Manual Transmission

2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
2005 TRANSMISSION
Manual Transaxle - RAV4
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
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.
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Tuesday, July 21, 2009 9:47:32
9:47:22 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
2005 Toyota 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.

d. Reinstall the drain plug.
Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
e. Refill new transaxle oil as shown, see Fig. 2.
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 2.5 liters (2.6 US qts, 2.2 Imp.qts)
f. Reinstall the filler plug.
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Tuesday, July 21, 2009 9:47:22 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.
2005 Toyota RAV4
Fig. 2: Identifying Transaxle Filler Plug

COMPONENTS
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2005 Toyota RAV4
Fig. 3: Exploded View Of R&I Components Related To Manual Transaxle & Torque Specifications
(2WD) (1 Of 2)
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2005 Toyota RAV4
Fig. 4: Exploded View Of R&I Components Related To Manual Transaxle & Torque Specifications
(2WD) (2 Of 2)
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2005 Toyota RAV4
REMOVAL
1. REMOVE HOOD
Remove the 4 bolts and hood.
Torque: 13 N.m (133 kgf.cm, 9.6 ft.lbf)
HINT:
At the time of installation, refer to the following item. Adjust the hood (See ADJUSTMENT ).
2. REMOVE AIR CLEANER ASSEMBLE WITH AIR HOSE

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

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2005 Toyota RAV4
5. DISCONNECT VEHICLE SPEED SENSOR AND BACK-UP LIGHT SWITCH CONNECTORS

6. DISCONNECT GROUND CABLE FROM TRANSAXLE
Remove the bolt and disconnect the ground cable.
Fig. 6: Disconnecting Ground Cable

7. REMOVE STARTER
a. Disconnect the starter connector.
b. Remove the nut and disconnect the starter cable.
c. Remove the 2 bolts and starter.
8. DISCONNECT CLUTCH RELEASE CYLINDER AND LINE

a. Remove the 3 bolts.
Torque:
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2005 Toyota RAV4
25 N.m (255 kgf.cm, 18 ft.lbf) for bolt A
12 N.m (120 kgf.cm, 9 ft.lbf) for bolt B
5 N.m (51 kgf.cm, 44 in.lbf) for bolt C
b. Remove the 2 bolts and heat insulator.
c. Remove the 2 bolts and disconnect the release cylinder and line.
Fig. 7: Removing Clutch Release Cylinder & Lines

9. REMOVE 5 MOUNTING BOLTS OF TRANSAXLE UPPER SIDE
Torque:
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Fig. 8: Removing Mounting Bolts Of Transaxle Upper Side

10. ATTACH ENGINE SUPPORT FIXTURE

a. Install the No. 2 engine hanger in the correct direction. Parts No. :
No. 2 engine hanger: 12281-28010
Bolt: 91512-61020
b. Using an engine sling device, attach the engine support fixture to the engine hangers.
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Fig. 9: Attaching Engine Support Fixture To Engine Hangers

11. DISCONNECT LEFT ENGINE MOUNTING INSULATOR FROM TRANSAXLE
Remove the bolt and nut.
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2005 Toyota RAV4
Fig. 10: Disconnecting Left Engine Mounting Insulator From Transaxle

12. REMOVE LH AND RH ENGINE UNDER COVERS

13. DRAIN TRANSAXLE OIL (See MANUAL TRANSAXLE UNIT (2WD))
14. REMOVE FRONT EXHAUST PIPE
a. Remove the 2 bolts and springs from the exhaust manifold.
b. Remove the 2 bolts and 2 gaskets with pipe.
HINT:
At the time of installation, using the new gasket.
15. REMOVE LH AND RH FRONT DRIVE SHAFTS (See REMOVAL )

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16. DISCONNECT 2 STABILIZER BAR LINKS
Remove the 2 nuts and disconnect the LH and RH stabilizer bar links.
Fig. 11: Disconnecting LH & RH Stabilizer Bar Links

17. REMOVE FRONT SUSPENSION CROSSMEMBER ASSEMBLY WITH STABILIZER BAR

a. Support the front suspension crossmember with a jack.
b. Remove the 2 set bolts of the PS gear assembly.
Torque: 137 N.m (1,397 kgf.cm, 101 ft.lbf)
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Fig. 12: Removing Set Bolts Of PS Gear Assembly

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
N.m (734 kgf.cm, 53 ft.lbf) Nut D: 72 N.m (734 kgf.cm, 53 ft.lbf)
18. REMOVE ENGINE MOUNTING CENTER MEMBER
Remove the 4 bolts and center member.
Torque:
Bolt E: 80 N.m (820 kgf.cm, 59 ft.lbf) Bolt F: 39 N.m (400 kgf.cm, 28 ft.lbf)
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Fig. 13: Removing Bolts Of Center Member

19. JACK UP TRANSAXLE SLIGHTLY
Using a transmission jack, support the transaxle.
20. REMOVE 4 MOUNTING BOLTS OF TRANSAXLE LOWER SIDE
Torque:
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Fig. 14: Removing Mounting Bolts Of Transaxle Lower Side

21. REMOVE TRANSAXLE
Lower the engine left side, then slowly and carefully remove the transaxle from the engine.
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.
 Temporarily tighten the transaxle mounting bolts.
INSTALLATION
Installation is in the reverse order of removal (See REMOVAL).
HINT:
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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

HINT:
Use a container to catch the transaxle oil.

e. Refill new transaxle oil as shown, see Fig. 15.
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 3.4 liters (3.6 US qts, 3.0 Imp.qts)
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Fig. 15: Identifying Transaxle Filler Plug

COMPONENTS
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Fig. 16: Exploded View Of Manual Transaxle & Torque Specifications (4WD)
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REMOVAL
1. REMOVE TRANSAXLE WITH ENGINE (See REMOVAL )

2. REMOVE TRANSAXLE CASE PROTECTOR
Remove the 2 bolts and transaxle case protector.
3. DISCONNECT BACK-UP LIGHT SWITCH AND VEHICLE SPEED SENSOR CONNECTORS

4. REMOVE TRANSFER STIFFENER PLATE
Remove the 5 bolts and stiffener plate.
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Fig. 17: Removing Stiffener Plate

5. REMOVE TRANSAXLE FROM ENGINE
Remove the 10 bolts, separate the engine and transaxle.
Torque:
44 N.m (440 kgf.cm, 32 ft.lbf) for bolt C
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Fig. 18: Removing Transaxle From Engine

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.
 Temporarily tighten the transaxle mounting bolts.
INSTALLATION
HINT:
After installation, check and inspect items as follows.

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 Check the front wheel alignment (See FRONT WHEEL ALIGNMENT ).

 Do the road test.
MANUAL TRANSAXLE ASSEMBLY

COMPONENTS
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Fig. 19: Exploded View Of Manual Transaxle Assembly & Torque Specifications (1 Of 5)
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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
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 78.4 N.m (800 kgf.cm, 58 ft.lbf)
b. Remove the 6 nuts.
Torque:
78.4 N.m (800 kgf.cm, 58 ft.lbf) for 17 mm nut
29.4 N.m (300 kgf.cm, 22 ft.lbf) for 14 mm nut
c. Using a plastic hammer, remove the transfer assembly from the transaxle.
HINT:
At the time of reassembly, refer to the following item.
 Shift into the 4th gear, and install the transfer assembly while turning the input shaft of the
transaxle.
 It is possible to apply FIPG either transaxle side or transfer side. In addition, be sure to apply
it on the center of the seal.
FIPG:
Part No. 08826-00100, THREE BOND 1281 or equivalent
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Fig. 24: Applying FIPG To Either Transaxle Side Or Transfer Side

3. 4WD:
REMOVE DIFFERENTIAL SIDE GEAR INTERMEDIATE SHAFT
4. REMOVE FILLER PLUG AND DRAIN PLUG WITH 2 GASKETS
5. REMOVE BACK-UP LIGHT SWITCH WITH GASKET
6. REMOVE BOLT AND VEHICLE SPEED SENSOR
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7. REMOVE CONTROL CABLE BRACKET
Remove the 3 bolts and control cable bracket.
8. REMOVE CLUTCH TUBE BRACKET
Remove the bolt and tube bracket.
9. REMOVE SELECTING BELLCRANK ASSEMBLY
Remove the 2 bolts and the selecting bellcrank assembly.
Fig. 25: Removing Selecting Bellcrank Assembly

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10. REMOVE CONTROL SHIFT LEVER AND DUST BOOT

a. Remove the nut and wave washer.
Torque: 6.4 N.m (65 kgf.cm, 57 in.lbf)
Fig. 26: Removing Control Shift Lever

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.

When fixing the lever lock pin, properly position the shaft groove.
c. Remove the control shift lever and dust boot.
NOTE: At the time of reassembly, refer to the following items.
 Install the dust boot into a groove in the control shift lever.
 Be sure to install the dust boot in the correct direction.
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Fig. 27: Tapping Out Lever Lock Pin

11. REMOVE LOCK BALL ASSEMBLY AND SHIFT AND SELECT LEVER SHAFT ASSEMBLY
a. Remove the lock ball assembly.
Sealant:
b. Remove the 4 bolts, shift and select lever shaft assembly and gasket.
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Fig. 28: Removing Shift & Select Lever Shaft Assembly

Sealant:
12. REMOVE CONTROL SHAFT COVER
Remove the control shaft cover from the shift and select lever shaft assembly.
NOTE: At the time of reassembly, refer to the following item.

Set the claws of the shift interlock plate into the shift head part of the gear
shift fork shaft securely.
13. REMOVE TRANSMISSION CASE COVER
Remove the 10 bolts and transmission case cover.

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FIPG:
Part No. 08826-00100, THREE BOND 1282B or equivalent
14. REMOVE BREATHER PLUG WITH GASKET
Fig. 29: Applying FIPG To Transmission Case Cover

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15. REMOVE OUTPUT SHAFT LOCK NUT

a. Unstake the lock nut.
b. Engage the gear double meshing.
c. Remove the lock nut.
d. Disengage the gear double meshing.

16. REMOVE NO. 3 HUB SLEEVE AND NO. 3 SHIFT FORK
a. Remove the No. 3 shift fork set bolt.
b. Remove the No. 3 hub sleeve and No. 3 shift fork.
Fig. 30: Removing No. 3 Hub Sleeve & No. 3 Shift Fork
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17. REMOVE 5TH DRIVEN GEAR
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

18. MEASURE 5TH GEAR THRUST CLEARANCE AND RADIAL CLEARANCE

a. Using a dial indicator, measure the thrust clearance.
Maximum clearance: 0.65 mm (0.0256 in.)
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Fig. 32: Measuring 5th Gear Thrust Clearance

b. Using a dial indicator, measure the radial clearance.
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Fig. 33: Measuring Radial Clearance

19. REMOVE NO. 3 CLUTCH HUB AND 5TH GEAR

a. Using 2 screwdrivers and a hammer, tap out the snap ring.
HINT:
At the time of the reassembly, refer to the following item.
Select a snap ring that allows the minimum axial play.
THICKNESS SPECIFICATION CHART

Mark Thickness mm (in.) Mark Thickness mm (in.)
a 1.75 (0.0689) f 2.00 (0.0787)
b 1.80 (0.0709) g 2.05 (0.0807)
c 1.85 (0.0729) h 2.10 (0.0827)
d 1.90 (0.0748) j 2.15 (0.0847)
e 1.95 (0.0768) - -
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Fig. 34: Locating Snap Ring

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)
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Fig. 35: Removing Clutch Hub With Synchronizer Ring & 5th Gear
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.
Sealant:
22. REMOVE SNAP RING

a. Using a snap ring expander, remove the input shaft rear bearing snap ring.
b. Using 2 screwdrivers and a hammer, remove the 2 snap rings.
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Fig. 36: Removing Snap Rings

23. REMOVE STRAIGHT SCREW PLUG
Using a hexagon wrench (6 mm), remove the plug.
Sealant:
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Fig. 37: Removing Straight Screw Plug

24. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND WASHER
Sealant:
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Fig. 38: Removing Reverse Idler Gear Shaft Lock Bolt & Washer
25. REMOVE TRANSMISSION CASE

a. Transaxle case side:
Remove the 3 bolts.
b. Transmission case side:
Remove the 14 bolts and tap out the case with a plastic hammer.
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Fig. 39: Removing Bolts Of Transmission Case

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
transmission case side
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Fig. 40: Applying FIPG To Transmission Case

26. REMOVE SHIM
HINT:
At the time of reassembly, refer to the following item. Install the previously selected shim by adjusting
output shaft preload (See REASSEMBLY).
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Fig. 41: Removing Shim

27. REMOVE OUTPUT SHAFT REAR BEARING OUTER RACE
Using SST and a hammer, remove the output shaft rear bearing outer race.
SST 09316-60011 (09316-00011)
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Fig. 42: Removing Output Shaft Rear Bearing Outer Race

28. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY
Remove the 2 bolts and pull off the reverse shift arm and bracket.
29. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft, remove the reverse idler gear and thrust washer.
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Fig. 43: Removing Reverse Idler Gear & Thrust Washer

HINT:
At the time of reassembly, refer to the following item. Align the matchmarks, as shown, see Fig. 44.
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Fig. 44: Locating Matchmarks

30. REMOVE STRAIGHT SCREW PLUGS
Using a hexagon wrench (6 mm), remove the 2 plugs.
Sealant:
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Fig. 45: Removing Straight Screw Plugs

31. REMOVE 3 SHIFT FORK SET BOLTS
32. REMOVE NO. 1 SHIFT FORK SHAFT
Pull up the No. 3 shift fork shaft, remove the No. 1 shift fork shaft.
HINT:
At the time of reassembly, refer to the following item. When it is difficult to push the fork shaft through
the reverse shift fork, pull up the No. 3 shift fork shaft.
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Fig. 46: Pulling Up No. 3 Shift Fork Shaft

33. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from the reverse shift fork.
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Fig. 47: Removing Interlock Roller From Reverse Shift Fork

34. REMOVE NO. 2 SHIFT FORK SHAFT, SHIFT HEAD AND NO. 1 SHIFT FORK
a. Pull out the No. 2 shift fork shaft.
b. Remove the shift head and No. 1 shift fork.
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Fig. 48: Removing No. 2 Shift Fork Shaft, Shift Head & No. 1 Shift Fork
35. REMOVE NO. 3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK AND NO. 2 SHIFT
FORK
a. Pull out the No. 3 shift fork shaft with the reverse shift fork.
b. Remove the No. 2 shift fork.
36. REMOVE SNAP RING
a. Using 2 screwdrivers and a hammer, remove the snap ring and reverse shift fork from the No. 3
shift fork shaft.
b. Using 2 screwdrivers and a hammer, remove the snap rings from the No. 1, No. 2 and No. 3 shift
fork shafts.
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Fig. 49: Removing Snap Rings

37. REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY

a. Leaning the output shaft to the differential side, remove the input shaft assembly.
b. Lift up the differential case assembly, remove the output shaft assembly.
38. REMOVE DIFFERENTIAL CASE ASSEMBLY
39. REMOVE MAGNET FROM TRANSAXLE CASE
40. REMOVE 2 BOLTS, NO. 1 AND NO. 2 OIL RECEIVER PIPES
41. REMOVE STRAIGHT SCREW PLUG FROM TRANSAXLE CASE
Sealant:

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42. REMOVE NO. 5 SYNCHRONIZER RING WITH KEY SPRING FROM NO. 3 CLUTCH HUB
a. Remove the No. 5 synchronizer ring with the key spring from the No. 3 clutch hub.
b. Using a screwdriver, remove the snap ring.
HINT:
Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.
c. Remove the synchronizer rings.
Fig. 50: Removing Snap Ring From Synchronizer

INSPECTION
1. INSPECT NO. 5 SYNCHRONIZER RING

a. Check for wear or damage.
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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. Lightly rub the synchronizer ring and gear cone together.
NOTE: Ensure the fine lapping compound is completely washed off after
rubbing.
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Fig. 51: Turning Synchronizer Ring

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.
rubbing.
Fig. 52: Measuring Clearance Between Synchronizer Ring Back & Gear Spline End
2. INSPECT NO. 3 SHIFT FORK AND HUB SLEEVE CLEARANCE

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Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
Fig. 53: Measuring Clearance Between Hub Sleeve & Shift Fork
REPLACEMENT
1. REPLACE INPUT SHAFT FRONT BEARING AND OIL SEAL

a. Remove the 3 bolts and transaxle case receiver.
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b. Using SST, pull out the bearing.
SST 09612-65014 (09612-01040, 09612-01050)
c. Using a screwdriver, remove the oil seal.
Fig. 54: Removing Bolts Of Transaxle Case Receiver

d. Using SST, drive in a new oil seal.
SST 09608-00081, 09950-70010 (09951-07150)
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Fig. 55: Using SST To Drive In A New Oil Seal

e. Coat the lip of seal with MP grease.

f. Using SST, drive in a new bearing.
SST 09950-60010 (09951-00580), 09950-70010 (09951-07150)
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Fig. 56: Installing New Bearing

g. Install the transaxle case receiver.

h. Install and torque the 3 bolts.
2. REPLACE OUTPUT SHAFT FRONT BEARING OUTER RACE AND OUTPUT SHAFT FRONT
COVER
a. Using SST, pull out the output shaft front bearing outer race.
SST 09308-00010
b. Remove the output shaft cover.
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Fig. 57: Pulling Out Output Shaft Front Bearing Outer Race
c. Install a new output shaft cover.
HINT:
Install the output shaft cover projection into the case side groove.
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Fig. 58: Installing New Output Shaft Cover

d. Using SST and a hammer, drive in a new output shaft front bearing outer race.
SST 09316-60011 (09316-00011, 09316-00021)
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Fig. 59: Using SST & A Hammer To Drive In A New Output Shaft Front Bearing Outer Race
3. REPLACE REVERSE RESTRICT PIN

a. Using a hexagon wrench (6 mm), remove the screw plug.
b. Using a pin punch (5 mm) and hammer, drive out the slotted spring pin.
c. Replace the reverse restrict pin.
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Fig. 60: Removing Screw Plug

d. Using a pin punch (5 mm) and hammer, drive in the slotted spring pin.
e. Apply sealant to the screw plug threads.
Sealant:
f. Using a hexagon wrench (6 mm), install and torque the screw plug.
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Fig. 61: Installing Screw Plug

4. REPLACE CONTROL SHAFT COVER OIL SEAL AND BUSHING

a. Using a screwdriver, pry out the oil seal.
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Fig. 62: Prying Control Shaft Cover Oil Seal

b. Using SST and a press, press out the bushing.
SST 09950-60010 (09951-00200, 09951-00210), 09950-70010 (09951-07150)
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Fig. 63: Pressing Out Bushing

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.)
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Fig. 64: Pressing In A New Bushing

d. Using SST and a plastic-faced hammer, carefully tap in a new oil seal.
SST 09950-60010 (09951-00270), 09950-70010 (09951-07150)
Depth: 0.70 +/- 0.50 mm (0.0276 +/- 0.0197 in.)
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Fig. 65: Tapping In A New Oil Seal

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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
from the gasket surfaces.
 Thoroughly clean all components to remove all the loose material.
 Clean both sealing surfaces with a non-residue solvent.
 Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing
surface.
 Parts must be assembled within 10 minutes of application. Otherwise, the
FIPG material must be removed and reapplied.
HINT:
 Before reassembly, select a shim by adjusting output shaft preload.

 Coat all of the sliding and rotating surfaces with gear oil before reassembly.
ADJUST OUTPUT SHAFT PRELOAD
a. Install the output shaft assembly to the transaxle case.

b. Install the transmission case to the transaxle case.
HINT:
If necessary, tap on the case with a plastic hammer.
c. Install and torque the 17 bolts.
Torque:
29 N.m (300 kgf.cm, 21 ft.lbf) for transaxle case side 30 N.m (306 kgf.cm, 22 ft.lbf) for transmission
case side
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Fig. 66: Installing Transmission Case To Transaxle Case Bolts

d. Install the output shaft rear taper roller bearing outer race.
e. Install the adjusting shim.
HINT:
When reusing the output shaft bearing, first install a shim of the same thickness as before. If installing a
new taper roller bearing, first select and install a shim of lesser thickness than before.
f. Install the rear bearing retainer.

g. Using a Torx(R) wrench (T45), install and torque the 7 Torx(R) screws.
h. Install a new lock nut to the output shaft.

i. Turn the output shaft right and left 2 or 3 times to allow the bearing to settle.
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j. Using a torque wrench, measure the preload.
Preload (at starting):
New bearing:
0.8 to 1.6 N.m (8 to 16 kgf.cm, 6.9 to 13.9 in.lbf)
Reused bearing:
If the preload is not within the specification, select an appropriate adjusting shim.
Fig. 67: Measuring Preload


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0 1.30 (0.0512) D 1.95 (0.0768)
1 1.35 (0.0531) E 2.00 (0.0787)
2 1.40 (0.0551) F 2.05 (0.0807)
3 1.45 (0.0571) G 2.10 (0.0827)
4 1.50 (0.0591) H 2.15 (0.0846)
5 1.55 (0.0610) J 2.20 (0.0866)
6 1.60 (0.0630) K 2.25 (0.0886)
7 1.65 (0.0650) L 2.30 (0.0906)
8 1.70 (0.0669) M 2.35 (0.0925)
9 1.75 (0.0689) N 2.40 (0.0945)
A 1.80 (0.0709) P 2.45 (0.0965)
B 1.85 (0.0728) Q 2.50 (0.0984)
C 1.90 (0.0748) - -
k. Remove the lock nut.

l. Remove the 5 parts. Removal is in the reverse order of installation.
1. Remove the rear bearing retainer.
2. Remove the shim.
3. Remove the transmission case.
4. Remove the output shaft assembly.
5. Remove the output shaft rear bearing outer race.
INPUT SHAFT
COMPONENTS
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Fig. 68: Exploded View Of Input Shaft

DISASSEMBLY
1. MEASURE 3RD AND 4TH GEARS THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Maximum clearance:
3rd gear: 0.35 mm (0.0138 in.)
4th gear: 0.57 mm (0.0224 in.)
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2005 Toyota RAV4
Fig. 69: Measuring 3rd & 4th Gears Thrust Clearance

2. CHECK 3RD AND 4TH GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between the gear and shaft.
Maximum clearance:
3rd gear: 0.053 mm (0.0021 in.)
4th gear: 0.051 mm (0.0020 in.)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
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2005 Toyota RAV4
Fig. 70: Checking 3rd & 4th Gears Radial Clearance

3. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.
4. REMOVE REAR BEARING AND 4TH GEAR
Using SST and a press, remove the rear bearing and 4th gear.
SST 09950-00020
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Fig. 71: Removing Rear Bearing & 4th Gear

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.
7. REMOVE NO. 2 HUB SLEEVE ASSEMBLY, SYNCHRONIZER RING AND 3RD GEAR
Using a press, remove the No. 2 hub sleeve assembly, synchronizer ring and 3rd gear.
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2005 Toyota RAV4
Fig. 72: Removing No. 2 Hub Sleeve Assembly, Synchronizer Ring & 3rd Gear
8. REMOVE 2 NEEDLE ROLLER BEARINGS

9. DISASSEMBLY NO. 2 HUB SLEEVE ASSEMBLY
a. Remove the No. 2 hub sleeve from the No. 2 clutch hub.
b. Remove the 3 shifting keys and springs from the No. 2 clutch hub.
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2005 Toyota RAV4
Fig. 73: Disassembling No. 2 Hub Sleeve Assembly

10. REMOVE INPUT SHAFT FRONT BEARING INNER RACE
Using a screwdriver and hammer, remove the input shaft front bearing inner race.
INSPECTION
1. INSPECT GEAR SYNCHRONIZER RING

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. Lightly rub the synchronizer ring and gear cone together.
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2005 Toyota RAV4
Fig. 74: Inspecting Gear Synchronizer Ring

rubbing.
c. Check again the braking effect of the synchronizer ring.

d. Using a feeler gauge, measure the clearance between the synchronizer ring back and spline end.
Minimum clearance:
3rd gear: 0.65 mm (0.0256 in.)
4th gear: 0.75 mm (0.0295 in.)
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2005 Toyota RAV4
Fig. 75: Measuring Clearance Between Synchronizer Ring Back & Spline End
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.
rubbing.
2. MEASURE NO. 2 SHIFT FORK AND HUB SLEEVE CLEARANCE
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Fig. 76: Measuring Clearance Between Hub Sleeve & Shift Fork
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.
Minimum outer diameter:
Part A: 27.957 mm (1.1007 in.)
Part B: 35.984 mm (1.4167 in.)
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2005 Toyota RAV4
Fig. 77: Measuring Outer Diameter Of Input Shaft Journal Surface

c. Using a dial indicator, check the shaft runout.
Maximum runout: 0.03 mm (0.0012 in.)
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Fig. 78: Checking Shaft Runout

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.
SST 09608-00071
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Fig. 79: Installing Input Shaft Front Bearing Inner Race

2. INSTALL NO. 2 CLUTCH HUB INTO NO. 2 HUB SLEEVE

a. Install the 3 springs and shifting keys to the clutch hub.
b. Install the hub sleeve to the clutch hub.
NOTE: Assembly the hub sleeve and clutch hub in the direction shown in
the illustration.
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2005 Toyota RAV4
Fig. 80: Installing Springs & Shifting Keys To Clutch Hub

3. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR, SYNCHRONIZER RING AND NO. 2
HUB SLEEVE ASSEMBLY TO INPUT SHAFT
a. Apply MP grease to the needle roller bearing and install it.
b. Install the 3rd gear.
c. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
d. Using SST and a press, install the No. 2 hub sleeve assembly.
SST 09506-35010
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Fig. 81: Installing 3rd Gear, Synchronizer Ring & No. 2 Hub Sleeve Assembly
4. INSTALL SNAP RING

a. Select a snap ring that allows the minimum axial play.

H 2.30 (0.0906) M 2.50 (0.0984)
J 2.35 (0.0925) N 2.55 (0.1004)
K 2.40 (0.0945) P 2.60 (0.1024)
L 2.45 (0.0965) - -
b. Using a screwdriver and hammer, tap in the snap ring.
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2005 Toyota RAV4
Fig. 82: Using A Screwdriver & Hammer To Tap In Snap Ring

5. MEASURE 3RD GEAR THRUST CLEARANCE (See DISASSEMBLY)

6. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, 4TH GEAR AND
REAR BEARING
a. Install the spacer.
b. Apply MP grease to the 2 needle roller bearings and install it.
c. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
d. Install the 4th gear.
e. Using SST and a press, install the rear bearing.
SST 09309-36010
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Fig. 83: Installing Spacer, Synchronizer Ring, Needle Roller Bearing, 4th Gear & Rear
Bearing

a. Select a snap ring that allows the minimum axial play.

1 2.35 (0.0925) 5 2.55 (0.1004)
2 2.40 (0.0945) 6 2.60 (0.1024)
3 2.45 (0.0965) 7 2.65 (0.1043)
4 2.50 (0.0984) 8 2.70 (0.1063)
b. Using a screwdriver and hammer, tap in the snap ring.
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2005 Toyota RAV4
Fig. 84: Measuring 4th Gear Thrust Clearance

8. MEASURE 4TH GEAR THRUST CLEARANCE (See DISASSEMBLY)
OUTPUT SHAFT
COMPONENTS
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2005 Toyota RAV4
Fig. 85: Exploded View Of Output Shaft

DISASSEMBLY
1. MEASURE 1ST AND 2ND GEARS THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Maximum clearance:
1st gear: 0.40 mm (0.0157 in.)
2nd gear: 0.35 mm (0.0138 in.)
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2005 Toyota RAV4
Fig. 86: Measuring 1st & 2nd Gears Thrust Clearance

2. CHECK 1ST AND 2ND GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between the gear and shaft.
Maximum clearance:
1st and 2nd gears: 0.053 mm (0.0021 in.)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
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2005 Toyota RAV4
Fig. 87: Measuring 1st & 2nd Gears Radial Clearance

3. REMOVE OUTPUT SHAFT REAR BEARING, 4TH DRIVEN GEAR AND SPACER
a. Using a press, remove the bearing and 4th driven gear.
b. Remove the spacer.
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2005 Toyota RAV4
Fig. 88: Removing Output Shaft Rear Bearing, 4th Driven Gear & Spacer
4. REMOVE 3RD DRIVEN GEAR AND 2ND GEAR
Using a press, remove the 3rd driven gear and 2nd gear.
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2005 Toyota RAV4
Fig. 89: Removing 3rd Driven Gear & 2nd Gear

5. REMOVE NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RINGS

6. REMOVE INNER RACE AND BALL FROM OUTPUT SHAFT
7. REMOVE NO. 1 HUB SLEEVE ASSEMBLY AND 1ST GEAR
Using a press, remove the No. 1 hub sleeve and 1st gear.
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Fig. 90: Removing No. 1 Hub Sleeve Assembly & 1st Gear
8. REMOVE SYNCHRONIZER RINGS AND NEEDLE ROLLER BEARING

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2005 Toyota RAV4
9. REMOVE 1ST GEAR BEARING INNER RACE
Using SST and a press, remove the 1st gear bearing inner race.
SST 09950-00020
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Fig. 91: Removing 1st Gear Bearing Inner Race

10. DISASSEMBLY NO. 1 HUB SLEEVE ASSEMBLY

a. Remove the No. 1 hub sleeve from the No. 1 clutch hub.
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2005 Toyota RAV4
b. Remove the 3 shifting keys and springs from the No. 1 clutch hub.
Fig. 92: Disassembly No. 1 Hub Sleeve Assembly

11. REMOVE OUTPUT SHAFT FRONT BEARING
Using SST, remove the output shaft front bearing.
SST 09950-00020,09950-00030
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Fig. 93: Removing Output Shaft Front Bearing

INSPECTION
1. INSPECT GEAR SYNCHRONIZER RINGS

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 it does not lock, replace the synchronizer ring.
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2005 Toyota RAV4
Fig. 94: Inspecting Gear Synchronizer Rings

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.
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2005 Toyota RAV4
Fig. 95: Measuring Clearance Between Synchronizer Ring Back & Gear Spline End
2. MEASURE NO. 1 SHIFT FORK AND HUB SLEEVE CLEARANCE
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Fig. 96: Measuring No. 1 Shift Fork And Hub Sleeve Clearance
3. INSPECT OUTPUT SHAFT

a. Check the output shaft for wear or damage.
b. Using a micrometer, measure the outer diameter of the output shaft journal surface.
Minimum outer diameter:
Part A: 37.610 mm (1.4807 in.)
Part B: 34.502 mm (1.3583 in.)
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Fig. 97: Measuring Outer Diameter Of Output Shaft Journal Surface

c. Using a dial indicator, check the shaft runout.
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Fig. 98: Checking Shaft Runout

REASSEMBLY
HINT:
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2005 Toyota RAV4
1. INSTALL NO. 1 CLUTCH HUB INTO NO. 1 HUB SLEEVE

a. Install the 3 springs and shifting keys to the clutch hub.
b. Install the hub sleeve to the clutch hub.
NOTE: Assemble the clutch hub and hub sleeve in the direction shown in
the illustration.
Fig. 99: Installing No. 1 Clutch Hub Into No. 1 Hub Sleeve
2. INSTALL 1ST GEAR BEARING INNER RACE
Using SST and a press, install the 1st gear bearing inner race.
SST 09506-35010
HINT:
Align the hole of the output shaft and inner race.
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2005 Toyota RAV4
Fig. 100: Installing 1st Gear Bearing Inner Race

3. INSTALL NEEDLE ROLLER BEARING, 1ST GEAR, SYNCHRONIZER RINGS AND NO. 1
HUB SLEEVE TO OUTPUT SHAFT
a. Apply MP grease to the needle roller bearing and install it.
b. Place the synchronizer rings on the 1st gear.
c. Install the 1st gear.
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Fig. 101: Placing 1st Gear, Synchronizer Rings & No. 1 Hub Sleeve To Output Shaft
d. Using SST and a press, install the 1st gear and No. 1 hub sleeve.
SST 09316-60011 (09316-00041)
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Fig. 102: Installing 1st Gear & No. 1 Hub Sleeve

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.
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2005 Toyota RAV4
Fig. 103: Installing Ball And Inner Race To Output Shaft

6. INSTALL SPACER, NEEDLE ROLLER BEARING, SYNCHRONIZER RINGS, 2ND GEAR

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2005 Toyota RAV4
AND 3RD DRIVEN GEAR

b. Apply MP grease to the needle roller bearing.
c. Place the synchronizer rings on the 2nd gear.
d. Install the 2nd gear.
e. Using a press, install the 3rd driven gear.
Fig. 104: Using A Press, Install 3rd Driven Gear

NOTE: Align the clutch hub grooves with the projections on the
synchronizer ring.
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Fig. 105: Aligning Clutch Hub Grooves With Projections On Synchronizer Ring
7. MEASURE 2ND GEAR THRUST CLEARANCE (See DISASSEMBLY)

8. INSTALL SPACER AND 4TH DRIVEN GEAR
b. Using a press, install the 4th driven gear.
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2005 Toyota RAV4
Fig. 106: Installing Spacer & 4th Driven Gear

9. INSTALL OUTPUT SHAFT REAR BEARING

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Using SST and a press, install a new bearing.
SST 09506-30012
Fig. 107: Installing NEW Output Shaft Rear Bearing

10. INSTALL OUTPUT SHAFT FRONT BEARING
Using SST and a press, install a new output shaft front bearing.
SST 09316-60011 (09316-00071)
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2005 Toyota RAV4
Fig. 108: Installing New Output Shaft Front Bearing

OIL PUMP (4WD)

COMPONENTS
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Fig. 109: Exploded View Of Oil Pump & Torque Specifications (4WD)
INSPECTION
1. CHECK ROTOR BODY CLEARANCE

a. Install the oil pump drive gear to the drive rotor.
b. Using a feeler gauge, measure the body clearance between the drive rotor and oil pump case.
Standard clearance:
0.10 to 0.16 mm (0.0039 to 0.0063 in.)
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2005 Toyota RAV4
Fig. 110: Measuring Body Clearance Between Drive Rotor & Oil Pump Case
2. CHECK ROTOR TIP CLEARANCE

a. Install the oil pump drive gear to the drive rotor.
b. Using a feeler gauge, measure the tip clearance between the drive and driven rotors.
Standard clearance:
0.08 to 0.15 mm (0.0031 to 0.0059 in.)
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2005 Toyota RAV4
Fig. 111: Measuring Tip Clearance Between Drive & Driven Rotors
3. CHECK SIDE CLEARANCE
Using a precision straight edge and feeler gauge, measure the side clearance of both rotors.
Standard clearance:
0.03 to 0.08 mm (0.0012 to 0.0031 in.)
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2005 Toyota RAV4
Fig. 112: Measuring Side Clearance Of Both Rotors

SHIFT AND SELECT LEVER SHAFT

COMPONENTS
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Fig. 113: Exploded View Of Shift & Select Lever Shaft

DIFFERENTIAL CASE (2WD)

COMPONENTS
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Fig. 114: Exploded View Of Differential Case & Torque Specifications (2WD)
DISASSEMBLY
1. Vehicle Speed sensor drive gear side:

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2005 Toyota RAV4
REMOVE TAPERED ROLLER BEARING FROM DIFFERENTIAL CASE
a. Using SST, remove the tapered roller bearing.
SST 09950-00020, 09950-00030,09950-40011 (09957-04010), 09950-60010 (09951-00530)
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

2. REMOVE RING GEAR

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2005 Toyota RAV4
a. Place matchmarks on the ring gear and differential case.

b. Remove the 16 bolts.
c. Using a copper hammer, tap on the ring gear to remove it from the differential case.
Fig. 116: Removing Bolts Of Ring Gear

3. Ring gear side:
REMOVE TAPERED ROLLER BEARING FROM DIFFERENTIAL CASE
Using SST, remove the tapered roller bearing.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00450)
HINT:
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2005 Toyota RAV4
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

4. INSPECT SIDE GEAR BACKLASH
Using a dial indicator, measure the backlash of one side gear while holding one pinion toward the
differential case.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
If the backlash is not within the specification, install the correct thrust washer to the side gears.
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Fig. 118: Measuring Side Gear Backlash

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.
c. Remove the 2 pinions and side gears with the 4 thrust washers from each gear.
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2005 Toyota 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.
c. Remove the shim.
d. Install the shim.
HINT:
First select and install a shim of lesser thickness than before.
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Fig. 119: Removing Oil Seal

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.
Fig. 120: Installing Tapered Roller Bearing Outer Race

f. Using SST and a hammer, drive in a new oil seal.
SST 09316-60010 (09316-00011, 09316-00031)
Drive in depth: 3.5 +/- 0.5 mm (0.138 +/- 0.020 in.)
g. Coat the lip of oil seal with MP grease.
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Fig. 121: Driving In NEW Oil Seal

2. Transaxle Case Side:
a. Using a screwdriver and hammer, drive out the oil seal from the transaxle case.
b. Using SST, remove the tapered roller bearing outer race.
SST 09316-60011 (09316-00011, 09316-00021)
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Fig. 122: Driving Oil Seal From Transaxle Case

c. Remove the oil baffle.

d. Install the oil baffle.
HINT:
Install the oil baffle projection into the case side cutout.
SST 09950-60020 (09951-00890), 09950-70010 (09951-00150)
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2005 Toyota RAV4

SST 09316-60011 (09316-00011, 09316-00041)
Drive in depth: 0 +/- 0.5 mm (0 +/- 0.020 in.)
g. Coat the oil seal lip with MP grease.
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2005 Toyota RAV4

REASSEMBLY
HINT:
1. ASSEMBLE DIFFERENTIAL CASE

a. Install the correct thrust washers and side gears.
Refer to the table below, select thrust washers which will ensure that the backlash is within the
specification. Try to select washers of the same size for both sides.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)

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2005 Toyota RAV4

Thickness mm (in.) Thickness mm (in.)
1.00 (0.0394) 1.20 (0.0472)
1.10 (0.0433) 1.30 (0.0512)
Fig. 125: Installing Correct Thrust Washers & Side Gears

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.
Measure the side gear backlash while holding one pinion toward the differential case.
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2005 Toyota RAV4
Fig. 126: Measuring Side Gear Backlash

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.
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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.
2. INSTALL RING GEAR ON DIFFERENTIAL CASE
a. Clean the contact surface of the differential case.
b. Heat the ring gear in boiling water.
c. Carefully take the ring gear out of the water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the
differential case.
HINT:
Align the matchmarks on the differential case and contact the ring gear.
e. Temporarily install the 16 set bolts.
CAUTION: The ring gear set bolts should not be tightened until the ring
gear has cooled sufficiently.
f. After the ring gear has cooled sufficiently, torque the ring gear set bolts uniformly at a time.
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2005 Toyota RAV4
Fig. 127: Installing Ring Gear On Differential Case

3. Ring gear side:
INSTALL TAPERED ROLLER BEARING
Using SST and a press, install a new tapered roller bearing.
SST 09316-60011 (09316-00011)
NOTE: When replacing the tapered roller bearing outer race, replace the tapered
roller bearing along with it.
HINT:
Set SST to the bearing inner race securely.
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Fig. 128: Installing Tapered Roller Bearing

4. Vehicle Speed sensor drive gear side:
a. Place the vehicle speed sensor drive gear in position to stop it turning and install the vehicle speed
sensor drive gear.
NOTE: Be sure to install the vehicle speed sensor drive gear in the correct
direction, as shown in the illustration.
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2005 Toyota RAV4

b. Using SST, a steel plate and press, install a new tapered roller bearing.
SST 09316-20011, 09316-60011 (09316-00011)
HINT:
Set SST to the bearing inner race securely.
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2005 Toyota RAV4

5. INSPECT DIFFERENTIAL TAPERED ROLLER BEARING PRELOAD
NOTE: Perform this only when replacing the tapered roller bearing and outer race
of the differential case.
a. Install the differential case assembly to the transaxle case.

b. Install the transmission case to the transaxle case with the 17 bolts.
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Fig. 131: Installing Differential Case Assembly To Transaxle Case

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.
SST 09564-32011
d. Using SST and a torque wrench, measure the preload.
SST 09564-32011
New bearing
Reused bearing

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2005 Toyota RAV4

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.

0 2.00 (0.0787) 9 2.45 (0.0965)
1 2.05 (0.0807) A 2.50 (0.0984)
2 2.10 (0.0827) B 2.55 (0.1004)
3 2.15 (0.0846) C 2.60 (0.1024)
4 2.20 (0.0866) D 2.65 (0.1043)
5 2.25 (0.0886) E 2.70 (0.1063)
6 2.30 (0.0906) F 2.75 (0.1083)
7 2.35 (0.0925) G 2.80 (0.1102)
8 2.40 (0.0945) H 2.85 (0.1122)
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2005 Toyota RAV4
e. Remove the 17 bolts and transmission case.

f. Remove the differential case assembly.
DIFFERENTIAL CASE (4WD)

COMPONENTS
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2005 Toyota RAV4
Fig. 133: Exploded View Of Differential Case & Torque Specifications (4WD)
DISASSEMBLY
1. REMOVE NO. 2 DIFFERENTIAL CASE

b. Remove the No. 2 differential case upward.
2. REMOVE DIFFERENTIAL RING GEAR
a. Place matchmarks on both the differential case and ring gear.
Fig. 134: Placing Matchmarks On Both Differential Case & Ring Gear
b. Using a plastic hammer, tap out the ring gear.
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2005 Toyota RAV4
Fig. 135: Using A Plastic Hammer To Tap Out Ring Gear

3. REMOVE NO. 2 DIFFERENTIAL SIDE GEAR THRUST WASHER AND CONICAL SPRING
WASHER
4. REMOVE FRONT DIFFERENTIAL CASE ASSEMBLY
5. DISASSEMBLE FRONT DIFFERENTIAL CASE
a. Remove the front differential side gear together with the thrust washer from the front differential
case.
b. Remove the front differential side gear thrust washer from the side gear.
c. Using a snap ring expander, remove the snap ring and spacer.
HINT:
Before removing the shaft snap ring, wrap vinyl tape around the case to prevent damage.
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Fig. 136: Removing Snap Ring & Spacer

d. Remove the parts from the front differential case.

1. Remove the 2 front differential pinion shafts.
2. Remove the No. 2 front differential pinion shaft.
3. Remove the front differential pinion shaft holder.
4. Remove the 4 differential pinions.
5. Remove the 4 differential pinion thrust washers.
6. Remove the front differential side gear.
7. Remove the front differential side gear thrust washer.
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2005 Toyota RAV4
Fig. 137: Exploded View Of Front Differential Case

6. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR

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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.
1. Remove the 4 differential pinion shafts.

2. Remove the pinion shaft holder.
3. Remove the 4 differential pinions.
4. Remove the 4 differential pinion thrust washers.
5. Remove the differential side gear subassembly.
6. Remove the conical spring washer.
7. Remove the No. 2 differential side gear thrust washer.
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2005 Toyota RAV4
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2005 Toyota RAV4
Fig. 138: Exploded View Of No. 1 Differential Case

8. No. 2 Differential Case Side:
REMOVE TAPERED ROLLER BEARING
SST 09950-00020, 09950-00030, 09950-60010 (09951-00520)
Fig. 139: Removing Tapered Roller Bearing (No. 2 Differential Case Side)
REMOVE TAPERED ROLLER BEARING
SST 09950-00020, 09950-00030, 09950-60010 (09951-00450)
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Fig. 140: Removing Tapered Roller Bearing (No. 1 Differential Case Side)
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.
Standard diameter:
A: 104.000 to 104.035 mm (4.0945 to 4.0959 in.)
B: 97.000 to 97.035 mm (3.8189 to 3.8203 in.)
Maximum diameter:
A: 104.060 mm (4.0969 in.)
B: 97.060 mm (3.8213 in.)
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2005 Toyota RAV4
Fig. 141: Measuring Inner Diameter Of No. 1 & No. 2 Differential Cases Bushing
2. MEASURE FRONT DIFFERENTIAL CASE
Using a micrometer, measure the outer diameter of the front differential case.
Standard diameter:
A: 103.929 to 103.964 mm (4.0917 to 4.0931 in.)
B: 96.929 to 96.964 mm (3.8161 to 3.8175 in.)
Minimum diameter:
A: 103.850 mm (4.0887 in.)
B: 96.850 mm (3.8130 in.)
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2005 Toyota RAV4
Fig. 142: Measuring Outer Diameter Of Front Differential Case

3. MEASURE CONICAL SPRING WASHER
Using calipers, measure the height of the conical spring washer.
Standard height:
No. 2 differential case side
2.60 to 2.80 mm (0.102 to 0.110 in.)

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2005 Toyota RAV4
1.55 to 1.75 mm (0.061 to 0.069 in.)
Minimum height:
2.50 mm (0.098 in.)
1.60 mm (0.063 in.)
Fig. 143: Measuring Height Of Conical Spring Washer

REPLACEMENT
1. Transmission Case Side:

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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.
c. Remove the shim.
d. Install the shim.
HINT:
First select and install a shim of lesser thickness than before.
Fig. 144: Driving Out Tapered Roller Bearing Outer Race

SST 09316-60011 (09316-00011, 09316-00041)
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SST 09316-60010 (09316-00011, 09316-00031)
Drive in depth: 0 +/- 0.5 mm (0 +/- 0.020 in.)
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g. Coat the lip of oil seal with MP grease.

2. Transaxle Case Side:
a. Using a screwdriver and hammer, drive out the oil seal from the transaxle case.
b. Using SST, remove the tapered roller bearing outer race.
SST 09316-60011 (09316-00011, 09316-00021)
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Fig. 147: Removing Tapered Roller Bearing Outer Race

c. Remove the oil baffle.

d. Install the oil baffle.
HINT:
Install the oil baffle projection into the case side cutout.
e. Using SST and a press, install the tapered roller bearing outer race.
SST 09316-60011 (09316-00011, 09316-00041).
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SST 09316-60011 (09316-00011, 09316-00041)
Drive in depth: 6.9 +/- 0.5 mm (0.272 +/- 0.020 in.)
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g. Coat the oil seal lip with MP grease.
REASSEMBLY
HINT:

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Using SST, install a new tapered roller bearing.
SST 09316-20011
Fig. 150: Installing NEW Tapered Roller Bearing

Using SST, install a new tapered roller bearing.
SST 09316-20011
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Fig. 151: Installing NEW Tapered Roller Bearing

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.
1. Install the No. 2 differential side gear thrust washer.
2. Temporarily install a 1.0 mm (0.039 in.) thick thrust washer.
3. Install the differential side gear subassembly.
4. Install the pinion shaft holder.
5. Install the 4 differential pinions.
6. Install the 4 differential pinion thrust washers.
7. Install the 4 differential pinion shafts.
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Fig. 152: Assembling No. 1 Differential Case

b. Using a dial indicator, measure the backlash of one pinion gear while holding the differential side
gear sub assembly toward the case.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
Fig. 153: Measuring Backlash Of One Pinion Gear

HINT:
Push the pinion gear of the right side of the differential case.
If the backlash is out of the specification, refer to the table on the next page and select a thrust
washer which will ensure that the backlash is within the specification.
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Thrust washer thickness: mm (in.)

MA 0.80 (0.0315) MH 1.15 (0.0453)
MB 0.85 (0.0335) MI 1.20 (0.0472)
MC 0.90 (0.0354) MJ 1.25 (0.0492)
MD 0.95 (0.0374) MK 1.30 (0.0512)
ME 1.00 (0.0394) ML 1.35 (0.0531)
MF 1.05 (0.0413) MN 1.40 (0.0551)
MG 1.10 (0.0433) - -
c. Disassemble the No. 1 differential case.

4. ASSEMBLE NO. 1 DIFFERENTIAL CASE
Install the parts to the No. 1 differential case.
1. Install the No. 2 side gear thrust washer (previously selected).

2. Install the conical spring washer.
3. Install the differential side gear subassembly.
4. Install the pinion shaft holder.
7. Install the 4 differential pinion shafts.
HINT:
Ensure that the conical spring washer is installed correctly.
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5. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR

a. Install the vehicle speed sensor drive gear and spacer.
b. Using a snap ring expander, install the snap ring.
Fig. 155: Installing Vehicle Speed Sensor Drive Gear

6. CHECK AND ADJUST FRONT SIDE GEAR BACKLASH (FRONT DIFFERENTIAL CASE
SIDE)
a. Install the parts to the front differential case.
1. Install the front differential side gear thrust washer.
2. Install the front differential side gear.
3. Install the front differential pinion shaft holder.
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6. Install the No. 2 front differential pinion shaft.
7. Install the 2 front differential pinion shafts.
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Fig. 156: Assembling Front Differential Case

b. Using a dial indicator, measure the backlash of one pinion gear while holding the front differential
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side gear toward the case.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
Fig. 157: Measuring Backlash Of One Pinion Gear

NOTE: Do not mount the surface of front differential case which contacts
with bushing in a vise.
If the backlash is out of the specification, refer to the table below and select a thrust washer which
will ensure that the backlash is within the specification.

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Mark Thickness mm (in.)

B 1.00 (0.0394)
C 1.05 (0.0413)
D 1.10 (0.0433)
E 1.15 (0.0453)
F 1.20 (0.0472)
G 1.25 (0.0492)
7. CHECK AND ADJUST FRONT DIFFERENTIAL SIDE GEAR THRUST CLEARANCE (NO. 2
DIFFERENTIAL CASE SIDE)
a. Engage the side gear to the above mentioned front differential case.
b. Install the differential case LH to the front differential case and measure its center.
c. After that, remove the differential case LH.
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Fig. 158: Installing Differential Case LH To Front Differential Case

d. Using a straight edge and feeler gauge, measure the clearance between the front differential case
and the side gear.
t= Thrust washer thickness
L= Clearance
t= L - 0.16 to 0.27 mm (0.0063 to 0.0106 in.)
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Fig. 159: Measuring Clearance Between Front Differential Case & Side Gear
HINT:
Refer to the table below and select a thrust washer which will ensure that the clearance is within the
specification.

Mark Thickness Mark Thickness.
A 0.95 (0.0373) F 1.20 (0.0472)
B 1.00 (0.0393) G 1.25 (0.0492)
C 1.05 (0.0413) H 1.30 (0.0512)
D 1.10 (0.0433) J 1.35 (0.0532)
E 1.15 (0.0453) K 1.40 (0.0552)
If the clearance is not within the specified value, parts may have been assembled incorrectly, so
check and reassemble it.

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b. Using a snap ring expander, install the shaft snap ring, as shown.
HINT:
Before installing the shaft snap ring, wrap vinyl tape around the case to avoid damaging the case.
Fig. 160: Installing Shaft Snap Ring

9. CHECK AND ADJUST CENTER DIFFERENTIAL SIDE GEAR THRUST CLEARANCE

(FRONT DIFFERENTIAL CASE SIDE)
a. Install the parts to the No. 2 differential case.
1. Install the front differential case assembly.
2. Install the front differential side gear.
3. Install the front differential side gear thrust washer.
4. Temporarily install a 1.0 mm (0.039 in.) thick No. 2 differential side gear thrust washer.
5. Install the No. 2 differential side gear thrust washer.
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HINT:
Engage the front differential side gear and pinion gear of the No. 1 differential case.
 The temporarily installed a 1.0 mm (0.039 in.) thick No. 2 side gear thrust washer is
used for reference when checking backlash.
b. Clean the contact surface of the No. 2 side gear thrust washer and No. 2 differential case.
c. Apply plastigage on the No. 2 side gear thrust washer, as shown.
HINT:
Apply the plastigage on the No. 2 side gear thrust washer in the 4 positions directly above the
pinion shafts in the No. 1 differential case's position.
Fig. 162: Locating Plastigage On No. 2 Side Gear Thrust Washer

d. Install the ring gear.
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1. Clean the contact surface of the differential left case.

2. Heat the ring gear to about 100°C (212°F) in boiling water. See Fig. 163
3. Carefully take the ring gear out of the water.
4. Clean the contact surface of the ring gear with cleaning solvent.
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

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Fig. 164: Aligning Matchmarks On No. 2 Differential Case & Ring Gear
e. Install the No. 2 differential case downward.
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Fig. 165: Installing No. 2 Differential Case Downward

HINT:
Align the matchmarks on the No. 1 differential case and contact the No. 2 differential case.
f. Temporarily install the 4 service bolts.
Parts No:
Service bolt: 90105-08055
g. Remove the 4 service bolts and No. 2 differential case upward.

h. Measure the Plastigage at its widest point.
Standard clearance: 0.16 to 0.25 mm (0.006 to 0.010 in.)

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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


0 0.80 (0.0315) 7 1.15 (0.0453)
1 0.85 (0.0335) 8 1.20 (0.0472)
2 0.90 (0.0354) 9 1.25 (0.0492)
3 0.95 (0.0374) A 1.30 (0.0512)
4 1.00 (0.0394) B 1.35 (0.0531)
5 1.05 (0.0413) C 1.40 (0.0551)
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6 1.10 (0.0433) - -
i. Remove the No. 2 differential case, No. 2 side gear thrust washer and (temporarily install) a 1.0
mm (0.039 in.) thick No. 2 side gear thrust washer.
10. ASSEMBLE NO. 2 DIFFERENTIAL CASE
a. Install the No. 2 side gear thrust washer (previously selected) and conical spring washer to the front
differential case.
HINT:
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
b. Install the No. 2 differential case to the No. 1 differential case.
HINT:
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Align the matchmarks on the No. 2 differential case and connect the No. 1 differential case.
c. Temporarily install the 4 service bolts.
Parts No:
Service bolt: 90105-08055
Fig. 168: Aligning Matchmarks On No. 2 Differential Case & Connect No. 1 Differential Case
11. ADJUST DIFFERENTIAL CASE SIDE BEARING PRELOAD

a. Install the differential case assembly to the transaxle case.
b. Install the transmission case.
HINT:
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If necessary, tap on the transmission case with a plastic hammer.
c. Install and torque the 17 bolts.
Torque:
29 N.m (300 kgf.cm, 21 ft.lbf) for transaxle case side
30 N.m (306 kgf.cm, 22 ft.lbf) for transmission case side
Fig. 169: Installing Transmission Case Bolts

d. Temporarily install the intermediate shaft.

e. Turn the intermediate shaft right and left 2 or 3 times to allow the bearing settle.
f. Remove the intermediate shaft.
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Fig. 170: Turning Intermediate Shaft To Settle Bearing

g. Using SST and a torque wrench, measure the differential preload.
SST 09564-32011
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Fig. 171: Measuring Differential Preload

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)

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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.

0 2.00 (0.0787) 9 2.45 (0.0965)
1 2.05 (0.0807) A 2.50 (0.0984)
2 2.10 (0.0827) B 2.55 (0.1004)
3 2.15 (0.0846) C 2.60 (0.1024)
4 2.20 (0.0866) D 2.65 (0.1043)
5 2.25 (0.0886) E 2.70 (0.1063)
6 2.30 (0.0906) F 2.75 (0.1083)
7 2.35 (0.0925) G 2.80 (0.1102)
8 2.40 (0.0945) H 2.85 (0.1122)
h. Remove the 17 bolts, tap the transmission case with a plastic hammer and remove it.
i. Remove the differential case assembly.
SHIFT LEVER AND CONTROL CABLE

COMPONENTS
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Fig. 172: Exploded View Of Shift Lever & Console Components

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Fig. 173: Exploded View Of Shift Lever & Control Cable & Torque Specifications
REMOVAL
1. DISCONNECT CONTROL CABLES FROM TRANSAXLE

a. Remove the 2 clips and 2 washers.
b. Remove the 2 clips and disconnect the 2 control cables.
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Fig. 174: Disconnecting Control Cables From Transaxle

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 ).
c. Remove the 6 bolts and the shift lever and control cables assembly.
Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) for bolt A
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf) for bolt B
d. Remove the shift and select control cables from the shift lever assembly.
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Fig. 175: Removing Bolts Of Shift Lever & Control Cables Assembly
INSTALLATION
NOTE: When installing the 2 control cables, you must observe the following items.
 When handling the cable, do not bend the cable less than R130°.
 Pay thorough attention not to damage the boots.
 When installing, do not apply force but install it gently.
 After finishing the installation, check the cable for twist. If there is any
irregularity, adjust it.
 Never reuse the board-type clip to fix the control cable.
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TRANSFER (4WD)
ON-VEHICLE REPAIR
REPLACE TRANSFER OIL

HINT:
Use a container to catch the transfer oil.

e. Refill new transfer oil as shown, see Fig. 176.
Oil grade: API GL-5
Viscosity: SAE 90
Capacity: 0.9 liters (0.95 US qts, 0.79 lmp.qts)
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Fig. 176: Identifying Transfer Case Filler Plug

COMPONENTS
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Fig. 177: Exploded View Of Transfer & Torque Specifications (4WD)

DISASSEMBLY
1. REMOVE GASKET
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Fig. 178: Removing Gasket

2. REMOVE NO. 2 INTERMEDIATE DIFFERENTIAL SIDE GEAR
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Fig. 179: Removing No. 2 Intermediate Differential Side Gear

3. REMOVE NO. 1 CASE COVER

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Fig. 180: Removing Bolts Of No. 1 Case Cover

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.
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Fig. 181: Removing No. 1 Case Cover

c. Remove the bolt and breather oil deflector from the case cover No. 1.
4. REMOVE PIN
5. REMOVE STUD BOLT
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6. INSTALL TRANSFER ON OVERHAUL ATTACHMENT
Fig. 182: Removing Bolt Of Breather Oil Deflector From Case Cover No. 1
7. REMOVE EXTENSION HOUSING

a. Using a plastic hammer, remove the dust deflector from the extension housing.
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Fig. 183: Removing Dust Deflector From Extension Housing

b. Using SST, remove the oil seal from the extension housing.
SST 09308-00010
NOTE: Be careful not to damage the extension housing.
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Fig. 184: Removing Oil Seal From Extension Housing

c. Remove the 4 bolts.
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Fig. 185: Removing Bolts

d. Using a plastic hammer, remove the extension housing.
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Fig. 186: Removing Extension Housing

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.
SST 09326-20011
0.9 to 1.3 N.m (9 to 13 kgf.cm, 7.8 to 12 in.lbf)
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Fig. 187: Measuring Driven Pinion Preload Of Backlash Between Driven Pinion & Ring Gear
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 a torque wrench.
b. Using SST and the torque wrench, measure the total preload.
SST 09326-20011
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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.).


 This torque value is effective in case that SST is parallel to a torque wrench.
9. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.
Backlash: 0.10 to 0.15 mm
10. CHECK TOOTH CONTACT
(See REASSEMBLY)
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Fig. 188: Measuring Ring Gear Backlash

11. REMOVE CENTER DIFFERENTIAL LOCK SLEEVE

a. Using a snap ring pliers, remove the shaft snap ring.
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Fig. 189: Removing Shaft Snap Ring

b. Using SST, remove the center differential lock sleeve.
SST 09308-00010
NOTE: Be careful not to damage the center differential lock sleeve.
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Fig. 190: Removing Center Differential Lock Sleeve

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.
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Fig. 191: Removing O-Ring From Center Differential Lock Sleeve

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.
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Fig. 192: Removing Oil Seal From Transfer Case

13. REMOVE BEARING RETAINER RH

a. Using SST, remove the oil seal from the bearing retainer RH.
SST 09308-00010
NOTE: Be careful not to damage the bearing retainer.
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Fig. 193: Removing Oil Seal From Bearing Retainer RH

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Fig. 194: Removing Bearing Retainer Bolts

c. Using a screwdriver and a hammer, make clearance by hitting between the bearing retainer RH and
the transfer case.
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Fig. 195: Making Clearance By Hitting Between Bearing Retainer RH & Transfer Case
d. Using SST, remove the bearing retainer RH from the transfer case.
SST 09520-10021
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Fig. 196: Removing Bearing Retainer RH From Transfer Case

e. Using a screwdriver, remove 2 O-rings from the bearing retainer RH.
NOTE: Be careful not to damage the bearing retainer RH.
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Fig. 197: Removing O-Rings From Bearing Retainer RH

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.
SST 09308-00010
NOTE: Be careful not to damage the bearing retainer RH.
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Fig. 198: Removing Outer Race From Bearing Retainer

h. Using snap ring pliers, remove the snap ring.
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Fig. 199: Removing Snap Ring

i. Remove the side gear shaft holder bearing from the bearing retainer RH.
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14. REMOVE CENTER DIFFERENTIAL CONTROL COUPLING ASSEMBLY
Fig. 200: Removing Center Differential Control Coupling Assembly

15. REMOVE TAPERED ROLLER BEARING LH AND RH
Using SST, remove the tapered roller bearing inner race LH and RH.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00360)
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Fig. 201: Removing Tapered Roller Bearing Inner Race LH & RH

16. CHECK RING GEAR RUNOUT
Using a dial indicator, check the ring gear runout.
Fig. 202: Checking Ring Gear Runout

17. REMOVE RING GEAR

a. Place matchmarks on both the ring gear and the center differential control coupling.
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Fig. 203: Placing Matchmarks On Both Ring Gear & Center Differential Control Coupling
c. Using a plastic hammer, remove the ring gear.
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Fig. 204: Removing Ring Gear

18. CHECK CENTER DIFFERENTIAL CONTROL COUPLING RUNOUT
Using a dial indicator, check the center differential control coupling runout.
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Fig. 205: Checking Center Differential Control Coupling Runout

19. REMOVE DRIVEN PINION

a. Using SST and a hammer, unstake the lock nut.
SST 09930-00010 (09931-00010, 09931-00020)
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Fig. 206: Using SST & A Hammer To Unstake Lock Nut

b. Using SST, remove the lock nut.
SST 09326-20011, 09556-16030
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Fig. 207: Removing Lock Nut

c. Using a press, remove the driven pinion, the rear bearing inner race and the spacer.
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Fig. 208: Removing Driven Pinion, Rear Bearing Inner Race & Spacer
NOTE:  Place a waste cloth inside the case to prevent the driven pinion
from dropping.
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 Keep the case level using a wood plate.
d. 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
20. REMOVE BEARING OUTER RACE LH
Using a brass bar and a hammer, remove the outer race and the washer.
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Fig. 210: Removing Bearing Outer Race LH And Washer

21. REMOVE FRONT BEARING OUTER RACE
Using a brass bar and a hammer, remove outer race and washer.
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Fig. 211: Removing Front Bearing Outer Race And Washer

22. REMOVE REAR BEARING OUTER RACE
Using a brass bar and a hammer, remove outer race.
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Fig. 212: Removing Rear Bearing Outer Race

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)
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Fig. 213: Installing Rear Bearing Outer Race

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.
b. Using SST, bolt and nut, install outer race to the transfer case.
SST 09950-60010 (09951-00610, 09951-00620), 09950-60020 (09951-00790, 09951-00810)
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Fig. 214: Installing Front Bearing Outer Race To Transfer Case

3. INSTALL BEARING OUTER RACE LH

a. Install the washer to the transfer case.
HINT:
First install a washer of the same thickness as before.
b. Using SST and a press, install outer race to the transfer case.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07200)
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Fig. 215: Installing Bearing Outer Race LH To Transfer Case

4. INSTALL DRIVEN PINION

a. Using SST and a press, install the front bearing inner race to the driven pinion.
SST 09316-60011 (09316-00041)
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Fig. 216: Installing Front Bearing Inner Race To Driven Pinion

b. Install the driven pinion to the transfer case.
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Fig. 217: Installing Driven Pinion To Transfer Case

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.
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Fig. 218: Installing Spacer & Rear Bearing Inner Race To Driven Pinion
e. Using SST, install the lock nut.
SST 09326-20011, 09556-16030
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Torque:
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

HINT:
 Using a torque wrench with a fulcrum length of 380 mm (15.03 in.).

 This torque value is effective in case the SST is parallel to torque wrench.
NOTE: Do not tighten the nut until the final adjustment of the preload,
tooth contact and backlash is completed.
5. CHECK DRIVEN PINION PRELOAD
Using SST and a torque wrench, measure the driven pinion preload.
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SST 09326-2001
New bearing:
Reused bearing:
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Fig. 220: Measuring Driven Pinion Preload

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.
 If the preload is not sufficient, adjust the driven pinion by tightening the lock nut by 5° to 10° and
measuring the preload until the preload is within the standard value.
 If the preload is more than the standard value, replace the spacer with a new one.
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If the tightening torque for a driven pinion nut is more than the standard value, and the preload is

not sufficient, loosen the lock nut, apply gear oil on the thread and bearing surface and adjust it as
described above. When the tightening torque is less than the standard value, replace the spacer with
a new one.
6. ASSEMBLE CENTER DIFFERENTIAL CONTROL COUPLING
a. Clean the contact surface of the ring gear and center differential control coupling.
b. Heat the ring gear in water and boil for 10 minutes.
Fig. 221: Heating Ring Gear In Boiling Water

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
center differential control coupling.
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Fig. 222: Installing Ring Gear To Center Differential Control Coupling (Line-up
Matchmarks)
e. Install the 12 bolts.
f. Using SST and a press, install the center differential case tapered roller bearing inner race LH and
RH.
SST 09223-00010, 09506-35010, 09950-60010 (09951-00420)
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2005 Toyota RAV4
Fig. 223: Installing Center Differential Case Tapered Roller Bearing Inner Race LH & RH
7. INSTALL CENTER DIFFERENTIAL CONTROL COUPLING ASSEMBLY
Fig. 224: Installing Center Differential Control Coupling Assembly

8. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING OUTER RACE

RH
a. Install the washer to the bearing retainer RH.
b. Using SST and a press, install the outer race to the bearing retainer RH.
SST 09550-60010 (09951-00620), 09950-70010 (09951-07150)
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2005 Toyota RAV4
Fig. 225: Installing Outer Race To Bearing Retainer RH

9. INSTALL BEARING RETAINER RH

a. Place the transfer with the installation surface for the retainer upward.
b. Do centering of the center differential control coupling assembly and the case.
Microsoft
2005 Toyota RAV4
Fig. 226: Installing Bearing Retainer RH

c. Insert the SST into the retainer.
SST 09387-00090
NOTE: Insert the SST straight down without making its tip interfered the lip
of the oil seal.
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2005 Toyota RAV4
Fig. 227: Inserting SST Into Retainer

d. Insert the retainer and the SST into the case together as a unit.
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2005 Toyota RAV4
Fig. 228: Inserting Retainer & SST Into Case Together As A Unit
NOTE:  Do not make the transfer case, bearing retainer RH and SST
interfere with the center differential control coupling.
 Do not damage the retainer O-ring only after adjusting the
backlash, tooth contact and total pre-loading.
HINT:
When the retainer cannot be inserted in the case, give a slight blow with a plastic hammer and
insert it.
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2005 Toyota RAV4
e. After inserting the retainer in the case, remove the SST.

f. Install the 7 bolts.
Fig. 229: Removing SST From Retainer

10. INSPECT BACKLASH
Using a dial indicator, measure the backlash of the ring gear at 3 positions at least.
Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 in.)
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2005 Toyota RAV4
Fig. 230: Measuring Backlash Of Ring Gear

HINT:
The measure values should be used as reference when selecting washer, so take a note of the values.
If the backlash is not within the specification replace the washer on the ring gear side with one of a
different thickness using the following procedure.
Microsoft
2005 Toyota RAV4
Fig. 231: Identifying Washer For Backlash Adjusting

Washer thickness: mm (in.)

Mark Thickness Mark Thickness
AA 2.07 (0.0815) FB 2.55 (0.1004)
AB 2.10 (0.0827) FC 2.58 (0.1016)
AC 2.13 (0.0839) GA 2.61 (0.1028)
BA 2.16 (0.0850) GB 2.64 (0.1039)
BB 2.19 (0.0862) GC 2.67 (0.1051)
BC 2.22 (0.0874) HA 2.70 (0.1063)
CA 2.25 (0.0886) HB 2.73 (0.1075)
CB 2.28 (0.0898) HC 2.76 (0.1087)
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2005 Toyota RAV4
CD 2.31 (0.0909) JA 2.79 (0.1098)

DA 2.34 (0.0921) JB 2.82 (0.1110)
DB 2.37 (0.0933) JC 2.85 (0.1122)
DC 2.40 (0.0945) KA 2.88 (0.1134)
EA 2.43 (0.0957) KB 2.91 (0.1146)
EB 2.46 (0.0969) KC 2.94 (0.1157)
EC 2.49 (0.0980) LA 2.97 (0.1169)
FA 2.52 (0.0992) LB 3.00 (0.1181)
11. INSPECT TOOTH CONTACT PATTERN

a. 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

b. Rotate the ring gear, inspect the teeth pattern.
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2005 Toyota RAV4
Fig. 233: Locating Teeth Pattern

c. If the teeth are not contacting properly, select the proper washer again.
Microsoft
2005 Toyota RAV4
Fig. 234: Identifying Washer Tooth Contact Adjusting


AA 1.20 (0.0472) HC 1.43 (0.0563)
AB 1.21 (0.0476) JA 1.44 (0.0567)
AC 1.22 (0.0480) JB 1.45 (0.0571)
BA 1.23 (0.0484) JC 1.46 (0.0575)
BB 1.24 (0.0488) KA 1.47 (0.0579)
BC 1.25 (0.0492) KB 1.48 (0.0583)
CA 1.26 (0.0496) KC 1.49 (0.0587)
CB 1.27 (0.0500) LA 1.50 (0.0591)
CC 1.28 (0.0504) LB 1.51 (0.0594)
DA 1.29 (0.0508) LC 1.52 (0.0598)
DB 1.30 (0.0512) MA 1.53 (0.0602)
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2005 Toyota RAV4
DC 1.31 (0.0516) MB 1.54 (0.0606)

EA 1.32 (0.0520) MC 1.55 (0.0610)
EB 1.33 (0.0524) NA 1.56 (0.0614)
EC 1.34 (0.0528) NB 1.57 (0.0618)
FA 1.35 (0.0531) NC 1.58 (0.0622)
FB 1.36 (0.0535) PA 1.59 (0.0626)
FC 1.37 (0.0539) PB 1.60 (0.0630)
GA 1.38 (0.0543) PC 1.61 (0.0634)
GB 1.39 (0.0547) QA 1.62 (0.0638)
GC 1.40 (0.0551) QB 1.63 (0.0642)
HA 1.41 (0.0555) QC 1.64 (0.0646)
HB 1.42 (0.0559) RA 1.65 (0.0650)
12. ADJUST TOTAL PRELOAD
Using SST and a torque wrench, measure the total preload.
SST 09326-20011
Total preload:
New bearing:
Driven pinion preload + 0.2 to 0.4 N.m (2 to 4 kgf.cm, 1.8 to 3.5 in.lbf)
Reused bearing:
Driven pinion preload + 0.1 to 0.3 N.m (1 to 3 kgf.cm, 0.9 to 2.6 in.lbf)
Microsoft
2005 Toyota RAV4

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.
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2005 Toyota RAV4
If the preload is not as specified, select a proper washer again.
Fig. 236: Identifying Washer Preload Adjusting


AA 1.47 (0.0579) GB 2.04 (0.0803)
AB 1.50 (0.0591) GC 2.07 (0.0815)
AC 1.53 (0.0602) HA 2.10 (0.0827)
BA 1.56 (0.0614) HB 2.13 (0.0839)
BB 1.59 (0.0626) HC 2.16 (0.0850)
BC 1.62 (0.0638) JA 2.19 (0.0862)
CA 1.65 (0.0650) JB 2.22 (0.0874)
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2005 Toyota RAV4
CB 1.68 (0.0661) JC 2.25 (0.0886)

CC 1.71 (0.0673) KA 2.28 (0.0898)
DA 1.74 (0.0685) KB 2.31 (0.0909)
DB 1.77 (0.0697) KC 2.34 (0.0921)
DC 1.80 (0.0709) LA 2.37 (0.0933)
EA 1.83 (0.0720) LB 2.40 (0.0945)
EB 1.86 (0.0734) LC 2.43 (0.0957)
EC 1.89 (0.0744) MA 2.46 (0.0969)
FA 1.92 (0.0756) MB 2.49 (0.0980)
FB 1.95 (0.0768) MC 2.52 (0.0992)
FC 1.98 (0.0780) NA 2.55 (0.1004)
GA 2.01 (0.0791) NB 2.58 (0.1016)
13. REMOVE BEARING RETAINER RH

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2005 Toyota RAV4
Fig. 237: Removing Bolts Of Bearing Retainer RH

b. Using a screwdriver and a hammer, make clearance by hitting between the bearing retainer RH and
the transfer case.
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2005 Toyota RAV4
Fig. 238: Using A Screwdriver & A Hammer To Make Clearance By Hitting Between Bearing
Retainer RH & Transfer Case
c. Using SST, remove the bearing retainer RH from the transfer case.
SST 09520-10021
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2005 Toyota RAV4
Fig. 239: Removing Bearing Retainer RH From Transfer Case

d. Using SST, remove the outer race and washer from the bearing retainer RH.
SST 09308-00010
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2005 Toyota RAV4
Fig. 240: Removing Outer Race & Washer From Bearing Retainer RH
14. ASSEMBLE BEARING RETAINER RH

a. Install the side gear shaft holder bearing to the bearing retainer RH.
b. Using snap ring pliers, install the snap ring.
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2005 Toyota RAV4
Fig. 241: Installing Snap Ring

c. Coat the oil seal lip with MP grease.

d. Using SST and a press, install the oil seal to the bearing retainer RH.
SST 09950-60010 (09951-00370, 09951-00540, 09952-06010), 09950-70010 (09951-07150)
Microsoft
2005 Toyota RAV4
Fig. 242: Installing Oil Seal To Bearing Retainer RH

e. Install the washer.

f. Using SST and a press, install the outer race to the bearing retainer RH
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
Microsoft
2005 Toyota RAV4
Fig. 243: Installing Outer Race To Bearing Retainer RH

g. Coat new 2 O-rings with gear oil, and install them to the bearing retainer RH.
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2005 Toyota RAV4
Fig. 244: Installing O-Rings To Bearing Retainer RH

15. INSTALL BEARING RETAINER RH

a. Place the transfer with the installation surface for the retainer upward.
b. Do centering of the center differential control coupling assembly and the case.
Microsoft
2005 Toyota RAV4
Fig. 245: Installing Bearing Retainer RH

c. Insert the SST into the retainer.
SST 09387-00090
NOTE: Insert the SST straight down without making its tip interfered the lip
of the oil seal.
Microsoft
2005 Toyota RAV4
Fig. 246: Inserting SST Into Retainer

d. Insert the retainer and the SST into the case together as a unit.
Microsoft
2005 Toyota RAV4
Fig. 247: Inserting Retainer & SST Into Case As Unit

NOTE:  Do not strongly make the case and retainer interfered. Neither
the SST or the center differential control coupling.
 Pay attention to the scratches and the curving up of the retainer
O-ring only after adjusting the backlash, tooth contact and total
pre-loading.
Microsoft
2005 Toyota RAV4
Microsoft
2005 Toyota RAV4
Fig. 248: Identifying Oil Seal & O-Ring

HINT:
When the retainer cannot be inserted in the case, give a slight blow with a plastic hammer and
insert it.
e. After inserting the retainer in the case, remove the SST.

f. Install the 7 bolts.
NOTICE:
16. RECHECK TOTAL PRELOAD (See step 12)

17. INSTALL OIL SEAL
a. Coat the oil seal lip with MP grease.
b. Using SST, install the oil seal to the bearing retainer RH.
SST 09223-46011
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2005 Toyota RAV4
Fig. 249: Installing Oil Seal To Bearing Retainer RH

c. Coat the oil seal lip with MP grease.

d. Using SST, install the oil seal to the transfer case.
SST 09387-00010, 09950-70010 (09951-07150)
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2005 Toyota RAV4
Fig. 250: Installing Oil Seal To Transfer Case

18. INSTALL CENTER DIFFERENTIAL LOCK SLEEVE

a. Coat new O-ring with gear oil, install it to the center differential lock sleeve.
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2005 Toyota RAV4
Fig. 251: Installing O-Ring To Center Differential Lock Sleeve

b. Using SST, install the center differential lock sleeve to the transfer case.
SST 09950-60010 (09951-00600), 09950-70010 (09951-07150)
Microsoft
2005 Toyota RAV4
Fig. 252: Installing Center Differential Lock Sleeve To Transfer Case

c. Using snap ring pliers, install the snap ring.
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2005 Toyota RAV4
Fig. 253: Installing Snap Ring

19. STAKE LOCK NUT
Using a chisel and a hammer, stake the lock nut.
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2005 Toyota RAV4
Fig. 254: Using A Chisel & A Hammer To Stake Lock Nut

20. INSTALL EXTENSION HOUSING

a. Coat the oil seal lip with MP grease.
b. Using SST, install the oil seal to the extension housing.
SST 09950-60010 (09951-00380, 09951-00590, 09952-06010) 09950-70010 (09951-07150)
Microsoft
2005 Toyota RAV4
Fig. 255: Installing Oil Seal To Extension Housing

c. Using SST and a press, install the dust deflector to the extension housing.
SST 09950-60010 (09951-00640), 09950-70010 (09951-07150)
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2005 Toyota RAV4
Fig. 256: Installing Dust Deflector To Extension Housing

d. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the
extension housing and the transfer case.
e. Apply FIPG to the extension housing.
FIPG:
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2005 Toyota RAV4
Fig. 257: Locating Seal Bend Width

f. Install the extension housing with 4 bolts.
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2005 Toyota RAV4
Fig. 258: Installing Extension Housing

21. INSTALL STUD BOLT
Install the 4 new stud bolts to the transfer case.
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2005 Toyota RAV4
Microsoft
2005 Toyota RAV4
Fig. 259: Installing Stud Bolts To Transfer Case

HINT:
From the bottom side of the stud bolt shown in Fig. 259, it should be installed to the case.

 Install the stud bolt to the transfer case which has sealer applied on it.
22. INSTALL PIN
Using a plastic hammer, install the 4 pins.
Fig. 260: Installing Pins

23. REMOVE TRANSFER FROM OVERHAUL ATTACHMENT

24. INSTALL CASE COVER
a. Install the oil deflector with a bolt to the case cover.
NOTE: Pay due attention to the direction of deflector bending.

Microsoft
2005 Toyota RAV4
Fig. 261: Installing Bolts Of Oil Deflector

b. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the case
cover and the transfer case.
c. Apply FIPG to the case cover.
FIPG:
Microsoft
2005 Toyota RAV4
Fig. 262: Identifying Seal Bend Width

d. Install the No. 1 case cover with 2 new seal bolts and 6 bolts.
Microsoft
2005 Toyota RAV4
Fig. 263: Identifying Location Of Seal Bolts (x2) In No. 1 Case Cover
25. INSTALL INTERMEDIATE SHAFT

26. INSTALL GASKET
Coat new gasket with ATF, install it to the transfer case.
Microsoft
2005 Toyota RAV4
Fig. 264: Installing Gasket Into Transfer Case

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2005 Toyota RAV4

2005 TRANSMISSION Manual Transaxle - RAV4

Manual Transaxle - RAV4

Fig. 1: Problem Symptoms Table

MANUAL TRANSAXLE UNIT (2WD)

REPLACE TRANSAXLE OIL

a. Loosen the filler plug.

Use a container to catch the transaxle oil.

c. Remove the filler plug.

Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)

e. Refill new transaxle oil as shown, see Fig. 2.

Oil grade: API GL-4 or GL-5

Viscosity: SAE 75W-90

Capacity: 2.5 liters (2.6 US qts, 2.2 Imp.qts)

f. Reinstall the filler plug.

Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)

Fig. 2: Identifying Transaxle Filler Plug

Remove the 4 bolts and hood.

Torque: 13 N.m (133 kgf.cm, 9.6 ft.lbf)

2. REMOVE AIR CLEANER ASSEMBLE WITH AIR HOSE

Fig. 5: Disconnecting Control Cables

5. DISCONNECT VEHICLE SPEED SENSOR AND BACK-UP LIGHT SWITCH CONNECTORS

Remove the bolt and disconnect the ground cable.

Fig. 6: Disconnecting Ground Cable

Torque: 37 N.m (378 kgf.cm, 28 ft.lbf)

8. DISCONNECT CLUTCH RELEASE CYLINDER AND LINE

25 N.m (255 kgf.cm, 18 ft.lbf) for bolt A

12 N.m (120 kgf.cm, 9 ft.lbf) for bolt B

5 N.m (51 kgf.cm, 44 in.lbf) for bolt C

b. Remove the 2 bolts and heat insulator.

Torque: 12 N.m (120 kgf.cm, 9 ft.lbf)

Torque: 12 N.m (120 kgf.cm, 9 ft.lbf)

Fig. 7: Removing Clutch Release Cylinder & Lines

9. REMOVE 5 MOUNTING BOLTS OF TRANSAXLE UPPER SIDE

64 N.m (650 kgf.cm, 47 ft.lbf) for bolt A

46 N.m (470 kgf.cm, 34 ft.lbf) for bolt B

Fig. 8: Removing Mounting Bolts Of Transaxle Upper Side

10. ATTACH ENGINE SUPPORT FIXTURE

No. 2 engine hanger: 12281-28010

Torque: 38 N.m (387 kgf.cm, 28 ft.lbf)

Fig. 9: Attaching Engine Support Fixture To Engine Hangers

11. DISCONNECT LEFT ENGINE MOUNTING INSULATOR FROM TRANSAXLE

Remove the bolt and nut.

Fig. 10: Disconnecting Left Engine Mounting Insulator From Transaxle

Torque: 56 N.m (571 kgf.cm, 41 ft.lbf)

12. REMOVE LH AND RH ENGINE UNDER COVERS

Torque: 43 N.m (439 kgf.cm, 32 ft.lbf)

b. Remove the 2 bolts and 2 gaskets with pipe.

Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)

At the time of installation, using the new gasket.

15. REMOVE LH AND RH FRONT DRIVE SHAFTS (See REMOVAL )

16. DISCONNECT 2 STABILIZER BAR LINKS

Torque: 44 N.m (450 kgf.cm, 32 ft.lbf)

Fig. 11: Disconnecting LH & RH Stabilizer Bar Links

17. REMOVE FRONT SUSPENSION CROSSMEMBER ASSEMBLY WITH STABILIZER BAR

Torque: 137 N.m (1,397 kgf.cm, 101 ft.lbf)

Fig. 12: Removing Set Bolts Of PS Gear Assembly

18. REMOVE ENGINE MOUNTING CENTER MEMBER

Remove the 4 bolts and center member.