how to troubleshoot differential noise in Toyota RAV4 XA40 (2013-2018)

Solution

1. Preparation

• Gather the necessary tools and parts.
• Park the vehicle on a level surface and engage the parking brake.
• Allow the vehicle to cool down if it has been driven recently.

2. Inspect Differential Fluid

• Tools Required: Fluid pump, clean rag, container for fluid.
• Remove the differential fill plug and check the fluid level.
• If the fluid is low, add the appropriate differential oil (typically 75W-90 GL-5).
• If the fluid is dirty or contains metal shavings, proceed to change the fluid.

3. Change Differential Fluid

• Tools Required: Socket set, torque wrench, fluid pump, clean pan for draining.
• Place a pan underneath the differential to catch old fluid.
• Remove the drain plug and allow old fluid to fully drain out.
• Clean the drain plug and replace it with a new washer.
• Refill with new differential fluid until it starts to seep out of the fill hole.
• Replace the fill plug and torque to manufacturer specifications (usually around 30 ft-lbs).

4. Inspect and Replace Differential Components (if necessary)

• Tools Required: Socket set, torque wrench, pry bar, differential rebuild kit (if needed).
• Remove the differential cover (if inspecting internal components).
• Inspect gears for wear, pitting, or scoring.
• If any components are damaged, replace them as needed (bearings, gears).
• Reassemble using a new gasket or sealant, torque the cover bolts to manufacturer specifications (typically around 15-20 ft-lbs).