OEM 2005 Toyota RAV4 Differential

2005 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to disassemble and reassemble the differential case on 2005 Toyota RAV4?

  A: The procedure to disassemble the differential case starts with removing the tapered roller bearing from the vehicle speed sensor drive gear side using Special Service Tools: 09950-00020, 09950-00030, 09950-40011 (09957-04010) and 09950-60010 (09951-00530). A proper claw placement on the bearing inner race must meet the security requirements to separate the vehicle speed sensor drive gear. Place matchmarks on the ring gear then remove its 16 bolts before hitting the ring gear with a copper hammer to disassemble it. To disassemble the ring gear side use Special Service Tool: 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-00010 (09951-00450) while setting the claw to the bearing inner race at the indented position. The dial indicator should be used to measure side gear backlash which must remain between 0.05 - 0.20 mm (0.0020 - 0.0079 inch); if the standard is not met install the appropriate thrust washer. The differential case disassembly process begins with removing the straight pin through pin punching and hammering then further includes removal of the pinion shaft and complete extraction of two pinions and side gears together with their respective four thrust washers. After removing the oil seal with a screwdriver and hammer, use a brass bar along with hammer to drive out the tapered roller bearing outer race. Then install a thinner shim followed by using Special Service Tool: 09316-60011 (09316-00011, 09316-00041) and a press to mount a new tapered roller bearing outer race. Install a new oil seal following the use of Service Tool: 09316-60010 (09316-00011, 09316-00031) until it reaches a depth of 3.5 ± 0.5 mm (0.138 ± 0.020 inch) while applying MP grease to the lip. To finish the assembly process on the transaxle case side technicians must drive out the oil seal after removing the tapered roller bearing outer race by using Special Service Tool: 09316-60011 (09316-00011, 09316-00021). Reinstalling the oil baffle correctly when its projection fits into the case side cutout. Before installing new components you must utilize Special Service Tools: 09950-60020 (09951-00890), 09950-70010 (09951-00150) together with a press while installing a new tapered roller bearing outer race. Next drive in a new oil seal using Special Service Tool: 09316-60011 (09316-00011, 09316-00041) to a depth of 0 - 0.5 mm (0 - 0.020 inch) and coat the oil seal lip with MP grease. Gear oil should be applied to all sliding and rotating components and then the correct thrust washers should be installed before inserting the pinion shaft to check side gear backlash. Insert the straight pin and apply the supplied calk material to the hole areas located around the differential case. Strengthen the ring gear by first cleaning the interface then submerging it in boiling water before rushing its installation onto the differential case and matching position pins. After the ring gear reaches room temperature users should install set bolts before uniform torquing them to 106 Nm (1,080 kgf-cm, 78 ft. lbs.). To install the ring gear side of the tapered roller bearing use Special Service Tool: 09316-60011 (09316-00011) for bearing press installation while replacing both tapered roller bearing and outer race. To install the new tapered roller bearing at the vehicle speed sensor drive gear side, place the component properly to prevent movement and apply Special Service Tool: 09316-20011, 09316-60011 (09316-00011), a steel plate, and press. To check differential tapered roller bearing preload measure the assembly torque with Special Service Tool: 09564-32011 while using a torque wrench until the readings fall within new and reused bearing specifications.