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4WD RAV4 gearbox removal

In Truth no its not easy--It CAN be done on axle stands and the engine DOES NOT have to come out, and the AIR CON DOES NOT NEED DRAINING you have to remove both strut assemblies complete with drive shafts, unbolt yet tie up the steering rack--dont let it come off the column, anti roll bar, Front sub frame, Main sub frame, starter motor, gear linkage assy's, wiring mounts of gearbox, disconnect & remove prop shaft--EXHAUST STAYS UN-TOUCHED, remove coolant pipes.

Use an engine hoist to support the engine while you remove all the gubbins mentioned above and leave the engine mounted on the alternator belt end engine mount only put a trolley jack under the engine sump and relocate the engine hoist onto the gearbox (3 point lift with a come along is best). Undo all the gearbox holding bolts not forgetting 2 on the alternator belt side of the transfer case. Split the joint and slowly pull out the gearbox bit by bit till there is a 12mm gap. Lower the trolley jack so the engine sags on the mount and lower the engine hoist bit by bit till the alternator belt tensioner is 1mm off the inner wing. The engine and box are now at about 25 degrees towards the floor, pull the box off further and tilt it towards the back of the car slightly to get the transfer case around the bell housing.

Next replace every wear item and now is the tricky part, organise your lift so the come along (Lever hoist) is used to get the right angle and manouvre the gearbox into position. This took me 2 hrs of up, down change the lift, up then down and change the lift (9 times till i got it spot on and it just goes clunk into position.

Then re-assemble. It took me 17.5 hrs to do a 2001 4wd 5sp manual rav4 with aircon.

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13y ago

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