2006 TOYOTA RAV4 Service Repair Manual

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Page 1433 of 2000

TOYOTA RAV4 2006 Service Repair Manual 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

Page 1434 of 2000

TOYOTA RAV4 2006 Service Repair Manual 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 rea

Page 1435 of 2000

TOYOTA RAV4 2006 Service Repair Manual 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 be

Page 1436 of 2000

TOYOTA RAV4 2006 Service Repair Manual 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

Page 1437 of 2000

TOYOTA RAV4 2006 Service Repair Manual 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 pe

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

Page 1438 of 2000

TOYOTA RAV4 2006 Service Repair Manual 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 re

Page 1439 of 2000

TOYOTA RAV4 2006 Service Repair Manual 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 patter

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

Page 1440 of 2000

TOYOTA RAV4 2006 Service Repair Manual 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
pinio

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)

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