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HOMESERVICE MANUALSTOYOTA2020RAV4 XLE, AWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 111 (TRANSFER CASE SYSTEM (GF2A) - SERVICE INFORMATION)TRANSFER ASSEMBLYDISASSEMBLY [11/2018 - 10/2019]PROCEDURE
2020 Toyota RAV4 XLE, AWD

Disassembly [11/2018 - 10/2019]: Procedure

2020 Toyota RAV4 XLE, AWDSECTION Procedure
WARNING: This page is about a different variant/trim than selected.
  1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT 
    1. GTY875436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Using 2 nuts, remove the 4 transfer and transaxle setting stud bolts.

  2. SECURE TRANSFER ASSEMBLY 
    GTY875435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Secure the transfer assembly to the overhaul attachment.
  3. REMOVE TRANSFER CASE STRAIGHT PIN 
    GTY875434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 transfer case straight pins.
  4. REMOVE NO. 1 TRANSFER CASE PLUG 
    GTY875573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the No. 1 transfer case plug and gasket.
  5. REMOVE TRANSFER DRAIN PLUG 
    GTY875440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a 10 mm socket hexagon wrench, remove the transfer drain plug and gasket.
  6. REMOVE TRANSFER FILLER PLUG 
    GTY875439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a 10 mm socket hexagon wrench, remove the transfer filler plug and gasket.
  7. REMOVE NO. 1 4 WHEEL DRIVE POSITION SWITCH 
    1. Remove the No. 1 4 wheel drive position switch.
      GTY875437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE TRANSFER CASE BREATHER PLUG 
    1. Remove the transfer case breather plug.
      GTY875438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE TRANSFER CASE OIL SEAL 

    See step  4

  10. REMOVE TRANSFER CASE OIL SEAL RH 
    1. Using SST, remove the transfer case oil seal RH from the electro magnetic cont clutch sub-assy.
      GTY846951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Transfer Case Oil Seal RH
      • SST: 09308-00010 
      NOTE:

      Do not scratch the press-fitting surface of the transfer case oil seal RH.

  11. INSPECT TOTAL PRELOAD 
    NOTE:
    • When replacing the output shaft companion flange and No. 2 transfer case oil seal, be sure to check the preload.
    • If the output shaft companion flange and No. 2 transfer case oil seal were replaced without checking the preload, replace the transfer assembly.
    1. Using a torque wrench, check the starting torque (total preload) with the teeth of the driven pinion and ring gear in contact.
      GTY886314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      • The torque wrench should be installed as shown in the illustration.
      • Record the measured value as it is used during assembly.
  12. REMOVE OUTPUT SHAFT COMPANION FLANGE NUT 
    1. Place a matchmark on the output shaft companion flange sub-assembly as shown in the illustration.
      GTY870315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark

      HINT: 

      Place a matchmark aligned with the groove on the transfer gear.

    2. Using a screwdriver and hammer, unstake the output shaft companion flange nut.
      GTY875267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Completely unstake the output shaft companion flange nut.
      • Do not damage the threads of the transfer gear.
  13. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Using SST, remove the output shaft companion flange sub-assembly.
      GTY942740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09950-30012 
        1. 09951-03010
        2. 09953-03010
        3. 09954-03010
        4. 09955-03030
      • SST: 09956-03090 
  14. REMOVE NO. 2 TRANSFER CASE OIL SEAL 

    See step  7

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.