Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000001N9OB
Model Year Start: 2020 Model: RAV4 Prod Date Range: [10/2019 -           ]
Title: GF2A (TRANSFER / 4WD / AWD): TRANSFER ASSEMBLY: REASSEMBLY; 2020 - 2024 MY RAV4 [10/2019 -        ]

REASSEMBLY

PROCEDURE

1. INSTALL NO. 2 TRANSFER CASE OIL SEAL

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2. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

(a) Align the matchmark on the output shaft companion flange with the transfer gear groove, and then temporarily install the output shaft companion flange sub-assembly as shown in the illustration.

*a

Matchmark

(b) Using SST, install the output shaft companion flange sub-assembly.

SST: 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

SST: 09956-03090

*a

Turn

*b

Hold

(c) Using SST, temporarily install the output shaft companion flange nut.

SST: 09330-00021

Torque:

140 N·m {1428 kgf·cm, 103 ft·lbf}

CAUTION:

The total preload may be within the standard even when the output shaft companion flange is loose. If the output shaft companion flange is installed in this state, the vehicle may be damaged or lead to a serious accident.

NOTICE:

Tighten the output shaft companion flange nut until there is no more looseness in the output shaft companion flange and it turns to the right and left with the same amount of force.

HINT:

After temporarily installing the output shaft companion flange nut, be sure to adjust the preoload.

*a

Turn

*b

Hold

3. INSPECT TOTAL PRELOAD

(a) Using a torque wrench, measure the total preload (starting torque) with the teeth of the transfer driven pinion and transfer ring gear in contact.

HINT:

  • The torque wrench should be installed as shown in the illustration.
  • For a more accurate measurement, rotate the bearing forward and backward several times before the measurement.
  • Use the preload value measured prior to disassembling the transfer assembly as the standard value.
  • Adjust within the standard value (Adjustable range within +/- 0.2 N*m of the measured preload value).

(b) If the preload is not as specified, perform the procedures below.

(1) If the measured preoload is higher than the standard value:

Replace the rear drive pinion bearing and transfer pinion bearing spacer, and then adjust the preload again.

(2) If the measured preoload is lower than the standard value:

Tighten the output shaft companion flange nut, and then adjust the preload again.

4. INSTALL OUTPUT SHAFT COMPANION FLANGE NUT

(a) Place a matchmark on SST as shown in the illustration.

SST: 09930-42010

*a

Matchmark

(b) Install SST aligned with the matchmark on the output shaft companion flange sub-assembly as shown in the illustration.

*a

Matchmark

(c) Using SST and a hammer, stake the output shaft companion flange nut.

NOTICE:

Check that the matchmarks are properly aligned.

5. INSTALL TRANSFER CASE OIL SEAL

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6. INSTALL TRANSFER CASE OIL SEAL RH

(a) Coat the lip of a new drive shaft oil seal RH with MP grease.

(b) Using SST and a hammer, tap in a new transfer case oil seal RH as shown in the illustration.

SST: 09223-46011

SST: 09631-32020

Drive in depth (A):

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

NOTICE:

  • Tap the transfer case oil seal RH uniformly so that the transfer case oil seal RH is straight.
  • Do not tap the transfer case oil seal RH in too far.

*1

Transfer Case Oil Seal RH

7. INSTALL TRANSFER CASE BREATHER PLUG

(a) Install a new transfer case breather plug to the transfer case.

Torque:

11.3 N·m {115 kgf·cm, 8 ft·lbf}

8. INSTALL NO. 1 4 WHEEL DRIVE POSITION SWITCH

(a) Using a SST, install the No. 1 4 wheel drive position switch to the transfer case.

SST: 09816-30010

Torque:

40.2 N·m {410 kgf·cm, 30 ft·lbf}

9. INSTALL TRANSFER CASE STRAIGHT PIN

(a) Using a plastic hammer, install straight pins to the locations shown in the illustration.

Drive in depth (A):

10.8 to 11.8 mm (0.426 to 0.464 in.)

10. INSTALL NO. 2 TRANSFER CASE PLUG

(a) Using a 10 mm socket hexagon wrench, install a new gasket and the No. 2 transfer case plug.

Torque:

39 N·m {398 kgf·cm, 29 ft·lbf}

11. INSTALL TRANSFER FILLER PLUG

(a) Using a 10 mm socket hexagon wrench, install a new gasket and the transfer filler plug.

Torque:

39 N·m {398 kgf·cm, 29 ft·lbf}

12. INSTALL TRANSFER DRAIN PLUG

(a) Using a 10 mm socket hexagon wrench, install a new gasket and the transfer drain plug.

Torque:

39 N·m {398 kgf·cm, 29 ft·lbf}

13. INSTALL NO. 1 TRANSFER CASE PLUG

(a) Install a new gasket and the No. 1 transfer case plug.

Torque:

49 N·m {500 kgf·cm, 36 ft·lbf}

14. REMOVE TRANSFER ASSEMBLY

(a) Remove the transfer assembly from the overhaul attachment.

15. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT

(a) Clean the bolt holes.

(b) Using 2 nuts, install 4 new stud bolts in the locations shown in the illustration.

Torque:

39.2 N·m {400 kgf·cm, 29 ft·lbf}

NOTICE:

Install the shorter threaded part of each stud bolt to the transfer side.

*a

Adhesive 1324

*b

64 mm (2.520 in.)