Last Modified: 01-30-2024 6.11:8.1.0 Doc ID: RM100000002FRA0
Model Year Start: 2024 Model: RAV4 Prod Date Range: [10/2023 -           ]
Title: GF2A (TRANSFER / 4WD / AWD): TRANSFER CASE REAR OIL SEAL: REPLACEMENT; 2024 MY RAV4 RAV4 HV [10/2023 -        ]

REPLACEMENT

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during the rear transfer case oil seal removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replacement Part or Procedure

Necessary Procedure

Effect/Inoperative when not Performed

Link

*1: When performing learning using the Techstream.

Click here 2024 MY RAV4 [10/2023 -        ]; PARK ASSIST / MONITORING: PARKING SUPPORT BRAKE SYSTEM (for Gasoline Model): CALIBRATION

*2: w/o Power Back Door System

Disconnect cable from negative battery terminal

Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes)

Stop and start system

2024 MY RAV4 [10/2023 -        ]; STOP AND START: STOP AND START SYSTEM: PRECAUTION

Perform steering sensor zero point calibration

Lane control system

2022 - 2024 MY RAV4 RAV4 HV [12/2021 -        ]; PRE-COLLISION: PRE-COLLISION SYSTEM: INITIALIZATION

Parking support brake system (for Gasoline model)*1

Pre-collision system

Reset back door close position

Power back door system

2024 MY RAV4 RAV4 HV [10/2023 -        ]; DOOR / HATCH: POWER BACK DOOR SYSTEM: INITIALIZATION

Back door lock initialization*2

Power door lock control system

2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; DOOR LOCK: POWER DOOR LOCK CONTROL SYSTEM: INITIALIZATION

Automatic transaxle assembly

  • Perform reset memory
  • Input transaxle compensation code into ECM
  • Perform road test to allow ECM to learn
  • Large shift shock
  • Deterioration of fuel efficiency

for Initialization: 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE SYSTEM: INITIALIZATION

for Registration: 2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE SYSTEM: REGISTRATION

Automatic transaxle fluid

ATF thermal degradation estimate reset

The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly

2019 - 2024 MY RAV4 [11/2018 -        ]; UB80F (AUTOMATIC TRANSMISSION / TRANSAXLE): AUTOMATIC TRANSAXLE SYSTEM: INITIALIZATION

Front electro magnetic control clutch sub-assembly

Disconnect system function check

Dynamic torque vectoring AWD system

2019 - 2024 MY RAV4 [11/2018 -        ]; GF2A (TRANSFER / 4WD / AWD): DYNAMIC TORQUE VECTORING AWD SYSTEM: CALIBRATION

Front wheel alignment adjustment

  • Perform reset memory
  • Perform acceleration sensor zero point calibration and store system information memorization.
  • VSC is disabled or malfunctions
  • DTCs are output
  • Slip indicator light illuminates
  • ABS warning light illuminates

2019 - 2024 MY RAV4 RAV4 HV [11/2018 -        ]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (w/ Vacuum Brake Booster): UTILITY

Suspension, tires, etc.

Television camera assembly optical axis (Back camera position setting)

Parking assist monitor system

2023 - 2024 MY RAV4 RAV4 HV [10/2022 -        ]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM: CALIBRATION

Parking assist ECU initialization

Panoramic view monitor system (for Gasoline model)

2023 - 2024 MY RAV4 [10/2022 -        ]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for Gasoline Model): CALIBRATION

Panoramic view monitor system (for HV model)

2023 - 2024 MY RAV4 HV [10/2022 -        ]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): CALIBRATION

NOTICE:

After the ignition switch is turned off, the navigation system requires approximately a minute to record various types of memory and settings. As a result, after turning the ignition switch off, wait a minute or more before disconnecting the cable from the negative (-) battery terminal.

Waiting Time before Disconnecting Cable from Negative (-) Battery Terminal

System Name

See Procedure

Vehicle enrolled in Toyota Audio Multimedia system or safety connect system

6 minutes

Vehicle not enrolled in Toyota Audio Multimedia system and safety connect system

1 minute

CAUTION:

  • The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop or the engine assembly with transaxle may fall off the engine lifter.

    *a

    An Object Exceeding Weight Limit of Engine Lifter

  • To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.
  • The automatic transaxle assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the transmission jack may suddenly drop.

    *a

    An Object Exceeding Weight Limit of Transmission Jack

PROCEDURE

1. REMOVE TRANSFER ASSEMBLY

Click here 2024 MY RAV4 [10/2023 -        ]; GF2A (TRANSFER / 4WD / AWD): TRANSFER ASSEMBLY: REMOVAL

2. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT

Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; GF2A (TRANSFER / 4WD / AWD): TRANSFER ASSEMBLY: DISASSEMBLY+

3. SECURE TRANSFER ASSEMBLY

Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; GF2A (TRANSFER / 4WD / AWD): TRANSFER ASSEMBLY: DISASSEMBLY+

4. INSPECT TOTAL PRELOAD

Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; GF2A (TRANSFER / 4WD / AWD): TRANSFER ASSEMBLY: DISASSEMBLY+

5. REMOVE OUTPUT SHAFT COMPANION FLANGE NUT

Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; GF2A (TRANSFER / 4WD / AWD): TRANSFER ASSEMBLY: DISASSEMBLY+

6. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; GF2A (TRANSFER / 4WD / AWD): TRANSFER ASSEMBLY: DISASSEMBLY+

7. REMOVE NO. 2 TRANSFER CASE OIL SEAL

(a) Using SST, remove the No. 2 transfer case oil seal from the transfer case.

SST: 09308-00010

NOTICE:

Do not damage the No. 2 transfer case oil seal press-fit surface.

*1

No. 2 Transfer Case Oil Seal

(b) Remove the spacer.

(c) Using SST, remove the rear drive pinion bearing (inner race).

SST: 09556-40010

*1

Rear Drive Pinion Bearing (Inner Race)

(d) Remove the transfer pinion bearing spacer.

(e) Using SST, remove the rear drive pinion bearing (outer race).

SST: 09950-40011

09951-04010

09952-04010

09953-04010

09954-04010

09957-04010

SST: 09506-42030

SST: 09955-04160

*1

Rear Drive Pinion Bearing (Outer Race)

-

-

*a

Turn

*b

Hold

8. INSTALL NO. 2 TRANSFER CASE OIL SEAL

(a) Using SST and a press, install the rear drive pinion bearing (outer race).

SST: 09506-42020

*1

Rear Drive Pinion Bearing (Outer Race)

(b) Install a new transfer pinion bearing spacer.

(c) Temporarily install the output shaft companion flange sub-assembly.

(d) Using SST, install the rear drive pinion bearing (inner race).

SST: 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

SST: 09956-03090

*a

Turn

*b

Hold

(e) Using SST, remove 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

(f) install the spacer.

(g) Apply a small amount of MP grease to the lip of a new No.2 transfer case oil seal.

(h) Using SST, install a new No. 2 transfer case oil seal to the transfer case.

*1

No. 2 Transfer Case Oil Seal

SST: 09554-42010

SST: 09950-60021

09951-01030

SST: 09950-70010

09951-07100

Drive in depth (A):

3.9 to 4.9 mm (0.154 to 0.193 in.)

NOTICE:

Do not damage the No. 2 transfer case oil seal press-fit surface.

HINT:

Press using the A surface.

9. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; GF2A (TRANSFER / 4WD / AWD): TRANSFER ASSEMBLY: REASSEMBLY+

10. INSPECT TOTAL PRELOAD

Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; GF2A (TRANSFER / 4WD / AWD): TRANSFER ASSEMBLY: REASSEMBLY+

11. INSTALL OUTPUT SHAFT COMPANION FLANGE NUT

Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; GF2A (TRANSFER / 4WD / AWD): TRANSFER ASSEMBLY: REASSEMBLY+

12. REMOVE TRANSFER ASSEMBLY

Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; GF2A (TRANSFER / 4WD / AWD): TRANSFER ASSEMBLY: REASSEMBLY+

13. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT

Click here 2020 - 2024 MY RAV4 [10/2019 -        ]; GF2A (TRANSFER / 4WD / AWD): TRANSFER ASSEMBLY: REASSEMBLY+

14. INSTALL TRANSFER ASSEMBLY

Click here 2023 - 2024 MY RAV4 [10/2022 -        ]; GF2A (TRANSFER / 4WD / AWD): TRANSFER ASSEMBLY: INSTALLATION