Manual Transaxle Assembly Installation

Install the case protector with the 2 bolts.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Align the input shaft with the clutch disc and install the transaxle to the engine.

Install the 10 bolts.

Torque:

64 N*m{653 kgf*cm, 47 ft.*lbf}for bolt A

46 N*m{469 kgf*cm, 34 ft.*lbf}for bolt B

44 N*m{449 kgf*cm, 32 ft.*lbf}for bolt C

Install the stiffener plate with the 4 bolts.

Torque:

46 N*m{469 kgf*cm, 34 ft.*lbf}

Install the stiffener plate with the 4 bolts.

Torque:

46 N*m{469 kgf*cm, 34 ft.*lbf}

Install the insulator with the 2 bolts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Install the bracket with the 3 bolts.

Torque:

45 N*m{459 kgf*cm, 33 ft.*lbf}

Install the bracket with the 3 bolts.

Torque:

64 N*m{653 kgf*cm, 47 ft.*lbf}

Install the bracket with the 3 bolts.

Torque:

64 N*m{653 kgf*cm, 47 ft.*lbf}

Connect the 2 cable ends with the 2 washers and 2 clips.

Install 2 new clips to the control cable bracket.

1AZ-FE:
Install the clutch release cylinder (RAV4_ACA30 RM000001DEP00AX.html).

2AZ-FE:
Install the clutch release cylinder (RAV4_ACA30 RM000001DEP00BX.html).

Install the back-up light switch and gasket to the manual transaxle case.

Torque:

40 N*m{410 kgf*cm, 30 ft.*lbf}

Connect the back-up light switch connector.

except K111F:
Install the transfer to the transaxle with the 6 nuts and 2 bolts.

Torque:

69 N*m{700 kgf*cm, 51 ft.*lbf}

for K111F:
Install the transfer to the transaxle with the 6 nuts and 2 bolts.

Torque:

69 N*m{700 kgf*cm, 51 ft.*lbf}

for 1AZ-FE:
Install the engine with manual transaxle (RAV4_ACA30 RM000001BC100NX.html).

for 2AZ-FE:
Install the engine with manual transaxle (RAV4_ACA30 RM000001BC100OX.html).

Stop the vehicle in a level place.

Remove the transaxle filler plug and gasket.

Check that the oil level is between 0 to 5 mm (0 to 0.20 in.) from the bottom lip of the filler plug opening. If the result is not as specified, add transaxle oil.

Oil grade:

GL-4

Viscosity:

SAE 75W

Standard capacity:

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

NOTICE:

1. Too much or too little oil will lead to transaxle problems.
   
2. After adjusting the oil level, drive the vehicle and check the oil level again.
   

Check for oil leakage if the oil level is low.

Install the transaxle filler plug and a new gasket.

Torque:

49 N*m{500 kgf*cm, 36 ft.*lbf}

Remove the transfer case plug No. 2 (for filler) and gasket.

Check that the oil level is between 0 to 5.0 mm (0 to 0.20 in.) from the bottom lip of the case plug (for filler) hole.
If the result is not as specified, add transfer oil.

Oil grade:

Hypoid gear oil SX API GL-5 or equivalent

Viscosity:

SAE 85W-90

Standard capacity:

0.45 liter (0.48 US qts, 0.40 Imp. qts)

NOTICE:

1. When adding oil, pour it slowly.
   
2. Too much or too little oil will lead to transfer problems.
   

When the oil level is too low, check for oil leakage.

Install a new gasket into the case plug (for filler) and then install the plug.

Torque:

39 N*m{398 kgf*cm, 28 ft.*lbf}