This procedure covers the replacement of the rear axle shaft seal on a 2019-2024 Toyota RAV4 2.5L I4 FWD, requiring removal of the rear axle shaft and differential cover to access and replace the seal.

Warnings

Tools required

Parts

• Rear axle shaft seal × 1 — Use OEM specification
• Differential cover gasket × 1 — Use OEM specification
• Axle nut × 1 — Use OEM specification (if staked type)
• RTV sealant (FIPG) × 1 — Toyota Genuine FIPG or equivalent

Fluids

• Toyota WS ATF — 2 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Chock the front wheels securely
3. Loosen rear wheel lug nuts before raising vehicle
4. Raise rear of vehicle and support on jack stands at manufacturer-specified lift points
5. Remove rear wheels
6. Allow differential to cool completely if vehicle was recently driven

Procedure

1. 1

   Remove rear axle nut
   Have an assistant apply brakes or use a pry bar to prevent hub rotation. Remove cotter pin (if equipped) or inspect for staked nut. Using breaker bar and appropriate socket, loosen and remove the rear axle nut. If nut is staked, you must replace it with a new nut.
2. 2

   Disconnect rear suspension components
   Remove the rear brake caliper and suspend it with wire or bungee cord (do not let it hang by brake hose). Remove brake rotor. Disconnect the rear lower control arm and trailing arm bolts as necessary to provide clearance for axle removal. Mark all fastener locations for proper reassembly.
3. 3

   Remove rear axle shaft
   Using a slide hammer or by tapping the axle shaft end with a rubber mallet, carefully extract the rear axle shaft from the differential housing. The shaft should pull straight out once the nut is removed and suspension components are disconnected. Inspect the shaft splines for damage or excessive wear.
4. 4

   Drain differential fluid
   Position drain pan under differential. Remove the differential cover bolts in a crisscross pattern to break seal evenly. Allow fluid to drain completely. Once drained, remove cover completely and set aside. Clean any remaining fluid from the differential housing.
   ⚠Fluid may drain suddenly when first bolt is loosened. Keep drain pan positioned to catch all fluid.
5. 5

   Remove old axle seal
   Using a seal puller or pick, carefully pry out the old axle seal from the differential housing bore. Work evenly around the seal to avoid damaging the housing bore. Once seal is removed, inspect the bore for any scoring, corrosion, or damage that could cause the new seal to leak.
   ⚠Be extremely careful not to scratch or gouge the seal bore surface as this will cause the new seal to leak.
6. 6

   Prepare seal bore and new seal
   Thoroughly clean the seal bore with brake cleaner and a lint-free cloth. Remove all old seal residue and contamination. Lightly coat the new seal outer diameter with ATF. Ensure the seal is oriented correctly with the lip facing inward toward the differential.
7. 7

   Install new axle seal
   Using a seal driver or appropriately sized socket that contacts only the outer edge of the seal, drive the new seal squarely into the bore. Tap evenly around the seal perimeter to ensure it seats fully and is not cocked. The seal should be flush with or slightly below the housing face. Coat the seal lip with clean ATF.
   ⚠Never strike the seal face directly. Only contact the outer metal ring to avoid damaging the seal lip.
8. 8

   Clean and prepare differential cover
   Remove all old gasket material from both the differential housing mating surface and cover using a plastic scraper. Clean surfaces thoroughly with brake cleaner. Inspect mating surfaces for warping or damage. Apply a thin, even bead of RTV sealant to the cover or install new gasket per manufacturer specifications.
9. 9

   Install differential cover
   Position the differential cover onto the housing, ensuring proper alignment. Install all differential cover bolts finger-tight. Following a crisscross pattern, torque bolts to specification. Allow RTV sealant to cure per manufacturer instructions before filling with fluid (typically 30 minutes minimum).
   Torque spec

   Differential Cover Bolts35 Nm (26 lb-ft)
10. 10

    Reinstall rear axle shaft
    Lightly coat the axle shaft splines and seal contact area with clean ATF. Carefully insert the axle shaft into the differential housing, ensuring proper engagement with the differential side gear. Push shaft in until it seats fully. Avoid damaging the new seal lip during insertion.
    ⚠Align shaft splines carefully to avoid cross-threading or damaging the seal during installation.
11. 11

    Reconnect suspension and install axle nut
    Reinstall rear suspension components including control arms and trailing arms to their marked positions. Install brake rotor and caliper. Thread new axle nut onto axle shaft hand-tight. With vehicle still on jack stands and brakes applied or hub held stationary, torque axle nut to specification. Install new cotter pin or stake nut per manufacturer specification.
    Torque spec

    Axle Nut250 Nm (184 lb-ft)
12. 12

    Fill differential with ATF
    Locate the differential fill plug on the housing. Remove fill plug and add Toyota WS ATF through the fill hole until fluid reaches the bottom of the fill hole threads (fluid should just begin to drip out). Reinstall fill plug. Total capacity is approximately 1.5-2.0 quarts depending on specific model configuration.
13. 13

    Reinstall wheels and lower vehicle
    Install rear wheels and thread lug nuts hand-tight. Lower vehicle until wheels just contact ground (still partially supported by jack). Torque lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all suspension bolts are torqued to manufacturer specifications (refer to suspension-specific procedures for those torque values)
2. Verify axle nut is properly staked or cotter pin is installed and bent correctly
3. Double-check that differential fill plug is properly installed and not leaking
4. Clean any spilled fluid from differential housing and surrounding components

Verification

• Test drive vehicle and listen for any unusual noises from rear axle area
• After test drive, inspect differential cover and fill plug for any signs of leakage
• Re-inspect axle seal area after 50-100 miles for any signs of fluid seepage
• Check differential fluid level after initial test drive to ensure proper fill
• Verify proper rear suspension operation and alignment if components were significantly disturbed

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