TOYOTA RAV4 2006 Service Repair Manual

DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLYDF–27
DF
26. REMOVE REAR DRIVE PINION REAR TAPERED
ROLLER BEARING
(a) 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)
(a) 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)
(b) 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
(a) 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.
(b) 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.
C110149
C110150E01
C110151E01
C110153E01
C110154E01

DF–28DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY
DF
HINT:
If the race is remains on the rear differential case,
repeat the step above to remove the race.
29. REMOVE DIFFERENTIAL RING GEAR
(a) Place matchmarks on the rear differential case and
differential ring gear.
(b) Remove the 10 bolts.
(c) 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
(a) Using a 5 mm socket hexagon wrench, remove the
2 bolts and rear differential breather plug oil
deflector.
31. REMOVE STRAIGHT PIN
(a) Using pliers, remove the 4 straight pins from the
rear differential carrier.
32. REMOVE ELBOW TUBE
33. REMOVE WIRING HARNESS CLAMP BRACKET
(a) Remove the bolt and bracket.
C110155E01
C110156
C110152

DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLYDF–29
DF
REASSEMBLY
1. INSTALL WIRING HARNESS CLAMP BRACKET
(a) Install the bracket with the bolt.
2. INSTALL ELBOW TUBE
3. INSTALL STRAIGHT PIN
(a) Using a plastic hammer, install the 4 straight pins to
the rear differential carrier.
(b) Thoroughly clean oil and water from the surface of
the rear differential case that will face the differential
ring gear.
4. INSTALL DIFFERENTIAL BREATHER PLUG OIL
DEFLECTOR
(a) Using a 5 mm socket hexagon wrench, install the
rear differential breather plug oil deflector with the 2
bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
NOTICE:
Install it so that the arrow mark faces the front
(transmission coupling side) of the vehicle.
5. INSTALL DIFFERENTIAL RING GEAR
(a) Align the matchmarks on the rear differential case
and differential ring gear, and install the differential
ring gear.
(b) Install 10 new differential case bolts.
Torque: 90 N*m (918 kgf*cm, 66 ft.*lbf)
NOTICE:
• The new bolts are coated with heat resistant
oil. Do not wash it off.
• Install the rear differential case bolts by
tightening diametrically opposite bolts
uniformly in several passes.
C110158E02
C110156E01
C110155E01

DF–30DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY
DF
6. INSTALL DIFFERENTIAL CASE BEARING
(a) Using SST and a press, press-fit the rear differential
case bearing RH (inner race) to the rear differential
case.
SST 09223-50010
NOTICE:
If the rear differential case bearing inner race is
damaged, replace it with a new one.
(b) Using SST and a press, press-fit the rear differential
case bearing LH (inner race) to the rear differential
case.
SST 09223-50010
NOTICE:
If the rear differential case bearing inner race is
damaged, replace it with a new one.
7. INSTALL DIFFERENTIAL CASE BEARING
(a) Using SST and a press, press-fit the rear differential
side gear shaft washer and rear differential case
bearing LH (outer race) to the differential side
bearing retainer.
SST 09950-60010 (09951-00510, 09951-00620,
09952-06010), 09950-70010 (09951-07150)
NOTICE:
• Install each rear differential side gear shaft
washer to the place it was removed from.
• When replacing a bearing, replace the inner
and outer races as a set.
• Install the rear differential side gear shaft oil
seal after performing the teeth contact
inspection and backlash adjustment.
(b) Using SST and a press, press-fit the rear differential
side gear shaft washer and rear differential case
bearing RH (outer race) to the rear differential
carrier.
SST 09950-60010 (09951-00510, 09951-00620,
09952-06010), 09950-70010 (09951-07150)
NOTICE:
• Install each rear differential side gear shaft
washer to the place it was removed from.
• When replacing a bearing, replace the inner
and outer races as a set.
• Install the rear differential side gear shaft oil
seal after performing the teeth contact
inspection and backlash adjustment.
C110159E01
C110160E01
C110161E01
C110162E01

DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLYDF–31
DF
8. INSTALL REAR DRIVE PINION FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, press-fit the rear drive
pinion tapered roller bearing front (outer race) to the
rear differential carrier.
SST 09950-60010 (09951-00550), 09950-60020
(09951-00680), 09950-70010 (09951-07100)
9. INSTALL REAR DRIVE PINION REAR TAPERED
ROLLER BEARING
(a) Using SST, bolts, nuts and washers, install the rear
drive pinion tapered roller bearing rear (outer race)
to the rear differential carrier.
SST 09950-60010 (09951-00600), 09950-60020
(09951-00680, 09951-00750)
HINT:
Use M12 x P1.25 bolts with shaft lengths of 186 mm
(part No. 90101-12159) and M12 x P1.25 nuts (part
No. 90179-12051) for the installation.
10. INSTALL REAR DRIVE PINION REAR TAPERED
ROLLER BEARING
(a) Install the rear differential drive pinion washer to the
differential drive pinion.
NOTICE:
Install each rear differential drive pinion washer
to the place it was removed from.
(b) Using SST and a press, press-fit the tapered roller
rear (inner race) to the differential drive pinion.
SST 09506-30012
11. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD
(a) Install the differential drive pinion (with rear drive
pinion tapered roller bearing rear inner race) to the
rear differential carrier.
(b) Install the rear drive pinion tapered roller bearing
front inner race and a new rear drive pinion nut to
the differential drive pinion.
NOTICE:
• New bearings are coated with anti-rust oil. If
using new bearings, do not wash it off.
• If reusing a bearing, coat it with hypoid gear
oil SX.
C110307E01
C110308E01
C110309E01

DF–32DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY
DF
(c) Using SST, tighten a new rear drive pinion nut a little
at a time until the specified preload is reached. Do
not exceed the torque limit shown below.
SST 09556-16011, 09564-16020
Torque: 245 N*m (2,500 kgf*cm, 181 ft.*lbf) for
use without SST
223 N*m (2,273 kgf*cm, 164 in.*lbf) for
use with SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
(d) Using SST and a torque wrench, measure the
starting torque of the differential drive pinion.
SST 09556-16011
Standard drive pinion preload (start torque)
NOTICE:
• For a more accurate measurement, rotate the
bearing forward and backward before
inspecting.
• Record the preload measurement for use with
the total preload inspection.
12. INSTALL DIFFERENTIAL CASE
(a) Install the rear differential case to the rear
differential carrier.
13. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
(a) Using a scraper and wire brush, clean the seal
packing from the rear differential carrier and
differential side bearing retainer.
NOTICE:
Do not scratch the installation area.
(b) Install the differential side bearing retainer to the
rear differential carrier with the 8 bolts.
Torque: 34 N*m (350 kgf*cm, 25 ft.*lbf)
C110310E01
C110311E01
Bearing Preload
New bearing 1.31 to 2.18 N*m (13 to 22 kgf*cm, 12
to 19 in.*lbf)
Reused bearing 0.24 to 0.37 N*m (2 to 4 kgf*cm, 2 to 3
in.*lbf)
C110144
C110142

DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLYDF–33
DF
14. ADJUST 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 09564-16020
NOTICE:
Measure at 3 or more areas around the
circumference of the ring gear.
(d) If the result is not within the specified range, select
washers that are thicker or thinner as necessary,
where the thickness for the left and right side is the
same. Then perform the rear differential case
bearing outer race installation.
HINT:
• If the backlash is small, select a thick washer for
the RH side and a thin washer for the LH side.
• If the backlash is large, select a thin washer for
the RH side and a thick washer for the LH side.
Rear differential side gear shaft washer
C110134E02
Part No. Thickness mm (in.) Identifying Mark Part No. Thickness mm (in.) Identifying Mark
90564-37022 1.59 to 1.61 (0.0625
to 0.0633)A0 90564-37040 2.13 to 2.15 (0.0839
to 0.0846)B8
90564-37023 1.62 to 1.64 (0.0637
to 0.0649)A1 90564-37041 2.16 to 2.18 (0.0850
to 0.0858)B9
90564-37024 1.65 to 1.67 (0.0650
to 0.0657)A2 90564-37042 2.19 to 2.21 (0.0862
to 0.0870)C0
90564-37025 1.68 to 1.70 (0.0661
to 0.0669)A3 90564-37043 2.22 to 2.24 (0.0874
to 0.0882)C1
90564-37026 1.71 to 1.73 (0.0673
to 0.0681)A4 90564-37044 2.25 to 2.27 (0.0886
to 0.0894)C2
90564-37027 1.74 to 1.76 (0.0685
to 0.0693)A5 90564-37045 2.28 to 2.30 (0.0898
to 0.0906)C3
90564-37028 1.77 to 1.79 (0.0697
to 0.0705)A6 90564-37046 2.31 to 2.33 (0.0909
to 0.0917)C4
90564-37029 1.80 to 1.82 (0.0709
to 0.0717)A7 90564-37047 2.34 to 2.36 (0.0921
to 0.0929)C5
90564-37030 1.83 to 1.85 (0.0720
to 0.0728)A8 90564-37048 2.37 to 2.39 (0.0930
to 0.0941)C6
90564-37031 1.86 to 1.88 (0.0732
to 0.0740)A9 90564-37049 2.40 to 2.42 (0.0945
to 0.0953)C7
90564-37032 1.89 to 1.91 (0.0744
to 0.0752)B0 90564-37050 2.43 to 2.45 (0.0957
to 0.0965)C8
90564-37033 1.92 to 1.94 (0.0756
to 0.0764)B1 90564-37051 2.46 to 2.48 (0.0969
to 0.0976)C9
90564-37034 1.95 to 1.97 (0.0768
to 0.0776)B2 90564-37052 2.49 to 2.51 (0.0980
to 0.0988)D0
90564-37035 1.98 to 2.00 (0.0780
to 0.0787)B3 90564-37053 2.52 to 2.54 (0.0992
to 0.1000)D1
90564-37036 2.02 to 2.04 (0.0795
to 0.0803)B4 90564-37054 2.55 to 2.57 (0.1004
to 0.1012)D2
90564-37037 2.04 to 2.06 (0.0803
to 0.0811)B5 90564-37055 2.58 to 2.60 (0.1016
to 0.1024)D3

DF–34DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY
DF
15. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION
(a) Remove the 8 bolts and differential side bearing
retainer from the rear differential carrier.
(b) Remove the rear differential carrier case.
(c) Uniformly apply a light coat of prussian blue on both
sides of the differential ring gear teeth.
(d) Install the rear differential case.
(e) Temporarily install the differential side bearing
retainer to the differential carrier with the 8 bolts.
(f) Rotate the differential side pinion several times.
(g) Remove the 8 bolts and rear differential side
bearing retainer from the differential carrier.
(h) Check the tooth contact pattern of the differential
drive pinion and differential ring gear.
NOTICE:
Check the tooth contact pattern at 2 or more
positions around circumference of the
differential ring gear.
(i) Perform the following procedures for face or flank
contact.
(1) Select washers that are thicker or thinner as
necessary, where the thickness for the left and
right side is the same. Then install the rear
differential case bearing outer race.(
*1)
90564-37038 2.07 to 2.09 (0.0815
to 823)B6 90564-37056 2.61 to 2.63 (1.1028
to 0.1035)D4
90564-37039 2.10 to 2.12 (0.0827
to 0.0835)B7 90564-37057 2.64 to 2.66 (0.1039
to 0.1047)D5 Part No. Thickness mm (in.) Identifying Mark Part No. Thickness mm (in.) Identifying Mark
ZK03673E02

DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLYDF–35
DF
(2) Repeat the differential ring gear and differential
drive pinion tooth contact pattern inspection.
HINT:
If the tooth contact pattern is not correct,
repeat*1.
(3) Repeat the differential ring gear and differential
drive pinion backlash inspection.
HINT:
If the differential ring gear and differential drive
pinion backlash is not as specified, replace the
differential ring gear and differential drive pinion
with new ones.
(j) Perform the following procedures for heel or toe
contact.
(1) Select a drive pinion washer again and perform
the rear drive pinion tapered roller bearing rear
installation.
Rear differential drive pinion washer
Part No. Thickness (mm) Identifying Mark Part No. Thickness (mm) Identifying Mark
90564-35041 1.695 to 1.705
(0.0667 to 0.0671)41 90564-35071 1.955 to 1.965
(0.0770 to 0.0774)71
90564-35042 1.705 to 1.715
(0.0671 to 0.0675)42 90564-35072 1.965 to 1.975
(0.0774 to 0.0778)72
90564-35043 1.715 to 1.725
(0.0675 to 0.0679)43 90564-35073 1.975 to 1.985
(0.0778 to 0.0781)73
90564-35044 1.725 to 1.735
(0.0679 to 0.0683)44 90564-35074 1.985 to 1.995
(0.0781 to 0.0785)74
90564-35045 1.735 to 1.745
(0.0683 to 0.0687)45 90564-35075 1.995 to 2.005
(0.0785 to 0.0789)75
90564-35046 1.745 to 1.755
(0.0687 to 0.0690)46 90564-35076 2.005 to 2.015
(0.0789 to 0.0793)76
90564-35047 1.755 to 1.765
(0.0690 to 0.0695)47 90564-35077 2.015 to 2.025
(0.0793 to 0.0797)77
90564-35048 1.765 to 1.775
(0.0695 to 0.0699)48 90564-35078 2.025 to 2.035
(0.0797 to 0.0801)78
90564-35049 1.775 to 1.785
(0.0699 to 0.0703)49 90564-35079 2.035 to 2.045
(0.0801 to 0.0805)79
90564-35050 1.785 to 1.795
(0.0703 to 0.0707)50 90564-35080 2.045 to 2.055
(0.0805 to 0.0809)80
90564-35051 1.795 to 1.805
(0.0707 to 0.0711)51 90564-35081 2.055 to 2.065
(0.0809 to 0.0813)81
90564-35052 1.805 to 1.815
(0.0707 to 0.0715)52 90564-35082 2.065 to 2.075
(0.0813 to 0.0817)82
90564-35053 1.815 to 1.825
(0.0715 to 0.0719)53 90564-35083 2.075 to 2.085
(0.0817 to 0.0821)83
90564-35054 1.825 to 1.835
(0.0719 to 0.0720)54 90564-35084 2.085 to 2.095
(0.0821 to 0.0825)84
90564-35055 1.835 to 1.845
(0.0719 to 0.0726)55 90564-35085 2.095 to 2.105
(0.0825 to 0.0829)85
90564-35056 1.845 to 1.855
(0.0726 to 0.0730)56 90564-35086 2.105 to 2.115
(0.0829 to 0.0833)86
90564-35057 1.855 to 1.865
(0.0730 to 0.0734)57 90564-35087 2.115 to 2.125
(0.0833 to 0.0837)87
90564-35058 1.865 to 1.875
(0.0734 to 0.0738)58 90564-35088 2.125 to 2.135
(0.0837 to 0.0841)88
90564-35059 1.875 to 1.885
(0.0734 to 0.0742)59 90564-35089 2.135 to 2.145
(0.0841 to 0.0844)89

DF–36DIFFERENTIAL – REAR DIFFERENTIAL CARRIER ASSEMBLY
DF16. INSPECT TOTAL PRELOAD
(a) Using SST and a torque wrench, measure the
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
NOTICE:
For a more accurate measurement, rotate the
case bearing forward and backward before
measuring.
(b) If the results are not within the specification, perform
the procedures below.
(1) Select a side gear shaft washer for the RH side
again, and then perform the rear differential
case bearing outer race installation (RH side
only).
(2) Repeat the total preload inspection.
(3) Repeat the ring gear backlash inspection.
(4) Repeat the differential ring gear and drive
pinion tooth contact pattern inspection.
17. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
(a) Remove the 8 bolts and differential side bearing
retainer from the rear differential carrier.
18. REMOVE DIFFERENTIAL CASE
(a) Remove the rear differential case from the rear
differential carrier.
19. REMOVE DIFFERENTIAL DRIVE PINION
90564-35060 1.885 to 1.895
(0.0742 to 0.0746)60 90564-35090 2.145 to 2.155
(0.0844 to 0.0848)90
90564-35061 1.895 to 1.905
(0.0746 to 0.0750)61 90564-35091 2.155 to 2.165
(0.0848 to 0.0852)91
90564-35062 1.905 to 1.915
(0.0750 to 0.0754)62 90564-35092 2.165 to 2.175
(0.0852 to 0.0856)92
90564-35063 1.915 to 1.925
(0.0754 to 0.0758)63 90564-35093 2.175 to 2.185
(0.0856 to 0.0860)93
90564-35064 1.925 to 1.935
(0.0758 to 0.076264 90564-35094 2.185 to 2.195
(0.0860 to 0.0864)94
90564-35065 1.935 to 1.945
(0.0762 to 0.0766)65 90564-35095 2.195 to 2.205
(0.0864 to 0.0868)95
90564-35070 1.945 to 1.955
(0.0766 to 0.0770)70--- Part No. Thickness (mm) Identifying Mark Part No. Thickness (mm) Identifying Mark
C110135E01
Bearing Preload
New bearing 1.18 to 1.63 N*m (12 to 17 kgf*cm, 10
to 14 in.*lbf)
Reused bearing 0.99 to 1.63 N*m (10 to 17 kgf*cm, 9
to 14 in.*lbf)