Device and repair of Toyota RAV4 SUVs (Toyota RAV) - Removal and installation of the mechanical transmission on fully - driving cars-//

Toyota PAB4-Toyota RAV4
1. Operation of the car
2. Maintenance
3. Engines
4. Cooling systems and conditioning
5. Fuel system and system of production of the fulfilled gases
6. System of ignition
7. The control system and decrease in toxicity of the fulfilled gases
8. Coupling
9. Transmission
   General information
   Specifications
   Repair of the transmission
   The repair and adjusting work performed on cars with the mechanical transmission
      Replacement of cables of control of the transmission
      Removal and installation of the lever of gear shifting
      Check and replacement of the switch of lamps of a backing
      Replacement of the oil heater of the transmission
      Removal and installation of the mechanical transmission on cars with one leading bridge
      Removal and installation of the mechanical transmission on fully - driving cars
   The repair and adjusting work performed on cars with the automatic transmission
10. Driveshaft and shaft of the drive of driving wheels
11. Brake system
12. Suspension bracket
13. Steering and running gear
14. Body
15. Electric equipment
Schemes of electric equipment


Toyota RAV4>> Transmission>> The repair and adjusting work performed on cars with the mechanical transmission>> Removal and installation of the mechanical transmission on fully - driving cars
       PREVENTION
The fuel system is under constant pressure therefore before a detachment of pipelines take off pressure in fuel system.
The air conditioning system is under the high pressure therefore do not open a contour of cooling of air conditioning system until coolant is pumped out.
Air conditioning system has to be served by the technicians trained in safe working methods with use of the special equipment and with observance of safety rules during the collecting and storage of automobile coolant.

       NOTE
Removal of the transmission on all-wheel drive models — very laborious work. The manufacturer recommends to remove the power unit assembled then to disconnect the transmission from the engine.

Switch off ignition and disconnect a wire of "weight" from the rechargeable battery.
Take off pressure in fuel system.
Remove a cowl. Remove the casing of the air-ventilation chamber located at the windshield basis.
Capes protect wings not to damage a paint and varnish covering.
Remove the case of the air filter.
Disconnect a cable of an accelerator and take him aside together with an arm.
Remove the rechargeable battery and its support.
Turn off nuts of fastening of forward wheels and power shafts to naves.
Merge engine oil and cooling liquid.
Remove a broad tank.
Take off belts of the drive of hinged units.
Mark and disconnect from the engine vacuum hoses and hoses of the cooling system, electric sockets, wires of connection with "weight" and fuel tubes.
Release clips and disconnect plaits of wires from the engine. Also disconnect wires from the control unit of the engine (PCM) in interior of the car and extend wires from interior of the car in a motor compartment.
Remove the generator and a starter.
Remove the radiator fan, a casing of the fan and a radiator. This operation is not obligatory, however it will prevent their damage at removal of the engine. If the radiator remains installed in the car, disconnect from it tubes of the oil heater of the transmission.
On models with air conditioning system turn out bolts of fastening of the compressor of the conditioner.
Move the conditioner compressor together with the wires and tubes attached to it aside and fix by a soft wire it on a body.

       PREVENTION
Do not open air conditioning system contour.

Separate a reception exhaust pipe from a final collector.
Disconnect drafts of control of the transmission. Also disconnect all electric sockets from the transmission.
If on the car the mechanical transmission is installed , remove the working cylinder of coupling from a transmission case.
Weaken nuts of fastening of power shafts to naves.
Disconnect cables of management from the transmission.
Lift the car on the elevator. Remove forward wheels and the lower protection of a motor compartment.
Merge oil from the transmission.
Remove power shafts.
Remove the driveshaft.
On models till 2001 remove the pump of the amplifier of steering.
Remove a reception exhaust pipe.
Remove the lower cross and longitudinal beams.
Lower the car and fix captures of the lifting mechanism for eyes of the power unit.
Turn out bolts of fastening of the right and left support of the power unit.
Lower the power unit on a floor, then disconnect captures of the lifting mechanism.
Lift the car and move the power unit from under the car.
Remove a starter.
Mark and disconnect all electric sockets and hoses from the transmission.
On models till 2001 turn out bolts and remove three plates of rigidity from a transmission case.
On models since 2001 turn out bolts and remove one plate of rigidity.

Fig. 9.8. An arrangement of bolts (A, B, C, D, E, F) fastenings of the transmission to the engine on models 4WD till 2001


Fig. 9.9. An arrangement of bolts (A, B, C) fastenings of the transmission to the engine on models 4WD since 2001


Turn out bolts of fastening of the transmission to the engine (fig. 9.8, 9.9) . Note an arrangement of bolts as further they need to be established on the same places.
Separate the transmission from the engine. On models till 2001 take away the transmission from the engine on 5–7 cm, then reject the left end of the transmission back and separate the transmission.
Installation
You make installation in the sequence, the return to removal, taking into account the following.
Clear a shlitsevy part of a main shaft of the transmission and grease with a thin layer of high-temperature lubricant. The layer of lubricant has to be thin and uniform, otherwise during the coupling work excessive lubricant will be rejected on the working surfaces of coupling that can break its work.
Move the transmission to the engine so that the main shaft of the transmission entered vents of the conducted clutch plate. For combination of shliyets of a main shaft of the transmission with vents of the conducted clutch plate, perhaps, it is necessary to turn a bent shaft of the engine slightly. At installation of the transmission do not allow a box to lean a main shaft on a clutch plate.
Having moved the transmission forward, install a coupling case on the directing plugs of the block of cylinders.
Tighten bolts of fastening of the transmission the required moment.
Fill in oil in the transmission.