Differential Oil Seal Replacement

Remove the filler plug and gasket.

Remove the drain plug and gasket, and then drain the manual transaxle oil.

Install a new gasket and the drain plug.

Torque:

49 N*m{500 kgf*cm, 36 ft.*lbf}

Remove the 2 bolts, 2 compression springs and front exhaust pipe.

Remove the gasket from the exhaust manifold.

Disconnect the sensor connector.

Remove the sensor clip (labeled A), bolt (labeled B) and sensor clamp (labeled C).

Remove the sensor clip (labeled D), bolt (labeled E) and sensor clamp (labeled F).

Remove the bolt and sensor from the knuckle.

NOTICE:

Keep the sensor tip and sensor installation hole free from foreign matter.

Remove the 2 nuts and stabilizer link.

Remove the bolt and 2 nuts.

Disconnect the lower arm from the ball joint.

Using SST, remove the front drive shaft.

SST

09520-01010
09520-24010(09520-32040)

NOTICE:

1. Be careful not to damage the transaxle case oil seal, inboard joint boot and drive shaft dust cover.
   
2. Be careful not to drop the drive shaft.
   

Using SST, tap out the transaxle case oil seal.

SST

09308-00010

Using SST, tap out the transaxle case oil seal.

Coat the lip of a new oil seal with MP grease.

Using SST and a hammer, tap in the oil seal.

SST

09608-10010
09950-70010(09951-07200)

Standard depth:

3.0 to 4.0 mm (0.118 to 0.158 in.)

NOTICE:

Be careful not to damage the lip of the oil seal.

Coat the lip of a new transaxle case oil seal with MP grease.

Using SST and a hammer, tap in the oil seal.

SST

09608-10010
09950-70010(09951-07200)

Standard depth:

5.5 to 6.5 mm (0.22 to 0.26 in.)

NOTICE:

Be careful not to damage the lip of the oil seal.

Coat the splines of the inboard joint shaft with gear oil.

Align the shaft splines and tap in the drive shaft with a brass bar and hammer.

NOTICE:

1. Set the snap ring with the opening facing downwards.
   
2. Be careful not to damage the oil seal, boot and dust cover.
   

Connect the lower arm to the ball joint with the 2 bolts and nut.

Torque:

92 N*m{938 kgf*cm, 68 ft.*lbf}

Install the link with the 2 nuts.

Torque:

74 N*m{755 kgf*cm, 55 ft.*lbf}

Set the sensor into the knuckle, and then install the sensor with the bolt.

Torque:

8.5 N*m{87 kgf*cm, 75 in.*lbf}

NOTICE:

1. Keep the sensor tip and sensor installation hole free from foreign matter.
   
2. Firmly insert the sensor body into the knuckle before tightening the bolt.
   
3. After installing the sensor to the knuckle, make sure that there is no clearance between the sensor stay and knuckle. Also make sure that no foreign matter is stuck between the parts.
   
4. To prevent interference between the sensor and magnetic rotor, do not rotate the sensor body during or after the insertion of the sensor body to the knuckle.
   

Install the sensor clamp and sensor clip as follows.

1. Simultaneously perform the following: 1) hang the hook part of the sensor clamp (labeled A) on the part of the flexible hose bracket (labeled C); and 2) insert the hook part of the sensor clamp (labeled B) to the part of the flexible hose bracket (labeled D).
   

   NOTICE:

   Do not twist the sensor wire when installing the clamp.

2. Install the sensor clamp to the flexible hose clamp and flexible hose bracket with the bolt (labeled E).
   

   Torque:

   18.5 N*m{189 kgf*cm, 14 ft.*lbf}

3. Insert the sensor clip (labeled F) into the hole on the absorber lower bracket.
   

Install the sensor clamp and sensor clip as follows.

1. Set the sensor clamp (labeled G) on the side member, and then install the bolt (labeled H).
   

   Torque:

   8.5 N*m{87 kgf*cm, 75 in.*lbf}

   NOTICE:

   Do not twist the sensor wire when installing the clamp.

2. Insert the sensor clip (labeled I) into the hole on the apron.
   

Connect the sensor connector.

Using a vernier caliper, measure the free length of the compression spring.

Minimum length:

41.5 mm (1.634 in.)

Install a new gasket by hand so that its surface is flush with the exhaust manifold.

NOTICE:

1. Make sure the gasket is facing the correct direction.
   
2. Do not reuse the removed gasket.
   
3. Do not push in the gasket while installing the front exhaust pipe.
   

Install the front exhaust pipe with the 2 compression springs and 2 bolts.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Inspect manual transaxle (RAV4_ACA30 RM000001YV2006X.html).