Applicability

REVISION NOTICE

May 2, 2016 Rev1:

• The Parts Information section has been updated.
• Any previous printed versions of this bulletin should be discarded.

Introduction

Some 2006 – 2012 model year 4WD RAV4 vehicles may exhibit a growl type noise from the rear differential coupling when driving as a result of contamination to the front bearing. Follow the procedure in this bulletin to address this condition.

Production Change Information

This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs shown below.

* Plant Code (11th digit): W = TMMC, 5 = Tahara, D = Shokki.

** For detailed information on VINs, please reference the 2012 VIN Decoder Chart found on the Technical Information System (TIS), under Reference Information: Technician Group.

Warranty Information

APPLICABLE WARRANTY

• This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.
• Warranty application is limited to occurrence of the specified condition described in this bulletin.

Parts Information

NOTE

• When ordering Deflector, be sure to order the correct part number based on original deflector shape.
• The Linear Solenoid Yoke of Coupling Sub-Assy PN 41303-42023 has 2 mounting holes while the original has 3. This is by design.

Required Tools & Equipment

* For detailed information on Gear Oil, please reference the 2006-2009 MY Fluid Specifications / 2010-2013 MY Fluid Specifications charts found on TIS, under Reference Information: Technician Group.

** Essential SST.

Required Tools & Equipment (Continued)

NOTE

• A mechanic's stethoscope or similar tool may be used in place of ChassisEAR™.
• ChassisEAR™ may be ordered by calling Approved Dealer Equipment (ADE) at 1-800-368-6787.

Repair Procedure Overview

• Confirm the condition.
• Remove rear differential coupling.
• Inspect rear differential coupling assembly.
• Replace or rebuild rear differential coupling assembly.
• Confirm repair.

Repair Procedure

1. Confirm the condition.

   Is there a growl type noise coming from the rear of the vehicle when driving?

   • YES – Continue to step 2.
   • NO – This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.
2. Install ChassisEAR™ and test drive, or use a stethoscope with the vehicle on a lift and confirm the noise is loudest from the rear differential coupling assembly.

   Is the noise loudest from the rear differential coupling?

   • YES – Continue to step 3.
   • NO – This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.
3. Remove the rear differential coupling.
   1. Drain rear differential fluid. Drain Plug Torque: 39 N*m (398 kgf*cm, 29 ft*lbf)
   2. Remove the rear propeller shaft. Refer to the Technical Information System (TIS), applicable model and model year Repair Manual:
      • 2006 / 2007 / 2008 / 2009 / 2010 / 2011 / 2012 RAV4: Drivetrain – Drive Shaft/Propeller Shaft – “Propeller Shaft: Propeller Shaft Assembly: Removal”
   3. Remove the 4 stud bolts.

      Using a double nut configuration, with new nuts, remove the 4 studs from the rear differential coupling.

      HINT: Use a wooden or plastic hammer/mallet handle to protect the stud threads and hold the coupling when loosening the stud bolts. Once the stud bolt is removed, loosely thread the stud bolt back into the coupling to allow for removal of the other stud bolts.

      [Image: Figure 3. A single stud bolt.]

      [Image: Figure 4. Mechanic using a hammer to loosen stud bolts on the differential.]

   4. Support the rear differential with a floor jack.
   5. Remove the 4 bolts from the rear differential No. 1 and No. 2 supports to allow clearance to remove the differential coupling.

      [Image: Figure 5. Diagram showing the rear differential with mounting bolts and supports.]

   6. Remove the 4 bolts and differential coupling assembly.
4. Inspect the rear differential coupling assembly.

   NOTE: Use the following criteria to determine if the rear differential coupling will be rebuilt or replaced.

   If the rear differential coupling body assembly shows any of the issues noted below, the rear differential coupling assembly CANNOT be rebuilt and must be replaced as an assembly.

   By comparing the part to Figures 6-10 below, can the rear differential coupling be rebuilt?

   • YES – Continue to step 6. Remove the rear differential coupling cover assembly.
   • NO – Continue to step 5. Replace the rear differential coupling assembly.

   [Image: Figure 6. Damage Where Propeller Shaft Contacts Coupling Body]

   [Image: Figure 7. Excessive Rust/Corrosion Buildup on Top of Coupling Body]

   [Image: Figure 8. Rust/Corrosion on Inside of Coupling Body]

   [Image: Figure 9. Excessive Rust/Corrosion Buildup on Edge of Coupling Body]

   [Image: Figure 10. Rear Differential Coupler Body Is Dark in Color]

5. Replace the rear differential coupling assembly.
   1. Install the coupling shim (use same shim from disassembly).
   2. Install the coupling conical spring washer to the rear differential carrier.

      [Image: Figure 11. Diagram illustrating the installation of the coupling conical spring washer. Label 1: Transmission Coupling Conical Spring Washer.]

   3. Clean the rear differential coupling and rear differential seal surfaces, then apply seal packing in a continuous line, 2 – 3 mm (0.08 – 0.12 in.) in diameter, to the rear differential coupling.

      FIPG Sealant: Three Bond 1281, or equivalent

      [Image: Figure 12. Diagram showing the application of seal packing on the rear differential coupling. Label 1: Seal Packing. Label 2: 2-3 mm.]

      NOTE: Install the rear differential coupling within 3 minutes of applying seal packing.

   4. Install the coupling to the rear differential with 4 bolts. Torque: 19.6 N*m (200 kgf*cm, 14 ft*lbf)
   5. Install the 4 bolts from the rear differential No. 1 and No. 2 supports. Torque: 55 N*m (561 kgf*cm, 41 ft*lbf)

      [Image: Figure 13. Diagram showing the installation of bolts for the rear differential supports.]

   6. Using a double nut configuration, install 4 stud bolts to the rear differential coupling.
   7. Fill rear differential assembly with oil. Torque: 39 N*m (398 kgf*cm, 29 ft*lbf)

      NOTICE: Be sure to clean off any oil that may have dripped onto the exhaust pipe during the oil fill procedure.

   8. Install the rear propeller shaft. Refer to TIS, applicable model and model year Repair Manual:
      • 2006 / 2007 / 2008 / 2009 / 2010 / 2011 / 2012 RAV4: Drivetrain – Drive Shaft/Propeller Shaft – “Propeller Shaft: Propeller Shaft Assembly: Installation”
   9. Test drive the vehicle and confirm the repair.
6. Remove the rear differential coupling cover and bearing assembly.
   1. Using a hydraulic press and the SST, place the rear differential coupling on the SST with only the cover in contact with the SST. SST: 09527-10011-01

      [Image: Figure 14. Image showing the rear differential coupling on a hydraulic press with SST, focusing on the cover. Label 1: Rear Differential Coupling Cover. Label 2: Rear Differential Coupling Body.]

   2. Using the SSTs, slowly press the rear differential coupling body out of the cover assembly. SST: 09951-00890-01 SST: 09950-70010

      CAUTION: Take care to support the rear differential coupling body as it is pressed out.

      [Image: Figure 15. Image showing the rear differential coupling body being pressed out of the cover assembly using SSTs. Label 1: SST 09950-70010. Label 2: SST 09951-00890-01. Label 3: Rear Differential Coupling Cover.]

   3. If the bearing assembly stays on the rear differential coupling body, use the SSTs to remove the bearing. SST: 09950-40011 (09951-04010, 09952-04010, 09955-04011, 09951-04020, 09958-04011, 09953-04030) SST: 09951-00890-01

      NOTE: If the bearing stayed inside the rear differential cover, proceed to step 7.

      [Image: Figure 16. Image showing the use of SSTs to remove a bearing from the rear differential coupling body. Label 1: SST 09950-40011. Label 2: Bearing. Label 3: Rear Differential Coupling Body Assembly. Label 4: SST 09951-00890-01.]

7. Inspect the rear differential coupling body bearing press surface.
   1. If there is rust or corrosion from the yellow line or above, the coupling CAN be rebuilt.
   2. If there is rust or corrosion below the yellow line, the coupling CANNOT be rebuilt. Replace the rear differential coupling assembly. Go to step 5.

   See Figures 18 and 19 for general guidelines.

   HINT: Some coupling bodies may have a slightly shorter bearing press surface, but all coupling bodies will have a machined center line (Red) that can be used to find the Yellow line.

   [Image: Figure 17. Diagram illustrating the bearing press surface inspection criteria with yellow, red lines, and bearing press surface. Label 1: Yellow Line = Approximate Center Line Between Red Line and Top of Coupling Body. Label 2: Red Line = Approximate Center Line of Bearing Press Surface (Machined Line). Label 3: Bearing Press Surface.]

   [Image: Figure 18. A collection of images showing coupling bodies that are acceptable for rebuild.]

   [Image: Figure 19. A collection of images showing coupling bodies that cannot be rebuilt.]

8. Based on the inspection criteria, can the rear differential coupling be rebuilt?
   • YES – Continue to step 8. Begin the rebuild process.
   • NO – Go to step 5 (page 7). Replace the rear differential coupling assembly.
9. Rebuild the rear differential coupling.
   1. Clean the coupling body assembly, prior to assembly, to remove any loose debris.
   2. Set the new coupling cover onto the coupling body and place the coupling body onto the SST. SST: 09527-10011-01

      NOTICE:

      • Be sure the SST is supporting the coupling body, NOT the coupling cover.
      • Be sure coupling is sitting level on SST 09527-10011-01.

      [Image: Figure 20. Image showing the coupling body placed on an SST, ready for cover installation. Label 1: Coupling Body. Label 2: New Coupling Cover with Bearing. Label 3: SST.]

      [Image: Figure 21. Diagram illustrating the setup for pressing the new coupling cover onto the coupling body. Label 1: Coupling Body. Label 2: Coupling Cover. Label 3: SST.]

   3. Using a press and the SSTs, slowly press the new coupling cover with the bearing onto the coupling body. SST: 09527-10011-01 SST: 09223-15030 SST: 09950-70010

      Press the bearing and cover assembly onto the coupling body until the bearing is fully seated against the coupling body.

      NOTE: Be sure the coupling body is level before pressing on the coupling cover with the bearing.

      [Image: Figure 22. Image showing the new coupling cover with bearing being pressed onto the coupling body using SSTs. Label 1: SST 09950-70010. Label 2: SST 09223-15030. Label 3: Coupling Cover Assembly. Label 4: Coupling Body Assembly. Label 5: SST 09527-10011-01.]

   4. Install the dust seal.
      1. Place the dust seal onto the coupling assembly as level as possible, and with the lip facing up as seen in Figure 23.

      NOTICE:

      • Take caution NOT to touch the lip of the seal, or contaminate the lip with debris.
      • Be sure the SST is supporting the coupling body, NOT the coupling cover.
      • Be sure coupling is sitting level on SST 09527-10011-01.

      [Image: Figure 23. Image showing the dust seal being placed onto the coupling assembly. Label 1: Dust Seal. Label 2: Coupling Cover. Label 3: Coupling Body.]

      [Image: Figure 24. Diagram illustrating the placement of the dust seal. Label 1: Coupling Body. Label 2: Coupling Cover. Label 3: SST.]

      1. Place the SSTs onto the dust seal flat surface. SST: 09518-36030-01 SST: 09950-70010

         NOTICE: Be sure that SST 09518-36030-01 is clean of debris that can contaminate the lip seal. Confirm the lip of the dust seal is NOT pinched and goes on the inside of the SST.

         [Image: Figure 25. Image showing SSTs being used to press the dust seal. Label 1: SST 09950-70010. Label 2: SST 09518-36030-01. Label 3: Coupling. Label 4: Dust Seal.]

      2. Slowly press the new dust seal into position until the edge of the seal ring is flush with the coupling cover.

         NOTICE:

         • Ensure the coupling body is in contact with SST 09527-10011-01, NOT the coupling cover, before pressing on the dust seal.
         • Be sure coupling is sitting level on SST 09527-10011-01.

         [Image: Figure 26. Image showing the dust seal pressed into position. Label 1: Coupling Body. Label 2: Dust Seal. Label 3: Coupling Cover.]

         [Image: Figure 27. Diagram illustrating the dust seal being pressed flush with the coupling cover. Label 1: Coupling Body. Label 2: Coupling Cover. Label 3: SST.]

   5. Install the deflector.

      NOTE: Confirm the correct deflector is installed based on original deflector shape.

      [Image: Figure 28. Image of a deflector type for P/N 41252-42020.]

      [Image: Figure 29. Image of a deflector type for P/N 41252-42013.]

      1. Set the deflector onto the dust seal so that it is level.

      NOTICE: Be sure the SST is supporting the coupling body, NOT the coupling cover.

      [Image: Figure 30. Image showing the deflector being set onto the dust seal. Label 1: Coupling Body. Label 2: Deflector. Label 3: Coupling Cover.]

      [Image: Figure 31. Diagram illustrating the placement of the deflector. Label 1: Coupling Body. Label 2: Coupling Cover. Label 3: SST.]

      1. Using the SSTs, slowly press the deflector onto the coupling assembly. The deflector should be even with the coupling body. SST: 09950-70010 SST: 09518-36030-01

         NOTICE: Ensure the coupling body is in contact with SST 09527-10011-01, NOT the coupling cover, before pressing on the deflector.

         [Image: Figure 32. Image showing the deflector being pressed onto the coupling assembly using SSTs. Label 1: SST 09950-70010. Label 2: SST 09518-36030-01. Label 3: Deflector. Label 4: Coupling Body.]

   6. Go back to step 5 (page 7) to reinstall the differential coupling assembly.