Differential Oil Seal Replacement

Remove the front drive shaft assembly (RAV4_ACA30 RM00000226Q008X.html).

Using SST, remove the transmission case oil seal.

SST

09308-00010

Remove the manual transaxle assembly (RAV4_ACA30 RM000001B3W02WX.html).

Using a union nut wrench, separate the clutch release bleeder sub-assembly from the clutch release cylinder to bleeder tube.

Remove the 2 bolts and clutch release bleeder sub-assembly from the manual transaxle assembly.

Remove the clutch tube boot from the manual transaxle assembly.

Remove the 3 bolts and clutch release with bearing cylinder assembly and clutch release cylinder to bleeder tube.

Using a union nut wrench, remove the clutch release cylinder to bleeder tube from the clutch release with bearing cylinder assembly.

Place the manual transaxle on wooden blocks.

Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.

Remove the 17 bolts.

Using a screwdriver with its tip wrapped with protective tape, separate the manual transmission case from the front transaxle case.

NOTICE:

Do not damage the manual transmission case.

Turn the outer No. 1 shift lever clockwise until it comes into contact with the boss.

Push the outer No. 1 shift lever and remove the manual transmission case.

Remove the reverse idler gear, thrust washer and reverse idler gear shaft from the front transaxle case.

Turn the reverse shift fork shaft clockwise and remove it from the front transaxle case.

Using a 5 mm pin punch and hammer, tap out the reverse shift fork slotted spring pin.

Remove the reverse shift fork from the reverse shift fork shaft.

Using a 6 mm hexagon socket wrench, remove the 2 bolts and reverse shift arm bracket from the front transaxle case.

Turn the shift and select lever shaft clockwise and remove it from the front transaxle case.

Remove the input shaft assembly, output shaft assembly and 2 gear shift fork shaft assemblies from the front transaxle case.

Remove the output shaft assembly together with the No. 1 gear shift fork shaft assembly from the input shaft assembly.

Remove the No. 1 gear shift fork shaft assembly from the output shaft assembly.

Remove the No. 2 gear shift fork shaft assemblies from the input shaft assembly.

Remove the differential case from the front transaxle case.

Using SST, remove the front differential case oil seal from the front differential case.

SST

09308-00010

Using SST, remove the front transaxle case oil seal.

SST

09308-00010

Coat the lip of a new oil seal with MP grease.

Using SST and a hammer, tap in the front transaxle case oil seal to the front transaxle case.

SST

09710-30050
09950-70010(09951-07100)

Standard depth:

5.5 to 6.5 mm (0.217 to 0.256 in.)

NOTICE:

Do not damage the oil seal lip.

Coat the lip of a new oil seal with MP grease.

Using SST and a hammer, tap in a new front differential case oil seal to the front differential case.

SST

09950-60010(09951-00330,09951-00410,09952-06010)
09950-70010(09951-07100)

Standard depth:

21.5 to 22.5 mm (0.846 to 0.885 in.)

NOTICE:

Do not damage the oil seal lip.

Coat the differential case assembly with gear oil and install it to the front transaxle case.

Coat the output shaft assembly with gear oil and install it to the front transaxle case.

Install the manual transmission case with the 17 bolts.

Torque:

29 N*m{300 kgf*cm, 22 ft.*lbf}

Using SST and a torque wrench, turn the differential case assembly clockwise and counterclockwise 2 or 3 times to allow the bearings to settle.

SST

09564-50010

Using SST and a torque wrench, measure the preload (value A). Calculate the rear output shaft bearing preload using the following formula.

SST

09564-50010

Formula:

Value A - Differential side bearing preload = Output shaft bearing preload

Preload (at starting):

New bearing:

3.17 to 6.35 N*m (32 to 65 kgf*cm, 28 to 56 in.*lbf)

Used bearing:

2.61 to 5.24 N*m (27 to 53 kgf*cm, 23 to 46 in.*lbf)

Standard Bearing Shim Thickness:

Mark	Specified Condition	Mark	Specified Condition
A	1.30 mm (0.511 in.)	P	1.95 mm (0.768 in.)
B	1.35 mm (0.531 in.)	Q	2.00 mm (0.787 in.)
C	1.40 mm (0.551 in.)	R	2.05 mm (0.807 in.)
D	1.45 mm (0.571 in.)	S	2.10 mm (0.827 in.)
E	1.50 mm (0.591 in.)	T	2.15 mm (0.846 in.)
F	1.55 mm (0.610 in.)	U	2.20 mm (0.866 in.)
G	1.60 mm (0.630 in.)	V	2.25 mm (0.886 in.)
H	1.65 mm (0.650 in.)	W	2.30 mm (0.906 in.)
J	1.70 mm (0.669 in.)	X	2.35 mm (0.925 in.)
K	1.75 mm (0.689 in.)	Y	2.40 mm (0.945 in.)
L	1.80 mm (0.709 in.)	Z	2.45 mm (0.965 in.)
M	1.85 mm (0.728 in.)	1	2.50 mm (0.984 in.)
N	1.90 mm (0.748 in.)	-	-

HINT:

Select a thicker bearing shim to increase the preload, or a thinner bearing shim to decrease the preload.

Remove the 17 bolts and manual transmission case.

Remove the output shaft assembly from the front transaxle case.

Remove the differential case from the front transaxle case.

Replace the installed rear output shaft bearing shim with the one selected above.

Coat the differential case tapered roller bearing with gear oil and install it to the front transaxle case.

Apply gear oil to all sliding and rotating parts.

Coat the No. 1 gear shift fork shaft with gear oil and install it onto the output shaft assembly.

Coat the No. 2 gear shift fork shaft with gear oil and install it onto the input shaft assembly.

Temporarily install the output shaft with No. 1 gear shift fork shaft to the input shaft assembly, and tie them with a rope or string.

Install the input shaft assembly, output shaft assembly and 2 gear shift fork shaft assemblies to the front transaxle case.

Install the shift interlock plate and shift and select lever shaft assembly to the front transaxle case, and then turn them counterclockwise.

HINT:

When installing the shift interlock plate, make sure to engage it with the inner select lever.

Coat the threads of the 2 bolts with adhesive, and then install the reverse shift arm bracket with the 2 bolts.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Torque:

17 N*m{175 kgf*cm, 13 ft.*lbf}

Using a 5 mm pin punch and a hammer, install the reverse shift fork slotted pin onto the reverse shift fork shaft.

Standard driven in depth:

-0.5 to 0.5 mm (-0.0196 to 0.0196 in.)

NOTICE:

Confirm the installation direction.

Coat the reverse shift fork shaft assembly with gear oil and install it onto the front transaxle case.

Coat the reverse idler gear sub-assembly, thrust washer and reverse idler gear shaft with gear oil, and install them as shown in the illustration.

HINT:

Raise the edge of the reverse shift arm bracket assembly and connect the reverse shift arm bracket assembly to the reverse shift fork shaft assembly.

NOTICE:

Using the bolt hole of the case for reference, align the I-groove mark of the reverse idler gear shaft within the range shown (approximately 20°).

Apply seal packing to the manual transmission case as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

Seal packing diameter:

1.2 mm (0.0472 in.)

NOTICE:

1. Remove any oil from the contact surfaces.
   
2. Assemble the parts within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
   

Push the outer No. 1 shift lever and install the manual transmission case.

HINT:

Pushing the outer No. 1 shift lever allows the manual transmission case to be installed.

Turn the outer No. 1 shift lever counterclockwise and then pull it.

Install the manual transmission case with the 17 bolts.

Torque:

29 N*m{300 kgf*cm, 22 ft.*lbf}

Install a new gasket and the reverse idler gear shaft bolt to the manual transmission case.

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

Temporarily install the clutch release cylinder to bleeder tube to a new clutch release with bearing cylinder assembly.

Clean and degrease all installation surfaces for the clutch release with bearing cylinder assembly.

Install the clutch release with bearing cylinder assembly with 3 new bolts.

Torque:

23 N*m{229 kgf*cm, 17 ft.*lbf}

NOTICE:

1. The clutch release with bearing cylinder and installation bolts cannot be reused and must be replaced with new ones.
   
2. Clean and degrease all installation surfaces and make sure the clutch release with bearing cylinder fits securely with the transaxle during installation. The first bolt should be tightened by hand while holding the clutch release with bearing cylinder.
   
3. Make sure that none of the clutch spline grease adheres to the clutch release with bearing cylinder.
   
4. The clutch release with bearing cylinder cannot be disassembled.
   

Install the clutch tube boot to the manual transaxle assembly.

Temporarily install the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.

Temporarily install the clutch release bleeder sub-assembly with the 2 bolts.

Using a union nut wrench, install the clutch release cylinder to bleeder tube to the clutch release with bearing cylinder assembly.

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (RAV4_ACA30 RM0000018UO018X.html).

Apply clutch spline grease to the input shaft spline.

Grease:

Toyota Genuine Clutch Spline Grease or equivalent

Separate the clutch release cylinder to bleeder tube from the clutch release bleeder sub-assembly.

Remove the 2 bolts and clutch release bleeder sub-assembly.

Using SST, apply a pressure of 100 kPa (1.0 kgf/cm², 15 psi) to the clutch pipe location shown in the illustration and confirm that pressure is maintained for 15 seconds or more.

SST

09992-00242

Temporarily install the clutch release cylinder to bleeder tube to the clutch release bleeder sub-assembly.

Install the clutch release bleeder sub-assembly with the 2 bolts.

Torque:

17 N*m{170 kgf*cm, 12 ft.*lbf}

Using a union nut wrench, install the clutch release cylinder to bleeder tube.

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (RAV4_ACA30 RM0000018UO018X.html).

the manual transaxle assembly (RAV4_ACA30 RM000001B3U02WX.html).

Coat the lip of a new oil seal with MP grease.

Using SST and a hammer, tap in the transmission case oil seal to the manual transmission case.

SST

09608-32010
09950-70010(09951-07100)

Standard depth:

-0.5 to 0.5 mm (-0.0197 to 0.0196 in.)

NOTICE:

Do not damage the oil seal lip.

Install the front drive shaft assembly (RAV4_ACA30 RM00000226O008X.html).