Page 1: Troubleshooting
Use the table below to help you find the cause of a problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace parts. Fig. 1: Problem Symptoms Table Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Page 2 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 MANUAL TRANSAXLE UNIT (2WD) ON-VEHICLE REPAIR REPLACE TRANSAXLE OIL a. Loosen the filler plug. b. Remove the drain plug. HINT: Use a container to catch the transaxle oil. c. Remove the filler plug.
Page 3 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 2: Identifying Transaxle Filler Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COMPONENTS...
Page 4 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 3: Exploded View Of R&I Components Related To Manual Transaxle & Torque Specifications (2WD) (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Page 5 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 4: Exploded View Of R&I Components Related To Manual Transaxle & Torque Specifications (2WD) (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Page 6 3. REMOVE ENGINE COOLANT RESERVOIR TANK 4. DISCONNECT CONTROL CABLES FROM TRANSAXLE a. Remove the 2 clips and 2 washers. b. Remove the 2 clips and disconnect the 2 control cables. Fig. 5: Disconnecting Control Cables Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Page 7 6. DISCONNECT GROUND CABLE FROM TRANSAXLE Remove the bolt and disconnect the ground cable. Fig. 6: Disconnecting Ground Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE STARTER a. Disconnect the starter connector. b. Remove the nut and disconnect the starter cable.
Page 8 Remove the 2 bolts and disconnect the release cylinder and line. Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) Fig. 7: Removing Clutch Release Cylinder & Lines Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. REMOVE 5 MOUNTING BOLTS OF TRANSAXLE UPPER SIDE Torque:...
Page 9 46 N.m (470 kgf.cm, 34 ft.lbf) for bolt B Fig. 8: Removing Mounting Bolts Of Transaxle Upper Side Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. ATTACH ENGINE SUPPORT FIXTURE a. Install the No. 2 engine hanger in the correct direction. Parts No. : No.
Page 10 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 9: Attaching Engine Support Fixture To Engine Hangers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. DISCONNECT LEFT ENGINE MOUNTING INSULATOR FROM TRANSAXLE Remove the bolt and nut.
Page 11 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 10: Disconnecting Left Engine Mounting Insulator From Transaxle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 56 N.m (571 kgf.cm, 41 ft.lbf) 12. REMOVE LH AND RH ENGINE UNDER COVERS 13.
Page 12 Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) Fig. 11: Disconnecting LH & RH Stabilizer Bar Links Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. REMOVE FRONT SUSPENSION CROSSMEMBER ASSEMBLY WITH STABILIZER BAR a. Support the front suspension crossmember with a jack.
Page 13 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 12: Removing Set Bolts Of PS Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 2 nuts, 5 bolts and front suspension crossmember assembly with the stabilizer bar. Torque: Bolt A: 113 N.m (1,150 kgf.cm, 82 ft.lbf) Bolt B: 157 N.m (1,600 kgf.cm, 115 ft.lbf) Bolt C: 72...
Page 14 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 13: Removing Bolts Of Center Member Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. JACK UP TRANSAXLE SLIGHTLY Using a transmission jack, support the transaxle. 20. REMOVE 4 MOUNTING BOLTS OF TRANSAXLE LOWER SIDE Torque: 46 N.m (470 kgf.cm, 34 ft.lbf) for bolt A...
Page 15 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 14: Removing Mounting Bolts Of Transaxle Lower Side Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE TRANSAXLE Lower the engine left side, then slowly and carefully remove the transaxle from the engine.
Page 16 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 After installation, check and inspect items as follows. Check the front wheel alignment (See FRONT WHEEL ALIGNMENT ).  Do the road test.  MANUAL TRANSAXLE UNIT (4WD) ON-VEHICLE REPAIR REPLACE TRANSAXLE OIL a.
Page 17 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 15: Identifying Transaxle Filler Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COMPONENTS...
Page 18 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 16: Exploded View Of Manual Transaxle & Torque Specifications (4WD) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Page 19 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 REMOVAL 1. REMOVE TRANSAXLE WITH ENGINE (See REMOVAL ) 2. REMOVE TRANSAXLE CASE PROTECTOR Remove the 2 bolts and transaxle case protector. Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) 3. DISCONNECT BACK-UP LIGHT SWITCH AND VEHICLE SPEED SENSOR CONNECTORS 4.
Page 20 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 17: Removing Stiffener Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE TRANSAXLE FROM ENGINE Remove the 10 bolts, separate the engine and transaxle. Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) for bolt A 46 N.m (470 kgf.cm, 34 ft.lbf) for bolt B...
Page 21 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 18: Removing Transaxle From Engine Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: At the time of installation, refer to the following items. Align the input shaft with the clutch disc and install the transaxle to the engine.
Page 22: Manual Transaxle Assembly
2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Check the front wheel alignment (See FRONT WHEEL ALIGNMENT ).  Do the road test.  MANUAL TRANSAXLE ASSEMBLY COMPONENTS...
Page 23 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 19: Exploded View Of Manual Transaxle Assembly & Torque Specifications (1 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Page 24 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 20: Exploded View Of Manual Transaxle Assembly & Torque Specifications (2 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Page 25 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 21: Exploded View Of Manual Transaxle Assembly & Torque Specifications (3 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Page 26 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 22: Exploded View Of Manual Transaxle Assembly & Torque Specifications (4 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Page 27 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 23: Exploded View Of Manual Transaxle Assembly & Torque Specifications (5 Of 5) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Page 28 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 DISASSEMBLY 1. REMOVE CLUTCH RELEASE FORK AND BEARING HINT: At the time of reassembly, refer to the following item. Apply molybdenum disulphide lithium base grease (See INSTALLATION ). 2. 4WD: REMOVE TRANSFER ASSEMBLY a.
Page 29 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 24: Applying FIPG To Either Transaxle Side Or Transfer Side Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. 4WD: REMOVE DIFFERENTIAL SIDE GEAR INTERMEDIATE SHAFT 4. REMOVE FILLER PLUG AND DRAIN PLUG WITH 2 GASKETS Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
Page 30 Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 9. REMOVE SELECTING BELLCRANK ASSEMBLY Remove the 2 bolts and the selecting bellcrank assembly. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) Fig. 25: Removing Selecting Bellcrank Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Page 31 Remove the nut and wave washer. Torque: 6.4 N.m (65 kgf.cm, 57 in.lbf) Fig. 26: Removing Control Shift Lever Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a pin punch and a hammer, tap out the lever lock pin. NOTE: At the time of reassembly, refer to the following item.
Page 32 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 27: Tapping Out Lever Lock Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE LOCK BALL ASSEMBLY AND SHIFT AND SELECT LEVER SHAFT ASSEMBLY a. Remove the lock ball assembly.
Page 33 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 28: Removing Shift & Select Lever Shaft Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 12.
Page 34 Part No. 08826-00100, THREE BOND 1282B or equivalent Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 14. REMOVE BREATHER PLUG WITH GASKET Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) Fig. 29: Applying FIPG To Transmission Case Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Page 35 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 15. REMOVE OUTPUT SHAFT LOCK NUT a. Unstake the lock nut. b. Engage the gear double meshing. c. Remove the lock nut. Torque: 123 N.m (1,250 kgf.cm, 90 ft.lbf) d. Disengage the gear double meshing.
Page 36 Using SST, remove the 5th driven gear. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03030) Fig. 31: Removing 5th Driven Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. MEASURE 5TH GEAR THRUST CLEARANCE AND RADIAL CLEARANCE a. Using a dial indicator, measure the thrust clearance.
Page 37 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 32: Measuring 5th Gear Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a dial indicator, measure the radial clearance. Maximum clearance: 0.050 mm (0.0020 in.)
Page 38 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 33: Measuring Radial Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. REMOVE NO. 3 CLUTCH HUB AND 5TH GEAR a. Using 2 screwdrivers and a hammer, tap out the snap ring.
Page 39 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 34: Locating Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, remove the No. 3 clutch hub with the synchronizer ring and 5th gear. SST 09950-30012 (09951-03010, 09953-03010, 09954-03010)
Page 40 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 35: Removing Clutch Hub With Synchronizer Ring & 5th Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 20. REMOVE NEEDLE ROLLER BEARINGS 21. REMOVE REAR BEARING RETAINER Using a Torx(R) socket wrench (T45), remove the 7 Torx(R) screws and rear bearing retainer.
Page 41 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 36: Removing Snap Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 23. REMOVE STRAIGHT SCREW PLUG Using a hexagon wrench (6 mm), remove the plug. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent...
Page 42 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 37: Removing Straight Screw Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND WASHER Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent...
Page 43 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 38: Removing Reverse Idler Gear Shaft Lock Bolt & Washer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. REMOVE TRANSMISSION CASE a. Transaxle case side: Remove the 3 bolts. b. Transmission case side:...
Page 44 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 39: Removing Bolts Of Transmission Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FIPG: Part No. 08826-00100, THREE BOND 1282B or equivalent Torque: 29 N.m (300 kgf.cm, 21 ft.lbf) for transaxle case side 30 N.m (306 kgf.cm, 22 ft.lbf) for...
Page 45 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 40: Applying FIPG To Transmission Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 26. REMOVE SHIM HINT: At the time of reassembly, refer to the following item. Install the previously selected shim by adjusting...
Page 46 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 41: Removing Shim Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 27. REMOVE OUTPUT SHAFT REAR BEARING OUTER RACE Using SST and a hammer, remove the output shaft rear bearing outer race.
Page 47 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 42: Removing Output Shaft Rear Bearing Outer Race Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 28. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY Remove the 2 bolts and pull off the reverse shift arm and bracket.
Page 48 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 43: Removing Reverse Idler Gear & Thrust Washer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: At the time of reassembly, refer to the following item. Align the matchmarks, as shown, see Fig. 44.
Page 49 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 44: Locating Matchmarks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 30. REMOVE STRAIGHT SCREW PLUGS Using a hexagon wrench (6 mm), remove the 2 plugs. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent...
Page 50 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 45: Removing Straight Screw Plugs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 31. REMOVE 3 SHIFT FORK SET BOLTS Torque: 24 N.m (240 kgf.cm, 17 ft.lbf) 32. REMOVE NO. 1 SHIFT FORK SHAFT Pull up the No.
Page 51 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 46: Pulling Up No. 3 Shift Fork Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 33. REMOVE INTERLOCK ROLLER Using a magnetic finger, remove the interlock roller from the reverse shift fork.
Page 52 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 47: Removing Interlock Roller From Reverse Shift Fork Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 34. REMOVE NO. 2 SHIFT FORK SHAFT, SHIFT HEAD AND NO. 1 SHIFT FORK a. Pull out the No. 2 shift fork shaft.
Page 53 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 48: Removing No. 2 Shift Fork Shaft, Shift Head & No. 1 Shift Fork Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 35. REMOVE NO. 3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK AND NO. 2 SHIFT FORK a.
Page 54 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 49: Removing Snap Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 37. REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY a. Leaning the output shaft to the differential side, remove the input shaft assembly.
Page 55 Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring. c. Remove the synchronizer rings. Fig. 50: Removing Snap Ring From Synchronizer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. INSPECT NO. 5 SYNCHRONIZER RING a. Check for wear or damage.
Page 56 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 b. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone.
Page 57 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 51: Turning Synchronizer Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.7 mm (0.028 in.) If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone.
Page 58 If the clearance exceeds the maximum, replace the shift fork or hub sleeve. Fig. 53: Measuring Clearance Between Hub Sleeve & Shift Fork Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT 1. REPLACE INPUT SHAFT FRONT BEARING AND OIL SEAL...
Page 59 SST 09612-65014 (09612-01040, 09612-01050) c. Using a screwdriver, remove the oil seal. Fig. 54: Removing Bolts Of Transaxle Case Receiver Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using SST, drive in a new oil seal. SST 09608-00081, 09950-70010 (09951-07150)
Page 60 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 55: Using SST To Drive In A New Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Coat the lip of seal with MP grease. f. Using SST, drive in a new bearing.
Page 61 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 56: Installing New Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Install the transaxle case receiver. h. Install and torque the 3 bolts. Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) 2.
Page 62 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 57: Pulling Out Output Shaft Front Bearing Outer Race Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install a new output shaft cover. HINT: Install the output shaft cover projection into the case side groove.
Page 63 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 58: Installing New Output Shaft Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using SST and a hammer, drive in a new output shaft front bearing outer race. SST 09316-60011 (09316-00011, 09316-00021)
Page 64 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 59: Using SST & A Hammer To Drive In A New Output Shaft Front Bearing Outer Race Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REPLACE REVERSE RESTRICT PIN a. Using a hexagon wrench (6 mm), remove the screw plug.
Page 65 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 60: Removing Screw Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a pin punch (5 mm) and hammer, drive in the slotted spring pin. e. Apply sealant to the screw plug threads.
Page 66 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 61: Installing Screw Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REPLACE CONTROL SHAFT COVER OIL SEAL AND BUSHING a. Using a screwdriver, pry out the oil seal.
Page 67 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 62: Prying Control Shaft Cover Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST and a press, press out the bushing. SST 09950-60010 (09951-00200, 09951-00210), 09950-70010 (09951-07150)
Page 68 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 63: Pressing Out Bushing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using SST and a press, press in a new bushing. SST 09950-60010 (09951-00200), 09950-70010 (09951-07150) Depth: 0.65 +/- 0.25 mm (0.0256 +/- 0.0098 in.)
Page 69 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 64: Pressing In A New Bushing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using SST and a plastic-faced hammer, carefully tap in a new oil seal. SST 09950-60010 (09951-00270), 09950-70010 (09951-07150)
Page 70 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 65: Tapping In A New Oil Seal...
Page 71 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 REASSEMBLY Reassembly is in the reverse order of disassembly (See DISASSEMBLY). NOTE: When working with FIPG material, you must observe the following items. Using a razor blade and gasket scraper, remove all the old FIPG material ...
Page 72 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 66: Installing Transmission Case To Transaxle Case Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the output shaft rear taper roller bearing outer race. e. Install the adjusting shim.
Page 73 Reused bearing: 0.5 to 1.0 N.m (5 to 10 kgf.cm, 4.3 to 8.7 in.lbf) If the preload is not within the specification, select an appropriate adjusting shim. Fig. 67: Measuring Preload Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. THICKNESS SPECIFICATION CHART...
Page 74: Input Shaft
2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Mark Thickness mm (in.) Mark Thickness mm (in.) 1.30 (0.0512) 1.95 (0.0768) 1.35 (0.0531) 2.00 (0.0787) 1.40 (0.0551) 2.05 (0.0807) 1.45 (0.0571) 2.10 (0.0827) 1.50 (0.0591) 2.15 (0.0846) 1.55 (0.0610) 2.20 (0.0866) 1.60 (0.0630)
Page 75 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 68: Exploded View Of Input Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY 1. MEASURE 3RD AND 4TH GEARS THRUST CLEARANCE Using a feeler gauge, measure the thrust clearance.
Page 76 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 69: Measuring 3rd & 4th Gears Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. CHECK 3RD AND 4TH GEARS RADIAL CLEARANCE Using a dial indicator, measure the radial clearance between the gear and shaft.
Page 77 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 70: Checking 3rd & 4th Gears Radial Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE SNAP RING Using 2 screwdrivers and a hammer, tap out the snap ring.
Page 78 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 71: Removing Rear Bearing & 4th Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE 2 NEEDLE ROLLER BEARINGS, SPACER AND SYNCHRONIZER RING 6. REMOVE SNAP RING Using 2 screwdrivers and a hammer, tap out the snap ring.
Page 79 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 72: Removing No. 2 Hub Sleeve Assembly, Synchronizer Ring & 3rd Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE 2 NEEDLE ROLLER BEARINGS 9. DISASSEMBLY NO. 2 HUB SLEEVE ASSEMBLY a.
Page 80 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 73: Disassembling No. 2 Hub Sleeve Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. REMOVE INPUT SHAFT FRONT BEARING INNER RACE Using a screwdriver and hammer, remove the input shaft front bearing inner race.
Page 81 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 74: Inspecting Gear Synchronizer Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Ensure the fine lapping compound is completely washed off after rubbing. c. Check again the braking effect of the synchronizer ring.
Page 82 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 75: Measuring Clearance Between Synchronizer Ring Back & Spline End Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone.
Page 83 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 76: Measuring Clearance Between Hub Sleeve & Shift Fork Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSPECT INPUT SHAFT a. Check the input shaft for wear or damage. b. Using a micrometer, measure the outer diameter of the input shaft journal surface.
Page 84 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 77: Measuring Outer Diameter Of Input Shaft Journal Surface Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a dial indicator, check the shaft runout. Maximum runout: 0.03 mm (0.0012 in.)
Page 85 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 78: Checking Shaft Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. 1. INSTALL INPUT SHAFT FRONT BEARING INNER RACE Using SST and a press, install a new input shaft front bearing inner race.
Page 86 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 79: Installing Input Shaft Front Bearing Inner Race Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL NO. 2 CLUTCH HUB INTO NO. 2 HUB SLEEVE a. Install the 3 springs and shifting keys to the clutch hub.
Page 87 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 80: Installing Springs & Shifting Keys To Clutch Hub Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR, SYNCHRONIZER RING AND NO. 2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT a.
Page 88 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 81: Installing 3rd Gear, Synchronizer Ring & No. 2 Hub Sleeve Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL SNAP RING a. Select a snap ring that allows the minimum axial play.
Page 89 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 82: Using A Screwdriver & Hammer To Tap In Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. MEASURE 3RD GEAR THRUST CLEARANCE (See DISASSEMBLY) 6. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, 4TH GEAR AND REAR BEARING a.
Page 90 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 83: Installing Spacer, Synchronizer Ring, Needle Roller Bearing, 4th Gear & Rear Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. INSTALL SNAP RING a. Select a snap ring that allows the minimum axial play.
Page 91: Output Shaft
2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 84: Measuring 4th Gear Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. MEASURE 4TH GEAR THRUST CLEARANCE (See DISASSEMBLY) OUTPUT SHAFT COMPONENTS...
Page 92 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 85: Exploded View Of Output Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY 1. MEASURE 1ST AND 2ND GEARS THRUST CLEARANCE Using a feeler gauge, measure the thrust clearance.
Page 93 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 86: Measuring 1st & 2nd Gears Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. CHECK 1ST AND 2ND GEARS RADIAL CLEARANCE Using a dial indicator, measure the radial clearance between the gear and shaft.
Page 94 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 87: Measuring 1st & 2nd Gears Radial Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE OUTPUT SHAFT REAR BEARING, 4TH DRIVEN GEAR AND SPACER a. Using a press, remove the bearing and 4th driven gear.
Page 95 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 88: Removing Output Shaft Rear Bearing, 4th Driven Gear & Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. REMOVE 3RD DRIVEN GEAR AND 2ND GEAR Using a press, remove the 3rd driven gear and 2nd gear.
Page 96 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 89: Removing 3rd Driven Gear & 2nd Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. REMOVE NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RINGS 6. REMOVE INNER RACE AND BALL FROM OUTPUT SHAFT 7.
Page 97 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 90: Removing No. 1 Hub Sleeve Assembly & 1st Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. REMOVE SYNCHRONIZER RINGS AND NEEDLE ROLLER BEARING...
Page 98 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 9. REMOVE 1ST GEAR BEARING INNER RACE Using SST and a press, remove the 1st gear bearing inner race. SST 09950-00020...
Page 99 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 91: Removing 1st Gear Bearing Inner Race Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. DISASSEMBLY NO. 1 HUB SLEEVE ASSEMBLY a. Remove the No. 1 hub sleeve from the No. 1 clutch hub.
Page 100 Remove the 3 shifting keys and springs from the No. 1 clutch hub. Fig. 92: Disassembly No. 1 Hub Sleeve Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE OUTPUT SHAFT FRONT BEARING Using SST, remove the output shaft front bearing.
Page 101 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 93: Removing Output Shaft Front Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. INSPECT GEAR SYNCHRONIZER RINGS a. Check for wear or damage. b. Check the braking effect of the synchronizer ring.
Page 102 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 94: Inspecting Gear Synchronizer Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.7 mm (0.028 in.)
Page 103 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 95: Measuring Clearance Between Synchronizer Ring Back & Gear Spline End Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. MEASURE NO. 1 SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Page 104 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 96: Measuring No. 1 Shift Fork And Hub Sleeve Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSPECT OUTPUT SHAFT a. Check the output shaft for wear or damage.
Page 105 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 97: Measuring Outer Diameter Of Output Shaft Journal Surface Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a dial indicator, check the shaft runout. Maximum runout: 0.03 mm (0.0012 in.)
Page 106 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 98: Checking Shaft Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.
Page 107 Fig. 99: Installing No. 1 Clutch Hub Into No. 1 Hub Sleeve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL 1ST GEAR BEARING INNER RACE Using SST and a press, install the 1st gear bearing inner race.
Page 108 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 100: Installing 1st Gear Bearing Inner Race Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL NEEDLE ROLLER BEARING, 1ST GEAR, SYNCHRONIZER RINGS AND NO. 1 HUB SLEEVE TO OUTPUT SHAFT a.
Page 109 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 101: Placing 1st Gear, Synchronizer Rings & No. 1 Hub Sleeve To Output Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using SST and a press, install the 1st gear and No. 1 hub sleeve.
Page 110 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 102: Installing 1st Gear & No. 1 Hub Sleeve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. MEASURE 1ST GEAR THRUST CLEARANCE (See DISASSEMBLY) 5. INSTALL BALL AND INNER RACE TO OUTPUT SHAFT HINT: Align the groove of the inner race and ball.
Page 111 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 103: Installing Ball And Inner Race To Output Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. INSTALL SPACER, NEEDLE ROLLER BEARING, SYNCHRONIZER RINGS, 2ND GEAR...
Page 112 Install the 2nd gear. e. Using a press, install the 3rd driven gear. Fig. 104: Using A Press, Install 3rd Driven Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Align the clutch hub grooves with the projections on the...
Page 113 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 105: Aligning Clutch Hub Grooves With Projections On Synchronizer Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. MEASURE 2ND GEAR THRUST CLEARANCE (See DISASSEMBLY) 8. INSTALL SPACER AND 4TH DRIVEN GEAR a.
Page 114 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 106: Installing Spacer & 4th Driven Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. INSTALL OUTPUT SHAFT REAR BEARING...
Page 115 Using SST and a press, install a new bearing. SST 09506-30012 Fig. 107: Installing NEW Output Shaft Rear Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. INSTALL OUTPUT SHAFT FRONT BEARING Using SST and a press, install a new output shaft front bearing.
Page 116 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 108: Installing New Output Shaft Front Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OIL PUMP (4WD) COMPONENTS...
Page 117 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 109: Exploded View Of Oil Pump & Torque Specifications (4WD) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. CHECK ROTOR BODY CLEARANCE a. Install the oil pump drive gear to the drive rotor.
Page 118 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 110: Measuring Body Clearance Between Drive Rotor & Oil Pump Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. CHECK ROTOR TIP CLEARANCE a. Install the oil pump drive gear to the drive rotor.
Page 119 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 111: Measuring Tip Clearance Between Drive & Driven Rotors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. CHECK SIDE CLEARANCE Using a precision straight edge and feeler gauge, measure the side clearance of both rotors.
Page 120 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 112: Measuring Side Clearance Of Both Rotors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SHIFT AND SELECT LEVER SHAFT COMPONENTS...
Page 121 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 113: Exploded View Of Shift & Select Lever Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DIFFERENTIAL CASE (2WD) COMPONENTS...
Page 122 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 114: Exploded View Of Differential Case & Torque Specifications (2WD) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY 1. Vehicle Speed sensor drive gear side:...
Page 123 HINT: Set the claw of SST to the bearing inner race securely. b. Remove the vehicle speed sensor drive gear. Fig. 115: Removing Tapered Roller Bearing From Differential Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE RING GEAR...
Page 124 Using a copper hammer, tap on the ring gear to remove it from the differential case. Fig. 116: Removing Bolts Of Ring Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Ring gear side: REMOVE TAPERED ROLLER BEARING FROM DIFFERENTIAL CASE Using SST, remove the tapered roller bearing.
Page 125 Set the claw of SST to the bearing inner race at the position where the differential case is indented. Fig. 117: Removing Tapered Roller Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSPECT SIDE GEAR BACKLASH Using a dial indicator, measure the backlash of one side gear while holding one pinion toward the differential case.
Page 126 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 118: Measuring Side Gear Backlash Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. DISASSEMBLE DIFFERENTIAL CASE a. Using a pin punch and hammer, drive out the straight pin. b. Remove the pinion shaft from the differential case.
Page 127 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 REPLACEMENT 1. Transmission Case Side: REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE a. Using a screwdriver and a hammer, remove the oil seal. b. Using a brass bar and hammer, drive out the tapered roller bearing outer race lightly and evenly.
Page 128 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 119: Removing Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using SST and a press, install a new tapered roller bearing outer race. SST 09316-60011 (09316-00011, 09316-00041) NOTE: When replacing the tapered roller bearing outer race, replace the tapered roller bearing along with it.
Page 129 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 121: Driving In NEW Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Transaxle Case Side: REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE a. Using a screwdriver and hammer, drive out the oil seal from the transaxle case.
Page 130 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 122: Driving Oil Seal From Transaxle Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the oil baffle. d. Install the oil baffle. HINT: Install the oil baffle projection into the case side cutout.
Page 131 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 123: Installing Tapered Roller Bearing Outer Race Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Using SST and a hammer, drive in a new oil seal. SST 09316-60011 (09316-00011, 09316-00041) Drive in depth: 0 +/- 0.5 mm (0 +/- 0.020 in.)
Page 132 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 124: Driving In NEW Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. 1. ASSEMBLE DIFFERENTIAL CASE a.
Page 133 1.10 (0.0433) 1.30 (0.0512) Fig. 125: Installing Correct Thrust Washers & Side Gears Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the thrust washers and side gears in the differential case. c. Install the pinion shaft. d. Using a dial indicator, check the side gear backlash.
Page 134 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 126: Measuring Side Gear Backlash Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) If the backlash is not within the specification, install a thrust washer of different thickness.
Page 135 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 e. Using a pin punch and hammer, drive in the straight pin through the differential case and hole in the pinion shaft. f. Using a chisel and hammer, caulk the pin holes around the circumference of the differential case.
Page 136 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 127: Installing Ring Gear On Differential Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Ring gear side: INSTALL TAPERED ROLLER BEARING Using SST and a press, install a new tapered roller bearing.
Page 137 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 128: Installing Tapered Roller Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Vehicle Speed sensor drive gear side: INSTALL TAPERED ROLLER BEARING a. Place the vehicle speed sensor drive gear in position to stop it turning and install the vehicle speed sensor drive gear.
Page 138 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 129: Installing Tapered Roller Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, a steel plate and press, install a new tapered roller bearing. SST 09316-20011, 09316-60011 (09316-00011)
Page 139 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 130: Installing Tapered Roller Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. INSPECT DIFFERENTIAL TAPERED ROLLER BEARING PRELOAD NOTE: Perform this only when replacing the tapered roller bearing and outer race of the differential case.
Page 140 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 131: Installing Differential Case Assembly To Transaxle Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using SST and a torque wrench, turn the differential case assembly right and left 2 or 3 times to allow the bearings to settle.
Page 141 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 132: Measuring Preload Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the preload is not within the specification, remove the transmission case side outer race of the tapered roller bearing with SST (See DISASSEMBLY). Select an appropriate shim.
Page 142 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 e. Remove the 17 bolts and transmission case. f. Remove the differential case assembly. DIFFERENTIAL CASE (4WD) COMPONENTS...
Page 143 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 133: Exploded View Of Differential Case & Torque Specifications (4WD) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY 1. REMOVE NO. 2 DIFFERENTIAL CASE a. Remove the 16 bolts. b. Remove the No. 2 differential case upward.
Page 144 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 135: Using A Plastic Hammer To Tap Out Ring Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE NO. 2 DIFFERENTIAL SIDE GEAR THRUST WASHER AND CONICAL SPRING WASHER 4.
Page 145 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 136: Removing Snap Ring & Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the parts from the front differential case. 1. Remove the 2 front differential pinion shafts.
Page 146 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 137: Exploded View Of Front Differential Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR...
Page 147 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 a. Using a snap ring expander, remove the snap ring. b. Remove the spacer and vehicle speed sensor drive gear. 7. DISASSEMBLE NO. 1 DIFFERENTIAL CASE Remove the parts from the No. 1 differential case.
Page 148 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4...
Page 149 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 138: Exploded View Of No. 1 Differential Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. No. 2 Differential Case Side: REMOVE TAPERED ROLLER BEARING Using SST, remove the tapered roller bearing.
Page 150 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 140: Removing Tapered Roller Bearing (No. 1 Differential Case Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. MEASURE NO. 1 AND NO. 2 DIFFERENTIAL CASES Using a cylinder gauge, measure the inner diameter of the No. 1 and No. 2 differential cases bushing.
Page 151 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 141: Measuring Inner Diameter Of No. 1 & No. 2 Differential Cases Bushing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. MEASURE FRONT DIFFERENTIAL CASE Using a micrometer, measure the outer diameter of the front differential case.
Page 152 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 142: Measuring Outer Diameter Of Front Differential Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. MEASURE CONICAL SPRING WASHER Using calipers, measure the height of the conical spring washer.
Page 153 2.50 mm (0.098 in.) No. 1 differential case side 1.60 mm (0.063 in.) Fig. 143: Measuring Height Of Conical Spring Washer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT 1. Transmission Case Side: REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE...
Page 154 First select and install a shim of lesser thickness than before. Fig. 144: Driving Out Tapered Roller Bearing Outer Race Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using SST and a press, install a new tapered roller bearing outer race.
Page 155 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 145: Installing Tapered Roller Bearing Outer Race Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Using SST and a hammer, drive in a new oil seal. SST 09316-60010 (09316-00011, 09316-00031)
Page 156 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 146: Driving In NEW Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Coat the lip of oil seal with MP grease. 2. Transaxle Case Side: REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE a.
Page 157 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 147: Removing Tapered Roller Bearing Outer Race Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the oil baffle. d. Install the oil baffle. HINT: Install the oil baffle projection into the case side cutout.
Page 158 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 148: Installing Tapered Roller Bearing Outer Race Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Using SST and a hammer, drive in a new oil seal. SST 09316-60011 (09316-00011, 09316-00041)
Page 159 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 149: Driving In NEW Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Coat the oil seal lip with MP grease. REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.
Page 160 Using SST, install a new tapered roller bearing. SST 09316-20011 Fig. 150: Installing NEW Tapered Roller Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. No. 2 Differential Case Side: INSTALL TAPERED ROLLER BEARING Using SST, install a new tapered roller bearing.
Page 161 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 151: Installing NEW Tapered Roller Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE GEAR BACKLASH (DIFFERENTIAL SIDE GEAR SUB-ASSEMBLY SIDE) a. Install the parts to the No. 1 differential case.
Page 162 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4...
Page 163 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 152: Assembling No. 1 Differential Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a dial indicator, measure the backlash of one pinion gear while holding the differential side gear sub assembly toward the case.
Page 164 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Thrust washer thickness: mm (in.) THICKNESS SPECIFICATION CHART Mark Thickness mm (in.) Mark Thickness mm (in.) 0.80 (0.0315) 1.15 (0.0453) 0.85 (0.0335) 1.20 (0.0472) 0.90 (0.0354) 1.25 (0.0492) 0.95 (0.0374) 1.30 (0.0512) 1.00 (0.0394)
Page 165 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4...
Page 166 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 154: Assembling No. 1 Differential Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR a. Install the vehicle speed sensor drive gear and spacer.
Page 167 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 5. Install the 4 differential pinion thrust washers. 6. Install the No. 2 front differential pinion shaft. 7. Install the 2 front differential pinion shafts.
Page 168 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 156: Assembling Front Differential Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a dial indicator, measure the backlash of one pinion gear while holding the front differential...
Page 169 Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) Fig. 157: Measuring Backlash Of One Pinion Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Do not mount the surface of front differential case which contacts with bushing in a vise.
Page 170 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Mark Thickness mm (in.) 1.00 (0.0394) 1.05 (0.0413) 1.10 (0.0433) 1.15 (0.0453) 1.20 (0.0472) 1.25 (0.0492) 7. CHECK AND ADJUST FRONT DIFFERENTIAL SIDE GEAR THRUST CLEARANCE (NO. 2 DIFFERENTIAL CASE SIDE) a.
Page 171 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 158: Installing Differential Case LH To Front Differential Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a straight edge and feeler gauge, measure the clearance between the front differential case and the side gear.
Page 172 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 159: Measuring Clearance Between Front Differential Case & Side Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Refer to the table below and select a thrust washer which will ensure that the clearance is within the specification.
Page 173 Before installing the shaft snap ring, wrap vinyl tape around the case to avoid damaging the case. Fig. 160: Installing Shaft Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE GEAR THRUST CLEARANCE (FRONT DIFFERENTIAL CASE SIDE) a.
Page 174 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4...
Page 175 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 161: Assembling No. 2 Differential Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Engage the front differential side gear and pinion gear of the No. 1 differential case. ...
Page 176 5. Quickly install the ring gear on the differential case. HINT: Align the matchmarks on the No. 2 differential case and connect the ring gear. Fig. 163: Heating Ring Gear In Boiling Water Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Page 177 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 164: Aligning Matchmarks On No. 2 Differential Case & Ring Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Install the No. 2 differential case downward.
Page 178 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 165: Installing No. 2 Differential Case Downward Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Align the matchmarks on the No. 1 differential case and contact the No. 2 differential case.
Page 179 Refer to the table on the next page, select the No. 2 thrust washer which will ensure that the backlash is within the specification. Try to select a washer of the same size. Fig. 166: Measuring Plastigage At Its Widest Point Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Thrust washer thickness: mm (in.) THICKNESS SPECIFICATION CHART Mark Thickness mm (in.) Mark Thickness mm (in.)
Page 180 Be careful not to mistake the direction of the conical spring washer. Fig. 167: Installing No. 2 Side Gear Thrust Washer & Conical Spring Washer To Front Differential Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the No. 2 differential case to the No. 1 differential case. HINT:...
Page 181 Torque: 33 N.m (337 kgf.cm, 24 ft.lbf) Fig. 168: Aligning Matchmarks On No. 2 Differential Case & Connect No. 1 Differential Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. ADJUST DIFFERENTIAL CASE SIDE BEARING PRELOAD a. Install the differential case assembly to the transaxle case.
Page 182 30 N.m (306 kgf.cm, 22 ft.lbf) for transmission case side Fig. 169: Installing Transmission Case Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Temporarily install the intermediate shaft. e. Turn the intermediate shaft right and left 2 or 3 times to allow the bearing settle.
Page 183 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 170: Turning Intermediate Shaft To Settle Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Using SST and a torque wrench, measure the differential preload. SST 09564-32011...
Page 184 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 171: Measuring Differential Preload Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Preload (at starting) New bearing: 0.8 to 1.6 N.m (8.0 to 16.3 kgf.cm, 7.1 to 14.2 in.lbf)
Page 185 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Reused bearing: 0.5 to 1.0 N.m (5.1 to 10.2 kgf.cm, 4.4 to 8.6 in.lbf) If the preload is not within the specification, select an appropriate adjusting shim. HINT: The total preload will change about 5.1 N (0.5 kgf, 1.1 lbf) for every 0.05 mm change in adjusting shim thickness.
Page 186 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 172: Exploded View Of Shift Lever & Console Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Page 187 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 173: Exploded View Of Shift Lever & Control Cable & Torque Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. DISCONNECT CONTROL CABLES FROM TRANSAXLE a. Remove the 2 clips and 2 washers.
Page 188 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 174: Disconnecting Control Cables From Transaxle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE SHIFT AND SELECT CONTROL CABLES a. Remove the front console box (See REMOVAL ). b. Remove the No. 1 and No. 2 instrument panel under cover (See REMOVAL ).
Page 189 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 175: Removing Bolts Of Shift Lever & Control Cables Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION Installation is in the reverse order of removal (See REMOVAL). NOTE: When installing the 2 control cables, you must observe the following items.
Page 190 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 TRANSFER (4WD) ON-VEHICLE REPAIR REPLACE TRANSFER OIL a. Loosen the filler plug. b. Remove the drain plug. HINT: Use a container to catch the transfer oil. c. Remove the filler plug.
Page 191 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 176: Identifying Transfer Case Filler Plug Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COMPONENTS...
Page 192 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 177: Exploded View Of Transfer & Torque Specifications (4WD) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY 1. REMOVE GASKET...
Page 193 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 178: Removing Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. REMOVE NO. 2 INTERMEDIATE DIFFERENTIAL SIDE GEAR...
Page 194 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 179: Removing No. 2 Intermediate Differential Side Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. REMOVE NO. 1 CASE COVER a. Remove the 8 bolts.
Page 195 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 180: Removing Bolts Of No. 1 Case Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a brass bar and hammer, remove the No. 1 case cover. NOTE: Be careful not to damage the transfer case and case cover No. 1.
Page 196 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 181: Removing No. 1 Case Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the bolt and breather oil deflector from the case cover No. 1. 4. REMOVE PIN...
Page 197 6. INSTALL TRANSFER ON OVERHAUL ATTACHMENT Fig. 182: Removing Bolt Of Breather Oil Deflector From Case Cover No. 1 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. REMOVE EXTENSION HOUSING a. Using a plastic hammer, remove the dust deflector from the extension housing.
Page 198 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 183: Removing Dust Deflector From Extension Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, remove the oil seal from the extension housing. SST 09308-00010 NOTE: Be careful not to damage the extension housing.
Page 199 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 184: Removing Oil Seal From Extension Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 4 bolts.
Page 200 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 185: Removing Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a plastic hammer, remove the extension housing.
Page 201 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 186: Removing Extension Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. CHECK PRELOAD a. Using SST and a torque wrench, measure the driven pinion preload of the backlash between the driven pinion and ring gear.
Page 202 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 187: Measuring Driven Pinion Preload Of Backlash Between Driven Pinion & Ring Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Using a torque wrench with a fulcrum length of 160 mm (6.3 in.).
Page 203 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Total preload (at starting): 1.0 to 1.6 N.m (10 to 16 kgf.cm, 8.9 to 14 in.lbf) HINT: Using a torque wrench with a fulcrum length of 160 mm (6.3 in.). ...
Page 204 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 188: Measuring Ring Gear Backlash Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. REMOVE CENTER DIFFERENTIAL LOCK SLEEVE a. Using a snap ring pliers, remove the shaft snap ring.
Page 205 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 189: Removing Shaft Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, remove the center differential lock sleeve. SST 09308-00010 NOTE: Be careful not to damage the center differential lock sleeve.
Page 206 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 190: Removing Center Differential Lock Sleeve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a screwdriver, remove the O-ring from the center differential lock sleeve. NOTE: Be careful not to damage the center differential lock sleeve.
Page 207 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 191: Removing O-Ring From Center Differential Lock Sleeve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. REMOVE OIL SEAL Using SST, remove the oil seal from the transfer case. SST 09308-00010 NOTE: Be careful not to damage the transfer case.
Page 208 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 192: Removing Oil Seal From Transfer Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. REMOVE BEARING RETAINER RH a. Using SST, remove the oil seal from the bearing retainer RH.
Page 209 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 193: Removing Oil Seal From Bearing Retainer RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 7 bolts.
Page 210 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 194: Removing Bearing Retainer Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a screwdriver and a hammer, make clearance by hitting between the bearing retainer RH and the transfer case.
Page 211 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 195: Making Clearance By Hitting Between Bearing Retainer RH & Transfer Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using SST, remove the bearing retainer RH from the transfer case. SST 09520-10021...
Page 212 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 196: Removing Bearing Retainer RH From Transfer Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using a screwdriver, remove 2 O-rings from the bearing retainer RH. NOTE: Be careful not to damage the bearing retainer RH.
Page 213 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 197: Removing O-Rings From Bearing Retainer RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Using soft jaws, hold the bearing retainer RH in a vise. g. Using SST, remove the outer race, washer and oil seal from the bearing retainer RH.
Page 214 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 198: Removing Outer Race From Bearing Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Using snap ring pliers, remove the snap ring.
Page 215 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 199: Removing Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. i. Remove the side gear shaft holder bearing from the bearing retainer RH.
Page 216 14. REMOVE CENTER DIFFERENTIAL CONTROL COUPLING ASSEMBLY Fig. 200: Removing Center Differential Control Coupling Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. REMOVE TAPERED ROLLER BEARING LH AND RH Using SST, remove the tapered roller bearing inner race LH and RH.
Page 217 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4...
Page 218 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 201: Removing Tapered Roller Bearing Inner Race LH & RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. CHECK RING GEAR RUNOUT Using a dial indicator, check the ring gear runout.
Page 219 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 203: Placing Matchmarks On Both Ring Gear & Center Differential Control Coupling Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a plastic hammer, remove the ring gear.
Page 220 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 204: Removing Ring Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. CHECK CENTER DIFFERENTIAL CONTROL COUPLING RUNOUT Using a dial indicator, check the center differential control coupling runout. Maximum runout: 0.07 mm (0.0028 in.)
Page 221 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 205: Checking Center Differential Control Coupling Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. REMOVE DRIVEN PINION a. Using SST and a hammer, unstake the lock nut. SST 09930-00010 (09931-00010, 09931-00020)
Page 222 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 206: Using SST & A Hammer To Unstake Lock Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, remove the lock nut. SST 09326-20011, 09556-16030...
Page 223 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 207: Removing Lock Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a press, remove the driven pinion, the rear bearing inner race and the spacer.
Page 224 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 208: Removing Driven Pinion, Rear Bearing Inner Race & Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Place a waste cloth inside the case to prevent the driven pinion ...
Page 225 Using SST and a press, remove the front bearing inner race from the driven pinion. SST 09950-00020 Fig. 209: Removing Front Bearing Inner Race From Driven Pinion Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 20. REMOVE BEARING OUTER RACE LH Using a brass bar and a hammer, remove the outer race and the washer.
Page 226 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 210: Removing Bearing Outer Race LH And Washer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. REMOVE FRONT BEARING OUTER RACE Using a brass bar and a hammer, remove outer race and washer.
Page 227 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 211: Removing Front Bearing Outer Race And Washer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. REMOVE REAR BEARING OUTER RACE Using a brass bar and a hammer, remove outer race.
Page 228 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 212: Removing Rear Bearing Outer Race Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY 1. INSTALL REAR BEARING OUTER RACE Using SST and a press, install the outer race. SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
Page 229 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 213: Installing Rear Bearing Outer Race Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. INSTALL FRONT BEARING OUTER RACE a. Install the washer to the transfer case. HINT: First install a washer of the same thickness as before.
Page 230 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 214: Installing Front Bearing Outer Race To Transfer Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. INSTALL BEARING OUTER RACE LH a. Install the washer to the transfer case.
Page 231 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 215: Installing Bearing Outer Race LH To Transfer Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. INSTALL DRIVEN PINION a. Using SST and a press, install the front bearing inner race to the driven pinion.
Page 232 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 216: Installing Front Bearing Inner Race To Driven Pinion Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the driven pinion to the transfer case.
Page 233 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 217: Installing Driven Pinion To Transfer Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the new spacer and the rear bearing inner race to the driven pinion. d. Coat gear oil (LSD type) to the thread of a new lock nut.
Page 234 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 218: Installing Spacer & Rear Bearing Inner Race To Driven Pinion Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using SST, install the lock nut. SST 09326-20011, 09556-16030...
Page 235 308 N.m (3,142 kgf.cm, 227 ft.lbf) for use with SST 349 N.m (3,560 kgf.cm, 257 ft.lbf) Fig. 219: Installing Lock Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Using a torque wrench with a fulcrum length of 380 mm (15.03 in.).
Page 236 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 SST 09326-2001 Preload (at starting): New bearing: 0.9 to 1.4 N.m (9 to 14 kgf.cm, 7.8 to 12.4 in.lbf) Reused bearing: 0.8 to 1.1 N.m (8 to 11 kgf.cm, 7.0 to 9.7 in.lbf)
Page 237 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 220: Measuring Driven Pinion Preload Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Using a torque wrench with a fulcrum length of 160 mm (6.3 in.).  This torque value is effective in case that SST is parallel to torque wrench.
Page 238 Heat the ring gear in water and boil for 10 minutes. Fig. 221: Heating Ring Gear In Boiling Water Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Carefully remove the ring gear from the water. d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the...
Page 239 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 222: Installing Ring Gear To Center Differential Control Coupling (Line-up Matchmarks) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Install the 12 bolts. Torque: 77.5 N.m (791 kgf.cm, 57 ft.lbf) f. Using SST and a press, install the center differential case tapered roller bearing inner race LH and...
Page 240 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4...
Page 241 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 223: Installing Center Differential Case Tapered Roller Bearing Inner Race LH & RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. INSTALL CENTER DIFFERENTIAL CONTROL COUPLING ASSEMBLY Fig. 224: Installing Center Differential Control Coupling Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Page 242 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 225: Installing Outer Race To Bearing Retainer RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. INSTALL BEARING RETAINER RH a. Place the transfer with the installation surface for the retainer upward.
Page 243 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 226: Installing Bearing Retainer RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Insert the SST into the retainer. SST 09387-00090 NOTE: Insert the SST straight down without making its tip interfered the lip...
Page 244 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 227: Inserting SST Into Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Insert the retainer and the SST into the case together as a unit.
Page 245 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 228: Inserting Retainer & SST Into Case Together As A Unit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Do not make the transfer case, bearing retainer RH and SST ...
Page 246 Install the 7 bolts. Torque: 28 N.m (286 kgf.cm, 115 ft.lbf) Fig. 229: Removing SST From Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. INSPECT BACKLASH Using a dial indicator, measure the backlash of the ring gear at 3 positions at least.
Page 247 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 230: Measuring Backlash Of Ring Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: The measure values should be used as reference when selecting washer, so take a note of the values.
Page 248 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 231: Identifying Washer For Backlash Adjusting Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Washer thickness: mm (in.) THICKNESS SPECIFICATION CHART Mark Thickness Mark Thickness 2.07 (0.0815) FB 2.55 (0.1004) 2.10 (0.0827) FC 2.58 (0.1016) 2.13 (0.0839) GA 2.61 (0.1028)
Page 249 Coat 3 or 4 teeth at the 4 different positions on the ring gear with red lead. Fig. 232: Coating Teeth On Ring Gear With Red Lead Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Rotate the ring gear, inspect the teeth pattern.
Page 250 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 233: Locating Teeth Pattern Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. If the teeth are not contacting properly, select the proper washer again.
Page 251 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 234: Identifying Washer Tooth Contact Adjusting Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Washer thickness: mm (in.) THICKNESS SPECIFICATION CHART Mark Thickness Mark Thickness 1.20 (0.0472) HC 1.43 (0.0563) 1.21 (0.0476) JA 1.44 (0.0567) 1.22 (0.0480) JB 1.45 (0.0571)
Page 252 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 1.31 (0.0516) MB 1.54 (0.0606) 1.32 (0.0520) MC 1.55 (0.0610) 1.33 (0.0524) NA 1.56 (0.0614) 1.34 (0.0528) NB 1.57 (0.0618) 1.35 (0.0531) NC 1.58 (0.0622) 1.36 (0.0535) PA 1.59 (0.0626) 1.37 (0.0539) PB 1.60 (0.0630) 1.38 (0.0543) PC 1.61 (0.0634)
Page 253 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 235: Measuring Preload Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: Using a torque wrench with a fulcrum length of 160 mm (6.3 in.). HINT: Turn the driven pinion counterclockwise and clockwise several times.
Page 254 2005 TRANSMISSION Manual Transaxle - RAV4 If the preload is not as specified, select a proper washer again. Fig. 236: Identifying Washer Preload Adjusting Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Washer thickness: mm (in.) THICKNESS SPECIFICATION CHART Mark Thickness Mark Thickness 1.47 (0.0579) GB 2.04 (0.0803)
Page 255 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 1.68 (0.0661) JC 2.25 (0.0886) 1.71 (0.0673) KA 2.28 (0.0898) 1.74 (0.0685) KB 2.31 (0.0909) 1.77 (0.0697) KC 2.34 (0.0921) 1.80 (0.0709) LA 2.37 (0.0933) 1.83 (0.0720) LB 2.40 (0.0945) 1.86 (0.0734) LC 2.43 (0.0957) 1.89 (0.0744) MA 2.46 (0.0969)
Page 256 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 237: Removing Bolts Of Bearing Retainer RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver and a hammer, make clearance by hitting between the bearing retainer RH and the transfer case.
Page 257 Fig. 238: Using A Screwdriver & A Hammer To Make Clearance By Hitting Between Bearing Retainer RH & Transfer Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using SST, remove the bearing retainer RH from the transfer case. SST 09520-10021...
Page 258 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 239: Removing Bearing Retainer RH From Transfer Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using SST, remove the outer race and washer from the bearing retainer RH. SST 09308-00010...
Page 259 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 240: Removing Outer Race & Washer From Bearing Retainer RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. ASSEMBLE BEARING RETAINER RH a. Install the side gear shaft holder bearing to the bearing retainer RH.
Page 260 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 241: Installing Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Coat the oil seal lip with MP grease. d. Using SST and a press, install the oil seal to the bearing retainer RH.
Page 261 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 242: Installing Oil Seal To Bearing Retainer RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Install the washer. f. Using SST and a press, install the outer race to the bearing retainer RH...
Page 262 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 243: Installing Outer Race To Bearing Retainer RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Coat new 2 O-rings with gear oil, and install them to the bearing retainer RH.
Page 263 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 244: Installing O-Rings To Bearing Retainer RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. INSTALL BEARING RETAINER RH a. Place the transfer with the installation surface for the retainer upward.
Page 264 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 245: Installing Bearing Retainer RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Insert the SST into the retainer. SST 09387-00090 NOTE: Insert the SST straight down without making its tip interfered the lip...
Page 265 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 246: Inserting SST Into Retainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Insert the retainer and the SST into the case together as a unit.
Page 266 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 247: Inserting Retainer & SST Into Case As Unit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Do not strongly make the case and retainer interfered. Neither  the SST or the center differential control coupling.
Page 267 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4...
Page 268 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 248: Identifying Oil Seal & O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: When the retainer cannot be inserted in the case, give a slight blow with a plastic hammer and insert it.
Page 269 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 249: Installing Oil Seal To Bearing Retainer RH Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Coat the oil seal lip with MP grease. d. Using SST, install the oil seal to the transfer case.
Page 270 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 250: Installing Oil Seal To Transfer Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. INSTALL CENTER DIFFERENTIAL LOCK SLEEVE a. Coat new O-ring with gear oil, install it to the center differential lock sleeve.
Page 271 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 251: Installing O-Ring To Center Differential Lock Sleeve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, install the center differential lock sleeve to the transfer case. SST 09950-60010 (09951-00600), 09950-70010 (09951-07150)
Page 272 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 252: Installing Center Differential Lock Sleeve To Transfer Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using snap ring pliers, install the snap ring.
Page 273 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 253: Installing Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. STAKE LOCK NUT Using a chisel and a hammer, stake the lock nut.
Page 274 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 254: Using A Chisel & A Hammer To Stake Lock Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 20. INSTALL EXTENSION HOUSING a. Coat the oil seal lip with MP grease.
Page 275 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 255: Installing Oil Seal To Extension Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using SST and a press, install the dust deflector to the extension housing. SST 09950-60010 (09951-00640), 09950-70010 (09951-07150)
Page 276 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 256: Installing Dust Deflector To Extension Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the extension housing and the transfer case.
Page 277 2005 TRANSMISSION Manual Transaxle - RAV4 Part No. 08826-00100, THREE BOND 1281 or equivalent Fig. 257: Locating Seal Bend Width Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Install the extension housing with 4 bolts. Torque: 25.5 N.m (260 kgf.cm, 19 ft.lbf)
Page 278 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 258: Installing Extension Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. INSTALL STUD BOLT Install the 4 new stud bolts to the transfer case. Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf)
Page 279 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4...
Page 280 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 259: Installing Stud Bolts To Transfer Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HINT: From the bottom side of the stud bolt shown in Fig. 259, it should be installed to the case.
Page 281 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 261: Installing Bolts Of Oil Deflector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the case cover and the transfer case.
Page 282 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 262: Identifying Seal Bend Width Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the No. 1 case cover with 2 new seal bolts and 6 bolts. Torque: 19.6 N.m (200 kgf.cm, 14 ft.lbf)
Page 283 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 263: Identifying Location Of Seal Bolts (x2) In No. 1 Case Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. INSTALL INTERMEDIATE SHAFT 26. INSTALL GASKET Coat new gasket with ATF, install it to the transfer case.
Page 284 2005 Toyota RAV4 2005 TRANSMISSION Manual Transaxle - RAV4 Fig. 264: Installing Gasket Into Transfer Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Toyota 2005 RAV4 Troubleshooting Manual

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TROUBLESHOOTING

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Summary of Contents for Toyota 2005 RAV4

Page 1: Troubleshooting

Page 22: Manual Transaxle Assembly

Page 74: Input Shaft

Page 91: Output Shaft