NHTSA ID Number: 10092682
Manufacturer Communication Number: T-SB-0080-13 REV
TSB/Document Date: 2017-02-23
Summary
TSB: 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.
Rear Differential Coupling Cover
2
Rear Differential Coupling Body
© 2016 Toyota
Motor Sales, USA
T-SB-0080-13
Rev1
June 14, 2013
Page 11 of 20
Rear Differential Coupling Growl Noise
Repair Procedure (Continued)
B. Using the SSTs, slowly press the rear
differential coupling body out of the cover
assembly.
Figure 15.
1
SST: 09951-00890-01
SST: 09950-70010
2
CAUTION
Take care to support the rear differential
coupling body as it is pressed out.
C. If the bearing assembly stays on the rear
differential coupling body, use the SSTs to
remove the bearing.
3
1
SST 09950-70010
2
SST 09951-00890-01
3
Rear Differential Coupling Cover
Figure 16.
SST: 09950-40011 (09951-04010, 09952-04010,
09955-04011, 09951-04020, 09958-04011,
09953-04030)
SST: 09951-00890-01
NOTE
1
If the bearing stayed inside the rear
differential cover, proceed to step 7.
4
2
3
1
SST 09950-40011
2
3
Rear Differential Coupling Body Assembly
4
SST 09951-00890-01
© 2016 Toyota Motor Sales, USA
T-SB-0080-13
Rev1
June 14, 2013
Page 12 of 20
Rear Differential Coupling Growl Noise
Repair Procedure (Continued)
7. Inspect the rear differential coupling body bearing press surface.
A. If there is rust or corrosion from the yellow line or above, the coupling CAN be rebuilt.
B. 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.
Figure 17.
1
2
See Figures 18 and 19 for general guidelines.
3
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.
1
Yellow Line = Approximate Center Line Between
Red Line and Top of Coupling Body
2
Red Line = Approximate Center Line of Bearing
Press Surface (Machined Line)
3
Bearing Press Surface
© 2016 Toyota Motor Sales, USA
T-SB-0080-13
Rev1
June 14, 2013
Rear Differential Coupling Growl Noise
Repair Procedure (Continued)
Figure 18. Examples of Coupling Bodies that Are OK to Rebuild
Figure 19. Examples of Coupling Bodies that CANNOT Be Rebuilt
© 2016 Toyota Motor Sales, USA
Page 13 of 20
T-SB-0080-13
Rev1
June 14, 2013
Page 14 of 20
Rear Differential Coupling Growl Noise
Repair Procedure (Continued)
C. 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.
8. Rebuild the rear differential coupling.
A. Clean the coupling body assembly, prior to assembly, to remove any loose debris.
B. 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.
Figure 20.
Figure 21.
1
2
1
2
3
3
1
Coupling Body
1
Coupling Body
2
Coupling Cover
2
New Coupling Cover with Bearing
3
SST
3
SST
© 2016 Toyota Motor Sales, USA
T-SB-0080-13
Rev1
June 14, 2013
Page 15 of 20
Rear Differential Coupling Growl Noise
Repair Procedure (Continued)
C. Using a press and the SSTs, slowly press the
new coupling cover with the bearing onto the
coupling body.
Figure 22.
SST: 09527-10011-01
SST: 09223-15030
1
SST: 09950-70010
2
Press the bearing and cover assembly onto
the coupling body until the bearing is fully
seated against the coupling body.
3
NOTE
5
Be sure the coupling body is level before
pressing on the coupling cover with
the bearing.
1
SST 09950-70010
2
SST 09223-15030
3
Coupling Cover Assembly
4
Coupling Body Assembly
5
SST 09527-10011-01
© 2016 Toyota Motor Sales, USA
4
Rev1
T-SB-0080-13
June 14, 2013
Page 16 of 20
Rear Differential Coupling Growl Noise
Repair Procedure (Continued)
D. 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.
Figure 23.
Figure 24.
2
1
1
3
2
3
1
Coupling Body
1
Dust Seal
2
Coupling Cover
2
Coupling Cover
3
SST
3
Coupling Body
© 2016 Toyota Motor Sales, USA
Rev1
T-SB-0080-13
June 14, 2013
Page 17 of 20
Rear Differential Coupling Growl Noise
Repair Procedure (Continued)
(2) 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.
Figure 25.
1
2
4
3
1
SST 09950-70010
3
Coupling
2
SST 09518-36030-01
4
Dust Seal
© 2016 Toyota Motor Sales, USA
Rev1
T-SB-0080-13
June 14, 2013
Page 18 of 20
Rear Differential Coupling Growl Noise
Repair Procedure (Continued)
(3) 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.
Figure 27.
Figure 26.
2
1
1
2
3
3
1
Coupling Body
1
Coupling Body
2
Coupling Cover
2
Dust Seal
3
SST
3
Coupling Cover
© 2016 Toyota Motor Sales, USA
Rev1
T-SB-0080-13
June 14, 2013
Page 19 of 20
Rear Differential Coupling Growl Noise
Repair Procedure (Continued)
E. Install the deflector.
NOTE
Confirm the correct deflector is installed based on original deflector shape.
Figure 28. Use P/N 41252-42020
Figure 29. Use 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.
Figure 30.
Figure 31.
2
1
1
2
3
3
1
Coupling Body
Coupling Body
2
Coupling Cover
Deflector
3
SST
1
2
3
Coupling Cover
© 2016 Toyota Motor Sales, USA
Rev1
T-SB-0080-13
June 14, 2013
Page 20 of 20
Rear Differential Coupling Growl Noise
Repair Procedure (Continued)
(2) 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.
Figure 32.
4
3
1
2
3
1
SST 09950-70010
3
Deflector
2
SST 09518-36030-01
4
Coupling Body
F. Go back to step 5 (page 7) to reinstall the differential coupling assembly.
© 2016 Toyota Motor Sales, USA
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TSB/Document ID: T-SB-0080-13 REV
Replacement Service Bulletin Number:
MFR Communication Date: 2016-05-02
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN
MFR Component System:
MFR Component Subsystem:
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