Transfer Case (Service Information): Overview Toyota RAV4 IV

Scheme 22

1. CHECK TRANSFER OIL Remove the transfer case plug No. 2 (for filler) and gasket. Check that the oil level is between 0 and 5.0 mm (0 and 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) NOTE: When adding oil, pour it slowly. Too much or too little oil will lead to transfer problems. When the oil level is too low, check for oil leaks. Install a new gasket into the case plug (for filler) and then tighten the plug. Torque: 39 N*m (398 kgf*cm, 28 ft.*lbf)
2. ADD TRANSFER OIL Remove the case plug (for filler) and gasket. Pour oil so that the oil level is between 0 and 5.0 mm (0 and 0.197 in.) from the bottom lip of the case plug (for filler) hole. NOTE: When adding oil, pour it slowly. Add oil a little at a time, waiting several minutes between each addition of oil. Wait approximately 5 minutes and check that the oil level has not changed. Install a new gasket and the case plug (for filler). Torque: 39 N*m (398 kgf*cm, 28 ft.*lbf)

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE ENGINE ASSEMBLY WITH AUTOMATIC TRANSAXLE for 2AR-FE: Remove the engine with automatic transaxle.Refer to «REMOVAL»(ref-493422-S26064459082012081000000). for 2GR-FE: Remove the engine with automatic transaxle.Refer to «REMOVAL»(ref-493421-S14032157822012081000000)
3. REMOVE REAR ENGINE MOUNTING BRACKET (for 2GR-FE).Refer to «REMOVAL - Step 6»(ref-493419-S23416338122012081000000)
4. REMOVE REAR ENGINE MOUNTING BRACKET (for 2AR-FE).Refer to «REMOVAL - Step 6»(ref-493417-S19648109112012081000000)
5. REMOVE TRANSFER ASSEMBLY Remove the 6 nuts, 2 bolts and transfer from the transaxle.

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT Remove the stud bolt.
2. REMOVE TRANSFER CASE STRAIGHT PIN Remove the 2 straight pins.
3. REMOVE TRANSFER CASE NO. 1 PLUG Remove the No. 1 plug. Remove the gasket from the No. 1 plug.
4. REMOVE TRANSFER CASE NO. 2 PLUG Remove the No. 2 plug. Remove the gasket from the No. 2 plug.
5. REMOVE TRANSFER DRAIN PLUG Remove the drain plug. Remove the gasket from the drain plug.
6. REMOVE TRANSFER CASE OIL SEAL LH Using SST, tap out the oil seal from the case. SST: 09308-00010 NOTE: Do not damage the oil seal lip.
7. REMOVE TRANSFER CASE OIL SEAL RH Using SST, tap out the oil seal from the case. SST: 09308-00010 NOTE: Do not damage the oil seal lip.
8. INSPECT RING GEAR BACKLASH Using a dial indicator, measure the backlash of the ring gear at 3 points. Standard backlash 0.10 to 0.20 mm (0.0039 to 0.0079 in.) If the backlash is not within the specified range, adjust the backlash or repair as necessary.
9. REMOVE NO. 1 TRANSFER CASE COVER Remove the 8 bolts. Using a brass bar and hammer, tap out the cover from the case.
10. REMOVE TRANSFER RING GEAR Remove the ring gear from the transfer case.
11. REMOVE TRANSFER CASE STRAIGHT PIN Remove the 2 straight pins from the transfer case.
12. REMOVE TRANSFER OUTPUT SHAFT Remove the 5 bolts and output shaft. Using SST and a hammer, unstake the lock nut. SST: 09930-00010 Remove the lock nut.
13. REMOVE TRANSFER OUTPUT REAR SHAFT SUB-ASSEMBLY Using SST and a press, press out the shaft from the driven pinion. SST: 09950-00020 SST: 09950-60010 09951-00220 SST: 09950-70010 09951-07100
14. REMOVE TRANSFER OUTPUT REAR SHAFT DUST DEFLECTOR Using SST and a press, press out the dust deflector from the output rear shaft. SST: 09950-00020
15. REMOVE TRANSFER DRIVEN PINION FRONT BEARING Using SST and a press, press out the driven pinion from the bearing. SST: 09950-00020 SST: 09950-60010 09951-00220 SST: 09950-70010 09951-07100 Remove the O-ring from the bearing.
16. REMOVE TRANSFER OUTPUT SHAFT WASHER Remove the washer from the transfer pinion gear.
17. REMOVE RING GEAR MOUNTING CASE BEARING (for LH side) Using SST, remove the bearing from the mounting case. SST: 09950-40011 09951-04010 09952-04010 09953-04030 09954-04010 09955-04061 09957-04010 09958-04011 SST: 09950-60010 09951-00540 Using SST and a hammer, tap out the bearing. SST: 09310-35010
18. REMOVE RING GEAR MOUNTING CASE WASHER
19. REMOVE RING GEAR MOUNTING CASE BEARING (for RH side) Using SST, remove the bearing from the mounting case. SST: 09950-40011 09951-04010 09952-04010 09953-04020 09954-04010 09955-04061 09957-04010 09958-04011 SST: 09950-60010 09951-00540 Using SST and a hammer, tap out the bearing (race) from the cover. SST: 09636-20010
20. REMOVE TRANSFER RING GEAR MOUNTING CASE NO. 2 WASHER
21. REMOVE SHAFT SNAP RING Using a snap ring expander, remove the snap ring.
22. REMOVE TRANSFER RING GEAR MOUNTING CASE Using SST and a press, press out the ring gear from the mounting case. SST: 09950-60010 09951-00400
23. REMOVE BREATHER OIL DEFLECTOR Remove the 2 bolts and oil deflector.
24. REMOVE TRANSFER CASE BREATHER PLUG Remove the breather plug from the transfer case.

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

1. INSTALL BREATHER OIL DEFLECTOR Install the deflector with the 2 bolts. Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf)
2. INSTALL RING GEAR MOUNTING CASE PLATE WASHER Install a new washer to the transfer case. HINT: Install a washer of the same thickness as before.
3. INSTALL TRANSFER RING GEAR MOUNTING CASE NO. 2 WASHER Install a new washer to the cover. HINT: Install a washer of the same thickness as before.
4. INSTALL TRANSFER RING GEAR MOUNTING CASE Using SST and a press, press in the mounting case to the ring gear. SST: 09316-12010 SST: 09950-60010 09951-00560
5. INSTALL SHAFT SNAP RING Using a snap ring expander, install a new snap ring.
6. INSTALL RING GEAR MOUNTING CASE BEARING (for RH side) Using SST and a press, press in the bearing (race) to the cover. SST: 09950-60020 09951-00750 09952-06010 SST: 09950-70010 09951-07150 Using SST and a press, press in the bearing to the mounting case. SST: 09336-16010 SST: 09950-60010 09951-00400 Apply gear oil to the bearing.
7. INSTALL RING GEAR MOUNTING CASE BEARING (for LH side) Using SST and a press, press in the bearing (race) to the case. SST: 09950-60010 09951-00540 09951-00620 09952-06010 SST: 09950-70010 09951-07150 Using SST and a press, press in the bearing to the mounting case. SST: 09336-16010 SST: 09950-60010 09951-00560 Apply gear oil to the mounting case bearing.
8. INSTALL TRANSFER OUTPUT SHAFT WASHER Install the washer to the driven pinion.
9. INSTALL TRANSFER DRIVEN PINION FRONT BEARING Using SST and a press, press in the bearing to the driven pinion. SST: 09950-60010 09951-00440 SST: 09950-60020 09951-00750 SST: 09950-70010 09951-07150
10. INSTALL TRANSFER OUTPUT REAR SHAFT DUST DEFLECTOR Using SST and a press, press in the dust deflector to the output shaft. SST: 09316-12010
11. INSTALL TRANSFER OUTPUT REAR SHAFT SUB-ASSEMBLY Using SST and a press, press in the output rear shaft to the driven pinion. SST: 09316-12010 Install a new lock nut to the output shaft. Torque: 360 N*m (3671 kgf*cm, 266 ft.*lbf)
12. INSTALL TRANSFER SHAFT Install a new O-ring to the driven pinion. Install the driven pinion to the case with the 5 bolts. Torque: 38 N*m (390 kgf*cm, 28 ft.*lbf)
13. INSPECT DRIVEN PINION PRELOAD Using a torque wrench, measure the preload. Standard preload (turning) 0.17 to 1.86 N*m (1.7 to 19.0 kgf*cm, 1.5 to 16.5 in.*lbf)
14. INSTALL TRANSFER RING GEAR Coat 3 or 4 teeth at the 4 different positions on the ring gear with Prussian blue. Install the mounting case to the transfer case.
15. INSTALL NO. 1 TRANSFER CASE COVER Install the transfer cover with the 8 bolts. Torque: 47 N*m (480 kgf*cm, 35 ft.*lbf)
16. ADJUST RING GEAR BACKLASH Using a dial indicator, measure the backlash of the ring gear at 3 positions at least. Standard backlash 0.10 to 0.20 mm (0.0039 to 0.0079 in.) 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. Standard washer thickness Mark Thickness Mark Thickness A0 1.97 mm (0.0776 in.) C0 2.37 mm (0.0933 in.) A1 1.99 mm (0.0783 in.) C1 2.39 mm (0.0941 in.) A2 2.01 mm (0.0791 in.) C2 2.41 mm (0.0949 in.) A3 2.03 mm (0.0799 in.) C3 2.43 mm (0.957 in.) A4 2.05 mm (0.0807 in.) C4 2.45 mm (0.0965 in.) A5 2.07 mm (0.0815 in.) C5 2.47 mm (0.0972 in.) A6 2.09 mm (0.0823 in.) C6 2.49 mm (0.098 in.) A7 2.11 mm (0.0831 in.) C7 2.51 mm (0.0988 in.) A8 2.13 mm (0.0839 in.) C8 2.53 mm (0.0996 in.) A9 2.15 mm (0.0846 in.) C9 2.55 mm (0.1004 in.) B0 2.17 mm (0.0854 in.) D0 2.57 mm (0.1012 in.) B1 2.19 mm (0.0862 in.) D1 2.59 mm (0.102 in.) B2 2.21 mm (0.087 in.) D2 2.61 mm (0.1028 in.) B3 2.23 mm (0.0878 in.) D3 2.63 mm (0.1035 in.) B4 2.25 mm (0.0886 in.) D4 2.65 mm (0.1043 in.) B5 2.27 mm (0.0894 in.) D5 2.67 mm (0.1051 in.) B6 2.29 mm (0.0902 in.) D6 2.39 mm (0.0941 in.) B7 2.31 mm (0.0909 in.) D7 2.71 mm (0.1067 in.) B8 2.33 mm (0.0917 in.) D8 2.73 mm (0.1075 in.) B9 2.35 mm (0.0925 in.) D9 2.75 mm (0.1083 in.)
17. ADJUST TOTAL PRELOAD Using a torque wrench, measure the total preload. Driven pinion preload 0.28 to 0.79 N*m (2.86 to 8.06 kgf*cm, 2.48 to 7.0 in.*lbf) HINT: Turn the driven pinion counterclockwise and clockwise several times. If the preload is not as specified, select a proper washer again. Standard washer thickness Mark Thickness Mark Thickness A0 1.18 mm (0.0465 in.) C2 1.62 mm (0.0638 in.) A1 1.20 mm (0.0472 in.) C3 1.64 mm (0.0646 in.) A2 1.22 mm (0.048 in.) C4 1.66 mm (0.0654 in.) A3 1.24 mm (0.0488 in.) C5 1.68 mm (0.0661 in.) A4 1.26 mm (0.0496 in.) C6 1.70 mm (0.067 in.) A5 1.28 mm (0.0504 in.) C7 1.72 mm (0.0677 in.) A6 1.30 mm (0.0512 in.) C8 1.74 mm (0.0685 in.) A7 1.32 mm (0.052 in.) C9 1.76 mm (0.0693 in.) A8 1.34 mm (0.0528 in.) D0 1.78 mm (0.0701 in.) A9 1.36 mm (0.535 in.) D1 1.80 mm (0.0709 in.) B0 1.38 mm (0.0543 in.) D2 1.82 mm (0.0717 in.) B1 1.40 mm (0.0551 in.) D3 1.84 mm (0.0724 in.) B2 1.42 mm (0.0559 in.) D4 1.86 mm (0.0732 in.) B3 1.44 mm (0.0567 in.) D5 1.88 mm (0.074 in.) B4 1.46 mm (0.0575 in.) D6 1.90 mm (0.0748 in.) B5 1.48 mm (0.0583 in.) D7 1.92 mm (0.0756 in.) B6 1.50 mm (0.0591 in.) D8 1.94 mm (0.0764 in.) B7 1.52 mm (0.0598 in.) D9 1.96 mm (0.0772 in.) B8 1.54 mm (0.0606 in.) E0 1.98 mm (0.0781 in.) B9 1.56 mm (0.0614 in.) E1 2.00 mm (0.0787 in.) C0 1.58 mm (0.0622 in.) E2 2.02 mm (0.0795 in.) C1 1.60 mm (0.063 in.)
18. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Rotate the ring gear several times. Peer into the service filler hole or remove the ring gear to check the tooth contact pattern. NOTE: Check the tooth contact pattern at 4 or more positions around the circumference of the ring gear. When replacing washers (backlash adjustment, preload adjustment or tooth contact adjustment), reapply Prussian blue. HINT: The Prussian blue pattern indicates the tooth contact points. If the teeth are not contacting properly, select a driven pinion bearing front (outer race) side washer from the chart and install the washer. NOTE: If a washer (for tooth contact adjustment) is replaced with one of a different thickness, the backlash will also change. Therefore, it is necessary to adjust the backlash. Perform the following procedures for face or flank contact. Use the backlash adjustment washer (ring gear mounting case washer) to move and adjust the ring gear. (*1) Perform the ring gear and driven pinion tooth contact inspection again. HINT: If the tooth contact is incorrect, repeat step *1. Perform the ring gear and driven pinion backlash inspection. If the ring gear and driven pinion backlash is not within the standard range, replace the ring gear and driven pinion with new ones. Perform the following procedures for heel or toe contact. Select a transfer driven pinion bearing front (outer race) side washer (transfer output shaft washer) from the chart and install the washer. NOTE: Do not reuse a transfer pinion bearing spacer. Standard washer thickness Mark Thickness Mark Thickness 01 1.02 mm (0.0402 in.) 15 1.30 mm (0.0512 in.) 02 1.04 mm (0.0409 in.) 16 1.32 mm (0.0520 in.) 03 1.06 mm (0.0417 in.) 17 1.34 mm (0.0528 in.) 04 1.08 mm (0.0425 in.) 18 1.36 mm (0.0535 in.) 05 1.10 mm (0.0433 in.) 19 1.38 mm (0.0543 in.) 06 1.12 mm (0.0441 in.) 20 1.40 mm (0.0551 in.) 07 1.14 mm (0.0449 in.) 21 1.42 mm (0.0559 in.) 08 1.16 mm (0.0457 in.) 22 1.44 mm (0.0567 in.) 09 1.18 mm (0.0465 in.) 23 1.46 mm (0.0575 in.) 10 1.20 mm (0.0472 in.) 24 1.48 mm (0.0583 in.) 11 1.22 mm (0.0480 in.) 25 1.50 mm (0.0591 in.) 12 1.24 mm (0.0488 in.) 26 1.52 mm (0.0598 in.) 13 1.26 mm (0.0496 in.) 27 1.54 mm (0.0606 in.) 14 1.28 mm (0.0504 in.) 28 1.56 mm (0.0614 in.)
19. COMPLETELY INSTALL TRANSFER SHAFT Using a screwdriver and hammer, unstake the pinion gear nut. Install the 5 bolts with the transfer shaft to the case. Torque: 38 N*m (390 kgf*cm, 28 ft.*lbf) Install the No. 1 transfer case cover. Using non-residue solvent, clean the contact surfaces of the housing and cover. Apply seal packing to the cover as shown in the illustration. Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Install the 8 bolts with the cover to the case. Torque: 47 N*m (480 kgf*cm, 35 ft.*lbf)
20. INSTALL TRANSFER CASE OIL SEAL LH See step 10
21. INSTALL TRANSFER CASE OIL SEAL RH See step 6
22. INSTALL TRANSFER CASE STRAIGHT PIN Using a plastic-faced hammer, install the straight pin as shown in the straight pin.
23. INSTALL TRANSFER CASE BREATHER PLUG Using SST and a hammer, tap in a new breather plug. SST: 09612-10093 09612-10061
24. INSTALL TRANSFER DRAIN PLUG Install a new gasket and the plug to the transfer case. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)
25. INSTALL TRANSFER CASE NO. 1 PLUG Install a new gasket and the plug to the transfer case. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)
26. INSTALL TRANSFER CASE NO. 2 PLUG Install a new gasket and the plug to the transfer case. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)
27. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT Apply sealer to stud bolts. Install the stud bolts. Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) HINT: Install the transfer side of the stud bolt (see illustration below) to the case.

See also:
• REMOVAL - Step 15
• REMOVAL - Step 1