OEM 2003 Toyota RAV4 Differential

2003 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to disassemble the differential on 2003 Toyota RAV4?

  A: The differential disassembly requires placing matchmarks on the ring gear and differential case and removing 1 bolts to free the ring gear with a plastic hammer strike. Apply the tapered roller bearing removal tools listed as 09950-00020, 09950-00030, 09950-60010 (09951-00480, 09951-00500) to extract the bearing that supports the FR speedometer drive gear and RR. The pin punch method using a hammer must drive the pin out from the ring gear side before removing the differential pinion shaft and all associated components including 2 differential pinions, 2 differential side gears, 2 differential pinion thrust washers and 2 differential side gear thrust washers. The side bearing outer race of the transaxle housing must be removed using a brass bar and hammer while the transaxle housing oil seal requires Special Service Tools 09649-17010, 09950-70010 (09951-07100) alongside a hammer before moving on to the oil seal of the transaxle case with Special Service Tool: 09308-00010. To install the side bearing outer race of the transaxle case begin by placing the shim followed by pressing in a new outer race with Special Service Tool: 09950-60020 (09951-00790), 09950-70010 (09951-07150) and a press while using a hammer. Before assembling the differential case, apply ATF to all thrust washers and pinion gears and side gears before you place the components inside the differential case. The alignment of pinion shaft lock pin holes should be maintained. During measurements of side gear backlash using one pinion gear that approaches the case the value should stay between 0.05 - 0.20 mm (0.0020 - 0.0079 inch) to determine the need for thrust washers. Drive the pin through the case and pinion shaft before staking the differential case then install the tapered roller bearing RR and speedometer drive gear by using Special Service Tool: 09316-20011, 09649-17010, and a press. Determine proper side bearing preload through these steps: thoroughly clean all surfaces, connect the differential to the transaxle case and use the specified torque values when tightening Bolt A to 22 Nm (224 kgf-cm, 16 ft. lbs.) then Bolts B and C to 29.4 Nm (300 kgf-cm, 22 ft. lbs.). Use Special Service Tool: 09564-32011 to rotate the differential while measuring preload which must remain between the parameters designated for new and used bearings. To make adjustments remove the differential and transaxle housing before installing the ring gear by cleaning the contact surface and heating the ring gear in water for 15 minutes then driving it with 1 bolts reaching 95.1 Nm (970 kgf-cm, 70 ft. lbs.) torque. To install the transaxle case oil seal and transaxle housing oil seal use the tools Special Service Tools: 09649-17010 and 09608-10010, 09950-70010 (09951-07150). Coating all seal lips with MP grease before installation.