Manual Transaxle Assembly Removal

Transmission. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35
E352F E359F Manual Transaxle. Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. REMOVE FRONT WHEELS

  3. DISCHARGE FUEL SYSTEM PRESSURE

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  5. DRAIN TRANSAXLE OIL

  6. DRAIN TRANSFER OIL

  7. REMOVE STARTER ASSEMBLY (for 1AZ-FE)

  8. REMOVE STARTER ASSEMBLY (for 2AZ-FE)

  9. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

  10. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

  11. DISCONNECT TRANSAXLE CONTROL CABLE ASSEMBLY

  12. REMOVE ENGINE ASSEMBLY WITH MANUAL TRANSAXLE

  13. REMOVE TRANSFER ASSEMBLY

  14. REMOVE FRONT ENGINE MOUNTING BRACKET

  15. REMOVE ENGINE MOUNTING BRACKET LH

  16. REMOVE REAR ENGINE MOUNTING BRACKET

  17. REMOVE OIL PAN INSULATOR

  18. REMOVE STIFFENER PLATE LH

  19. REMOVE STIFFENER PLATE RH

  20. REMOVE MANUAL TRANSAXLE ASSEMBLY

  21. REMOVE MANUAL TRANSAXLE CASE PROTECTOR

Manual Transaxle Assembly -- Removal



1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD


2. REMOVE FRONT WHEELS


3. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
  1. DISCHARGE FUEL SYSTEM PRESSURE procedures must be performed before disconnecting any part of the fuel system.
  2. After performing the DISCHARGE FUEL SYSTEM PRESSURE procedures, pressure will remain in the fuel line. When disconnecting the fuel line, place a cloth or equivalent over fittings to reduce the risk of fuel spray.

  1. Remove the console box (RAV4_ACA30 RM000001RHJ00GX_01_0039.html).



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.E352F E359F Manual Transaxle.Manual Transaxle System.Manual Transaxle Assembly Removal

  1. Disconnect the connector.

  1. Start the engine. After the engine has stopped, turn the ignition switch off.

    HINT:
    DTC P0171 (system too lean) may be set.

  1. Check that the engine does not start.

  1. Remove the fuel tank cap, and let the air out of the fuel tank.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.E352F E359F Manual Transaxle.Manual Transaxle System.Manual Transaxle Assembly Removal

  1. Connect the connector.

  1. Install the console box (RAV4_ACA30 RM000001RHG00HX_01_0010.html).



4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.


5. DRAIN TRANSAXLE OIL

  1. Remove the filler plug and gasket.

  1. Remove the drain plug and gasket, and drain the oil.

  1. Install a new gasket and the drain plug.

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


6. DRAIN TRANSFER OIL

  1. Remove the drain plug and gasket, and drain the oil.

  1. Install a new gasket and the drain plug.

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


7. REMOVE STARTER ASSEMBLY (for 1AZ-FE)

  1. Remove the starter (RAV4_ACA30 RM000000YQ400RX.html).



8. REMOVE STARTER ASSEMBLY (for 2AZ-FE)

  1. for 1.6 kW Type:
    Remove the starter (RAV4_ACA30 RM000000YQ400SX.html).

  1. for 1.7 kW Type:
    Remove the starter (RAV4_ACA30 RM000000YQ400TX.html).



9. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.E352F E359F Manual Transaxle.Manual Transaxle System.Manual Transaxle Assembly Removal

  1. Disconnect the back-up light switch connector.

  1. Remove the back up light switch and gasket from the manual transaxle case.



10. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

  1. for 1AZ-FE:
    Disconnect the clutch release cylinder (RAV4_ACA30 RM000001DEN00AX_01_0002.html).

  1. for 2AZ-FE:
    Disconnect the clutch release cylinder (RAV4_ACA30 RM000001DEN00BX.html).



11. DISCONNECT TRANSAXLE CONTROL CABLE ASSEMBLY


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 2 clips and 2 washers, and disconnect the 2 cables from the transaxle.

  1. Remove the 2 clips, and disconnect the 2 cables from the bracket.



12. REMOVE ENGINE ASSEMBLY WITH MANUAL TRANSAXLE

  1. for 1AZ-FE:
    Remove the engine with transaxle (RAV4_ACA30 RM000001BC300NX.html).

  1. for 2AZ-FE:
    Remove the engine with transaxle (RAV4_ACA30 RM000001BC300OX.html).



13. REMOVE TRANSFER ASSEMBLY


    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. except K111F:
    Remove the 6 nuts, 2 bolts and transfer from the transaxle.



    Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. for K111F:
    Remove the 6 nuts and transfer from the transaxle.



14. REMOVE FRONT ENGINE MOUNTING BRACKET


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 3 bolts and bracket.



15. REMOVE ENGINE MOUNTING BRACKET LH


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 3 bolts and bracket.



16. REMOVE REAR ENGINE MOUNTING BRACKET


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 3 bolts and mounting bracket.



17. REMOVE OIL PAN INSULATOR


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 2 bolts and insulator from the stiffener plate.



18. REMOVE STIFFENER PLATE LH


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 4 bolts and stiffener plate from the engine and transaxle assembly.



19. REMOVE STIFFENER PLATE RH


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35

  1. Remove the 4 bolts and stiffener plate from the engine and transaxle assembly.



20. REMOVE MANUAL TRANSAXLE ASSEMBLY


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.E352F E359F Manual Transaxle.Manual Transaxle System.Manual Transaxle Assembly Removal

  1. Remove the 10 bolts.

  1. Separate and remove the transaxle from the engine.



21. REMOVE MANUAL TRANSAXLE CASE PROTECTOR


Toyota Rav4. Aca30, 33, 38 Gsa33 Zsa30, 35.E352F E359F Manual Transaxle.Manual Transaxle System.Manual Transaxle Assembly Removal

  1. Remove the 2 bolts and case protector.