Toyota RAV4 2005 User manual

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

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.
Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.

Fig. 2: Identifying Transaxle Filler Plug
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
COMPONENTS
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 3 © 2005 Mitchell Repair Information Company, LLC.

Fig. 3: Exploded View Of R&I Components Related To Manual Transaxle & Torque Specifications
(2WD) (1 Of 2)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 4 © 2005 Mitchell Repair Information Company, LLC.

Fig. 4: Exploded View Of R&I Components Related To Manual Transaxle & Torque Specifications
(2WD) (2 Of 2)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 5 © 2005 Mitchell Repair Information Company, LLC.

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
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 6 © 2005 Mitchell Repair Information Company, LLC.

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
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
7. REMOVE STARTER
a. Disconnect the starter connector.
b. Remove the nut and disconnect the starter cable.
c. Remove the 2 bolts and starter.
Torque: 37 N.m (378 kgf.cm, 28 ft.lbf)
8. DISCONNECT CLUTCH RELEASE CYLINDER AND LINE
a. Remove the 3 bolts.
Torque:
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 7 © 2005 Mitchell Repair Information Company, LLC.

25 N.m (255 k
g
f.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)
c. Remove the 2 bolts and disconnect the release cylinder and line.
Torque: 12 N.m (120 kgf.cm, 9 ft.lbf)
Fig. 7: Removing Clutch Release Cylinder & Lines
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
9. REMOVE 5 MOUNTING BOLTS OF TRANSAXLE UPPER SIDE
Torque:
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 8 © 2005 Mitchell Repair Information Company, LLC.

64 N.m (650 k
g
f.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
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
10. ATTACH ENGINE SUPPORT FIXTURE
a. Install the No. 2 engine hanger in the correct direction. Parts No. :
No. 2 engine hanger: 12281-28010
Bolt: 91512-61020
Torque: 38 N.m (387 kgf.cm, 28 ft.lbf)
b
.Usin
g
an en
g
ine slin
g
device, attach the en
g
ine support fixture to the en
g
ine han
g
ers.
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 9 © 2005 Mitchell Repair Information Company, LLC.

Fig. 9: Attaching Engine Support Fixture To Engine Hangers
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
11. DISCONNECT LEFT ENGINE MOUNTING INSULATOR FROM TRANSAXLE
Remove the bolt and nut.
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 10 © 2005 Mitchell Repair Information Company, LLC.

Fig. 10: Disconnecting Left Engine Mounting Insulator From Transaxle
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Torque: 56 N.m (571 kgf.cm, 41 ft.lbf)
12. REMOVE LH AND RH ENGINE UNDER COVERS
13. DRAIN TRANSAXLE OIL (See MANUAL TRANSAXLE UNIT (2WD))
14. REMOVE FRONT EXHAUST PIPE
a. Remove the 2 bolts and springs from the exhaust manifold.
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)
HINT:
At the time of installation, using the new gasket.
15. REMOVE LH AND RH FRONT DRIVE SHAFTS (See REMOVAL )
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 11 © 2005 Mitchell Repair Information Company, LLC.

16. DISCONNECT 2 STABILIZER BAR LINKS
Remove the 2 nuts and disconnect the LH and RH stabilizer bar links.
Torque: 44 N.m (450 kgf.cm, 32 ft.lbf)
Fig. 11: Disconnecting LH & RH Stabilizer Bar Links
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
17. REMOVE FRONT SUSPENSION CROSSMEMBER ASSEMBLY WITH STABILIZER BAR
a. Support the front suspension crossmember with a jack.
b. Remove the 2 set bolts of the PS gear assembly.
Torque: 137 N.m (1,397 kgf.cm, 101 ft.lbf)
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 12 © 2005 Mitchell Repair Information Company, LLC.

Fig. 12: Removing Set Bolts Of PS Gear Assembly
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
c. Remove the 2 nuts, 5 bolts and front suspension crossmember assembly with the stabilizer bar.
Torque:
Bolt A: 113 N.m (1,150 kgf.cm, 82 ft.lbf) Bolt B: 157 N.m (1,600 kgf.cm, 115 ft.lbf) Bolt C: 72
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)
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
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Fig. 13: Removing Bolts Of Center Member
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
19. JACK UP TRANSAXLE SLIGHTLY
Using a transmission jack, support the transaxle.
20. REMOVE 4 MOUNTING BOLTS OF TRANSAXLE LOWER SIDE
Torque:
46 N.m (470 kgf.cm, 34 ft.lbf) for bolt A
44 N.m (440 kgf.cm, 32 ft.lbf) for bolt B
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 14 © 2005 Mitchell Repair Information Company, LLC.

Fig. 14: Removing Mounting Bolts Of Transaxle Lower Side
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
21. REMOVE TRANSAXLE
Lower the engine left side, then slowly and carefully remove the transaxle from the engine.
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:
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 15 © 2005 Mitchell Repair Information Company, LLC.

After installation, check and inspect items as follows.
Check the front wheel alignment (See FRONT WHEEL ALIGNMENT ).
Do the road test.
MANUAL TRANSAXLE UNIT (4WD)
ON-VEHICLE REPAIR
REPLACE TRANSAXLE OIL
a. 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. 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)
f. Reinstall the filler plug.
Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 16 © 2005 Mitchell Repair Information Company, LLC.

Fig. 15: Identifying Transaxle Filler Plug
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
COMPONENTS
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 17 © 2005 Mitchell Repair Information Company, LLC.

Fig. 16: Exploded View Of Manual Transaxle & Torque Specifications (4WD)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 18 © 2005 Mitchell Repair Information Company, LLC.

REMOVAL
1. REMOVE TRANSAXLE WITH ENGINE (See REMOVAL )
2. REMOVE TRANSAXLE CASE PROTECTOR
Remove the 2 bolts and transaxle case protector.
Torque: 18 N.m (180 kgf.cm, 13 ft.lbf)
3. DISCONNECT BACK-UP LIGHT SWITCH AND VEHICLE SPEED SENSOR CONNECTORS
4. REMOVE TRANSFER STIFFENER PLATE
Remove the 5 bolts and stiffener plate.
Torque: 34 N.m (347 kgf.cm, 25 ft.lbf)
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 19 © 2005 Mitchell Repair Information Company, LLC.

Fig. 17: Removing Stiffener Plate
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
5. REMOVE TRANSAXLE FROM ENGINE
Remove the 10 bolts, separate the engine and transaxle.
Torque:
64 N.m (650 kgf.cm, 47 ft.lbf) for bolt A
46 N.m (470 kgf.cm, 34 ft.lbf) for bolt B
44 N.m (440 kgf.cm, 32 ft.lbf) for bolt C
2005 Toyota RAV4
2005 TRANSMISSION Manual Transaxle - RAV4
Microsoft
Tuesday, July 21, 2009 9:47:22 AM Page 20 © 2005 Mitchell Repair Information Company, LLC.