-ASSEMBLY LH (See page SP-24)
6. CONNECT FRONT SUSPENSION LOWER NO. 1 ARM
SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
7. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
(See page SP-31)
8. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
9. INSTALL TIE ROD END SUB-ASSEMBLY LH (See
page PS-45)
10. INSTALL TIE ROD END SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
11. CONNECT FRONT SPEED SENSOR LH
(a) Connect the speed sensor (see page BC-193).
12. CONNECT FRONT SPEED SENSOR RH
HINT:
Use the same procedures described for the LH side.
13. INSTALL FRONT AXLE HUB NUT (See page AH-11)
14. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
15. ADD AUTOMATIC TRANSAXLE FLUID
(a) Add automatic transaxle fluid for U140F (see page
AX-152).
(b) Add automatic transaxle fluid for U241E (see page
AX-151).
(c) Add automatic transaxle fluid for U151F (see page
AX-178).
16. CHECK FOR AUTOMATIC TRANSAXLE FLUID
LEAKAGE
17. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (see
page SP-3).
C129488E04

DF–18DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY
DF
REMOVAL
1. DRAIN DIFFERENTIAL OIL
2. REMOVE REAR WHEEL
3. REMOVE TAILPIPE ASSEMBLY
(a) Remove the tailpipe (see page EX-2).
4. REMOVE CENTER EXHAUST PIPE ASSEMBLY
(a) Remove the center pipe (see page EX-2).
5. REMOVE PROPELLER WITH CENTER BEARING
SHAFT ASSEMBLY (See page PR-3)
6. REMOVE REAR SUSPENSION MEMBER BRACE LH
(a) Remove the 2 bolts and brace from the suspension
member.
7. REMOVE REAR SUSPENSION MEMBER BRACE RH
HINT:
Use the same procedures described for the LH side.
8. REMOVE REAR DIFFERENTIAL CARRIER SUB-
ASSEMBLY
(a) Disconnect the harness clamp.
(b) Remove the breather tube.
(c) Disconnect the connector.
C127572
C127575

DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLYDF–19
DF
(d) Support the rear differential carrier with a
transmission jack or equivalent.
(e) Fix the nuts in place and remove bolt A, bolt B and
bolt C.
NOTICE:
Do not loosen the nuts. Loosen the bolts.
(f) Slowly lower the jack and then tilt the rear
differential carrier.
(g) Set the tip of the tire lever to the position on the rear
drive shaft inboard joint shown in the illustration.
Then, using the ribbed part of the rear differential
carrier as a fulcrum, disconnect the left and right
rear drive shafts.
NOTICE:
Do not scratch the rear drive shaft dust cover.
C129479E01
C129480
C129481

DF–20DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY
DF
9. REMOVE REAR DIFFERENTIAL NO. 1 AND NO. 2
SUPPORT
(a) Remove the 4 bolts and differential No. 1 and No. 2
supports from the differential carrier.
10. REMOVE REAR DIFFERENTIAL SUPPORT
(a) Remove the 4 bolts and differential support from the
differential carrier.
C127578
C127579

DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLYDF–21
DF
DISASSEMBLY
1. FIX DIFFERENTIAL CARRIER SUB-ASSEMBLY
(a) Fix the rear differential carrier in place with the
overhaul attachment.
2. REMOVE STUD BOLT
(a) Remove the 4 stud bolts from the transmission
coupling.
3. REMOVE DIFFERENTIAL DRAIN PLUG
(a) Using a 10 mm socket hexagon wrench, remove the
rear differential drain plug and gasket.
4. REMOVE DIFFERENTIAL FILLER PLUG
(a) Using a 10 mm socket hexagon wrench, remove the
rear differential filler plug and gasket.
5. REMOVE DIFFERENTIAL CARRIER COVER PLUG
(a) Using an 8 mm socket hexagon wrench, remove
rear differential carrier cover plug.
6. REMOVE DIFFERENTIAL CARRIER COVER
BREATHER PLUG
(a) Using a chisel and hammer, slightly lift up the rear
differential carrier cover breather plug.
(b) Using a screwdriver, lightly pry up and remove the
rear differential carrier cover breather plug.
C110127
C110128
C110129
C110130

DF–22DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY
DF
7. INSPECT RUNOUT OF TRANSMISSION COUPLING
ASSEMBLY
(a) Install a dial gauge so that it is perpendicular to the
inner side of the transmission coupling.
(b) 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.)
(c) Install a dial gauge perpendicularly onto the
transmission coupling assembly, as shown in the
illustration.
(d) 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
(a) 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
(a) Using a snap ring expander, remove the snap ring.
(b) Remove the solenoid from the yoke.
(c) Remove the O-ring from the solenoid.
C110131E01
C110132
C129932
C129931

DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLYDF–23
DF
10. REMOVE YOKE
(a) Using a 5 mm socket hexagon wrench, remove the
3 bolts and yoke from the differential carrier.
11. REMOVE TRANSMISSION COUPLING CONICAL
SPRING WASHER
(a) Remove the spring washer from the differential
carrier.
12. REMOVE TRANSMISSION COUPLING SHIM
(a) Remove the shim from the differential carrier.
13. INSPECT DIFFERENTIAL RING GEAR BACKLASH
(a) Insert a dial gauge through the rear differential
carrier cover plug hole, and set it perpendicular to
the ring gear tooth surface's tip.
(b) Using SST, fix the drive pinion in place.
SST 09556-16011
(c) 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.
C129930
C109021E01
C109022E01
C110134E01

DF–24DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY
DF
14. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD
(a) 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
(a) 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
(a) 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
(a) Using SST, remove the diaphragm oil seal from the
rear differential carrier.
SST 09308-10010
C110135E01
C110135E01
C110136E01
C110140E01

DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLYDF–25
DF
18. REMOVE DRIVE PINION NUT
(a) 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
(b) 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
(a) 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
(a) Remove the 8 bolts.
(b) 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.
C110138E01
C110139E01
C110141E01
C110142
C110143

DF–26DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY
DF
21. REMOVE DIFFERENTIAL CASE SUB-ASSEMBLY
(a) Remove the rear differential case from the rear
differential carrier.
22. REMOVE DIFFERENTIAL DRIVE PINION
(a) Remove the differential drive pinion from the rear
differential carrier.
23. REMOVE DIFFERENTIAL DRIVE PINION BEARING
SPACER
(a) Remove the rear differential drive pinion bearing
spacer from the differential drive pinion.
24. REMOVE REAR DRIVE PINION REAR TAPERED
ROLLER BEARING
(a) 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.
(b) Remove the rear differential drive pinion washer.
25. REMOVE REAR DRIVE PINION FRONT TAPERED
ROLLER BEARING
(a) 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)
C110144
C110145
C110146
C110147E01
C110148E01