Toyota RAV4 2000-05

Transaxle Removal & Installation

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2wd





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Fig. Manual transaxle and related components-2000-2003 2WD

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner case assembly with hose
     
    Engine coolant reservoir tank
     
    Engine wire clamp set nut
     
    Starter
     

  4.  
  5. Remove the clutch release cylinder, as follows:

    Clutch line bracket-to-transaxle set bolts
     
    Release cylinder and line
     

  6.  
  7. Remove or disconnect the following:

    Ground cable from the transaxle
     
    Vehicle Speed Sensor (VSS) and backup light switch connector
     
    Control cable by removing the 4 clips and washers
     
    4 upper side transaxle-to-engine bolts
     
    Left mount insulator
     

  8.  
  9. Install a engine support to the engine.
  10.  
  11. Support rack and pinion to the engine support fixture with a rope.
  12.  
  13. Remove or disconnect the following:

    Front wheels
     
    Left and right side engine undercovers
     

  14.  
  15. Drain the transaxle oil.
  16.  
  17. Remove the left and right halfshafts.
  18.  
  19. Remove the front exhaust pipe, as follows:

    3 exhaust manifold nuts and gasket
     
    Both exhaust pipe-to-center exhaust pipe bolts
     
    Exhaust pipe
     

  20.  
  21. Remove the front suspension crossmember assembly with the sway bar, as follows:
    1. Support the front suspension crossmember with a jack.
    2.  
    3. Disconnect the ring from the center exhaust pipe.
    4.  
    5. Remove the 2 set bolts and nuts of the power steering rack and pinion assembly.
    6.  
    7. Remove the suspension crossmember assembly with the sway bar by removing the 2 nuts and 6 bolts.
    8.  

  22.  
  23. Remove the engine mounting centermember by removing the 4 bolts.
  24.  
  25. Jack up the transaxle slightly.
  26.  
  27. Remove or disconnect the following:

    Left mounting bracket from the mounting insulator by removing the set bolt
     
    Stiffener plate, No. 2 rear endplate and transaxle lower side mounting bolt
     

  28.  
  29. Lower the engine left side
  30.  
  31. Remove or disconnect the following:

    Transaxle
     
    Transaxle case protector by removing both bolts
     

  32.  

To install:

  1. Install or connect the following:

    Transaxle case protector. Tighten both bolts to 18 ft. lbs. (25 Nm).
     
    Transaxle
     

  2.  
  3. Install the No. 2 rear endplate and transaxle bolts. Tighten the bolts, as follows:

    Bolt C: 22 ft. lbs. (29 Nm)
     
    Bolt D: 34 ft. lbs. (46 Nm)
     
    Bolt E: 18 ft. lbs. (25 Nm)
     
    Bolt F: 78 inch lbs. (9.0 Nm)
     

  4.  
  5. Install or connect the following:

    Stiffener plate. Tighten both bolts to 27 ft. lbs. (37 Nm).
     
    Engine left mounting insulator to the left mounting bracket. Tighten the bolt to 47 ft. lbs. (64 Nm).
     
    Engine mount centermember. Tighten the radiator support bolts to 26 ft. lbs. (35 Nm) and the mount insulator to 59 ft. lbs. (80 Nm).
     

  6.  
  7. Install the front suspension crossmember with the sway bar, as follows:
    1. Install the sway bar and suspension crossmember. Tighten the nuts/bolts, as follows:

      Vehicle bolt A: 152 ft. lbs. (206 Nm)
       
      Lower control arm bracket bolt B: 101 ft. lbs. (137 Nm)
       
      Rear mounting bracket bolt C: 82 ft. lbs. (112 Nm)
       

    2.  
    3. Connect the rack and pinion to the crossmember. Tighten both nuts/bolts to 83 ft. lbs. (113 Nm).
    4.  
    5. Connect the ring for the center exhaust pipe.
    6.  

  8.  
  9. Install the front exhaust pipe, as follow:

    Pipe with new gaskets
     
    Front pipe to the center exhaust pipe. Tighten both bolts to 35 ft. lbs. (48 Nm).
     
    Front exhaust pipe to the exhaust manifold. Tighten the 3 nuts to 46 ft. lbs. (62 Nm).
     

  10.  
  11. Install or connect the following:

    Left and right halfshafts
     
    Front wheels
     
    Engine left mounting insulator. Tighten the fasteners to 47 ft. lbs. (64 Nm).
     

  12.  
  13. Remove the engine support fixture.
  14.  
  15. Install or connect the following:

    4 transaxle upper side mount bolts. Tighten bolt A to 47 ft. lbs. (64 Nm) and bolt B to 26 ft. lbs. (35 Nm).
     
    Ground cable with the clips and washers
     
    VSS and backup light switch connectors
     
    Ground cable to the transaxle
     
    Clutch release cylinder and line
     
    Starter. Tighten both bolts to 29 ft. lbs. (39 Nm).
     
    Engine wire clamp with the nut
     
    Engine coolant reservoir tank
     
    Air cleaner case assembly with the air hose
     
    Negative battery cable
     

  16.  
  17. Fill the transaxle with fluid. Check all fluids.
  18.  



Click image to see an enlarged view

Fig. Manual transaxle and related components-2004-2005 2WD

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the hood.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the coolant reservoir.
  10.  
  11. Remove the control cables from the transaxle.
  12.  
  13. Remove the wiring from the speed sensor and back-up light switch.
  14.  
  15. Remove the ground cable from the transaxle.
  16.  
  17. Remove the starter.
  18.  
  19. Remove the clutch release cylinder.
  20.  
  21. Remove the 5 upper transaxle-to-engine bolts.
  22.  
  23. Attach an engine support fixture, such as 12281-28010, or equivalent.

    Click image to see an enlarged view

    Fig. Attach an engine support fixture, such as 12281-28010, or equivalent-2004-2005 2WD

  24.  
  25. Disconnect the left engine mount from the transaxle.
  26.  
  27. Remove the engine under-covers.
  28.  
  29. Drain the transaxle.
  30.  
  31. Remove the front exhaust pipe.
  32.  
  33. Remove the halfshafts.
  34.  
  35. Remove the stabilizer bar.
  36.  
  37. Remove the power steering gear mounting bolts. Support the gear.
  38.  
  39. Remove the front suspension crossmember.
  40.  
  41. Remove the engine mount center member.
  42.  
  43. Using a transaxle jack, slightly raise the transaxle.
  44.  
  45. Remove the lower transaxle-to-engine bolts and lower the transaxle from the vehicle.
  46.  
  47. Installation is the reverse of removal. Observe the following torques:

    Lower transaxle-to-engine bolts (see the illustration): bolts -A- 34 ft. lbs. (46 Nm); bolt -B- 32 ft. lbs. (44 Nm)

    Click image to see an enlarged view

    Fig. Lower transaxle-to-engine bolts-2004-2005 2WD



    Click image to see an enlarged view

    Fig. Center member and front member bolts-2004-2005 2WD

     
    Engine mount center member (see the illustration): bolt -E- 59 ft. lb. (80 Nm); bolts -F- 28 ft. lbs. (39 Nm)
     
    Front suspension crossmember (see the illustration): bolt -A- 82 ft. lbs. (113 Nm); bolt -B- 115 ft. lbs. (157 Nm); bolts -C- and -D- 53 ft. lbs. (72 Nm)
     
    Power steering gear set bolts: 101 ft. lbs. (137 Nm)
     
    Stabilizer bar links: 32 ft. lbs. (44 Nm)
     
    Exhaust pipe-to-manifold: 32 ft. lbs. (43 Nm)
     
    Exhaust pipe-to-pipe: 14 ft. lbs. (19 Nm)
     
    Left engine mount through-bolt: 41 ft. lbs. (56 Nm)

    Click image to see an enlarged view

    Fig. Upper transaxle-to-engine bolts-2004-2005 2WD

     
    Upper transaxle-to-engine bolts (see the illustration): bolts -A- 47 ft. lbs. (64 Nm); bolts -B- 34 ft. lbs. (46 Nm)
     

  48.  
  49. Clutch release cylinder (see the illustration): bolt -A- 18 ft. lbs. (25 Nm); bolt -B- 9 ft. lbs. (12 Nm); bolt -C- 44 inch lbs. (5 Nm)

    Click image to see an enlarged view

    Fig. Clutch release cylinder bolts-2004 2WD



    Starter: 28 ft. lbs. (37 Nm)
     
    Hood: 10 ft. lbs. (13 Nm)
     

  50.  

4wd





Click image to see an enlarged view

Fig. Manual transaxle and related components-2000-2003 4WD

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Transaxle/engine assembly
     
    Transaxle case protector, by removing the 2 bolts
     
    Starter
     
    Transfer vacuum actuator bracket, by removing the 4 bolts
     

  4.  
  5. Remove the transfer vacuum actuator assembly, as follows:

    4 solenoid hoses from the transfer vacuum actuator assembly
     
    Transfer vacuum actuator assembly, by removing the 2 bolts
     

  6.  
  7. Remove or disconnect the following:

    Right transfer stiffener plate, by removing the 5 bolts
     
    Center transfer stiffener plate, by removing the 3 bolts
     
    Stiffener plate by removing the 2 bolts
     
    Transaxle from the engine, by removing the 9 transaxle mount bolts
     

  8.  

To install:

  1. Connect the transaxle to the engine. Tighten the 9 bolts, as follows:

    Bolt A: 47 ft. lbs. (64 Nm)
     
    Bolt B: 26 ft. lbs. (35 Nm)
     
    Bolt C: 22 ft. lbs. (29 Nm)
     
    Bolt D: 34 ft. lbs. (46 Nm)
     
    Bolt E: 18 ft. lbs. (25 Nm)
     
    Bolt F: 78 inch lbs. (9.0 Nm)
     

  2.  
  3. Install or connect the following:

    Stiffener plate. Tighten both bolts to 27 ft. lbs. (37 Nm).
     
    Center transfer stiffener plate. Tighten the 3 bolts to 27 ft. lbs. (37 Nm).
     
    Right transfer stiffener plate. Tighten the 5 bolts to 27 ft. lbs. (37 Nm).
     

  4.  
  5. Install the transfer vacuum actuator assembly, as follows:

    Transfer vacuum actuator assembly. Tighten both bolts to 27 ft. lbs. (37 Nm).
     
    4 solenoid hoses to the transfer vacuum actuator assembly
     

  6.  
  7. Install or connect the following:

    Transfer vacuum actuator bracket. Tighten the 4 bolts to 27 ft. lbs. (37 Nm).
     
    Starter. Tighten both bolts to 29 ft. lbs. (39 Nm).
     
    Transaxle case protector. Tighten both bolts to 18 ft. lbs. (25 Nm).
     
    Transaxle/engine assembly
     

  8.  



Click image to see an enlarged view

Fig. Manual transaxle and related components-2004-2005 4WD



Click image to see an enlarged view

Fig. Manual transaxle bolt identification-2004-2005 4WD

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine and transaxle as a unit, from the vehicle.
  6.  
  7. Remove the transaxle case protector.
  8.  
  9. Remove the engine-to-transaxle wiring.
  10.  
  11. Remove the stiffener plate.
  12.  
  13. Remove the 10 bolts and separate the transaxle from the engine.
  14.  
  15. Installation is the reverse of removal. Observe the following torques:

    Transaxle-to-engine (see the illustration): bolt -A- 47 ft. lbs. (64 Nm); bolt -B- 34 ft. lbs. (46 Nm); bolt -C- 32 ft. lbs. (44 Nm)
     
    Stiffener plate: 25 ft. lbs. (34 Nm)
     
    Case protector: 13 ft. lbs. (18 Nm)
     

  16.  

 
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