Differential Case Disassembly

Transmission. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
E352F E359F Manual Transaxle. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. REMOVE SPEEDOMETER DRIVE GEAR

  2. REMOVE FRONT DIFFERENTIAL RING GEAR

  3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH

  4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN

  5. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT

  6. REMOVE FRONT DIFFERENTIAL SIDE GEAR

Differential Case -- Disassembly



1. REMOVE SPEEDOMETER DRIVE GEAR


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.E352F E359F Manual Transaxle.Manual Transaxle System.Differential Case Disassembly

  1. Remove the drive gear from the front differential case.



2. REMOVE FRONT DIFFERENTIAL RING GEAR


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.E352F E359F Manual Transaxle.Manual Transaxle System.Differential Case Disassembly

  1. Put matchmarks on the ring gear and the differential case.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.E352F E359F Manual Transaxle.Manual Transaxle System.Differential Case Disassembly

  1. Remove the 16 bolts.

  1. Using a plastic-faced hammer, tap out the differential case.



3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.E352F E359F Manual Transaxle.Manual Transaxle System.Differential Case Disassembly

  1. Hold the differential pinion to the front differential case side. Using a dial indicator, measure the differential side gear backlash.

    Standard backlash:
    0.05 to 0.20 mm (0.0020 to 0.0079 in.)
    If the backlash is out of the specification, install proper side gear thrust washers.


4. REMOVE FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.E352F E359F Manual Transaxle.Manual Transaxle System.Differential Case Disassembly

  1. Using SST and a hammer, unstake the staked part of the differential case.

    SST
    09930-00010


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.E352F E359F Manual Transaxle.Manual Transaxle System.Differential Case Disassembly

  1. Using a pin punch and hammer, tap out the straight pin from the differential case.



5. REMOVE FRONT NO. 1 DIFFERENTIAL PINION SHAFT


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.E352F E359F Manual Transaxle.Manual Transaxle System.Differential Case Disassembly

  1. Remove the No. 1 differential pinion shaft from the differential case.



6. REMOVE FRONT DIFFERENTIAL SIDE GEAR


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.E352F E359F Manual Transaxle.Manual Transaxle System.Differential Case Disassembly

  1. Remove the 2 differential pinions, 2 differential pinion thrust washers, 2 differential side gears and 2 No. 1 differential side gear thrust washers from the differential case.

    HINT:
    Remove the 2 pinion thrust washers and side gear thrust washers while turning the differential pinion.