TOYOTA RAV4 1996 Service Repair Manual

for transmission removal.
3. Remove starter. On 4WD models, remove front drive shaft bracket. This is the bracket that the front drive
shaft center bearing assembly was bolted on.
4. On 2WD models, remove lower stiffener plate located between side of cylinder block and front of
transmission. On 4WD models, remove transmission-to-cylinder block through-bolt located near bottom
of transmission.
5. On all models, remove upper stiffener plate located just above the starter opening. Upper stiffener plate
fits between cylinder block and front of transmission. Remove torque converter bolts.
6. Remove transmission oil cooler pipes and brackets as necessary. Remove exhaust pipe support bracket
located between transmission and exhaust pipe. Support transmission with transmission jack.
7. Remove bolts/nuts from rear transmission mount. Remove transmission-to-cylinder block bolts. Lower
transmission from vehicle.
Installation
1. Before installing transmission, use dial indicator to check drive plate runout. Drive plate runout should be
checked right next to the starter ring gear on the drive plate. Replace drive plate if runout
exceeds .0079" (.200 mm).
2. Install torque converter on transmission. To ensure torque converter is fully seated, torque converter
depth should be checked. Using straightedge and caliper, measure torque converter depth from torque
converter bolt lug on torque converter to the surface on transmission. See Fig. 1
.
3. Torque converter depth should be more than 1.250" (31.75 mm). If torque converter depth is less than
specified, check for improperly seated torque converter.
4. To install, reverse removal procedure. Tighten all bolts/nuts to specification. See TORQUE
SPECIFICATIONS When installing torque converter bolts, apply Loctite to torque converter bolt
threads before installing. Adjust all cables and fill with ATF. See appropriate TRANSMISSION
SERVICING article.
Removal (RAV4 2WD)
1. Disconnect negative battery cable. Disconnect throttle valve cable from throttle body. Remove coolant
reservoir tank. Remover air cleaner assembly. Remove ground cable.
2. Remove starter. Remove the 3 upper transaxle-to-cylinder block bolts located at top of transaxle. Raise
and support vehicle. Remove lower engine covers.
3. Support engine with hoist. Steering gear assembly must be supported in place during transaxle removal.
Secure steering gear assembly to the engine hoist using an attaching strap placed at each end of steering
gear assembly.
4. Remove transaxle-to-mount bolts/nuts from top of transaxle at driver's side end of transaxle.
5. Remove front wheels. Drain transaxle fluid. Remove axle shafts from transaxle. See FWD AXLE
SHAFTS article in DRIVE AXLES.
6. Remove front exhaust pipe located between exhaust manifold and rear exhaust pipe. Support transaxle
with transmission jack. Disconnect shift cable, necessary electrical connectors and oil cooler hoses at
transaxle.
7. Remove shift cable brackets from suspension crossmember. Suspension crossmember is located below

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
Installation

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the engine and fits between both lower control arms. See Fig. 8. Remove steering gear assembly-to-
suspension crossmember bolts.
8. Support suspension crossmember with floor jack. Remove bolts/nuts, engine mount crossmember and
suspension crossmember with stabilizer bar. See Fig. 8
.
9. Remove bolts and stiffener plate. Stiffener plate fits between side of cylinder block and front of transaxle.
Remove torque converter cover from front of transaxle. Remove torque converter bolts.
10. Remove the 2 cylinder block-to-transaxle bolts. These bolts are located on cylinder block side and thread
into the transaxle. Lower transaxle from vehicle.
Fig. 8: Identifying Engine Mount Crossmember, Suspension Crossmember & Bolt Tightening
Specifications (RAV4 2WD)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
Installation

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Installation
1. Before installing transaxle, use dial indicator to check drive plate runout. Drive plate runout should be
checked right next to the starter ring gear on the drive plate. Replace drive plate if runout
exceeds .0079" (.200 mm).
2. Install torque converter on transaxle. To ensure torque converter is fully seated, torque converter depth
should be checked. Using straightedge and caliper, measure torque converter depth from torque converter
bolt lug on torque converter to the surface on transaxle. See Fig. 1
.
3. Torque converter depth should be more than .502" (12.75 mm). If torque converter depth is less than
specified, check for improperly seated torque converter.
4. To install, reverse removal procedure. Tighten all bolts/nuts to specification. See TORQUE
SPECIFICATIONS When installing torque converter bolts, apply Loctite to torque converter bolt
threads before installing. Ensure the Gray torque converter bolt is installed first before installing the
remaining torque converter bolts.
5. When installing suspension crossmember and engine mount crossmember, ensure all bolts and nuts are
installed before tightening to specification. See Fig. 8
.
6. Use NEW gaskets and NEW nuts when installing front exhaust pipe. Adjust all cables and fill with ATF.
See appropriate TRANSMISSION SERVICING article.
Removal (RAV4 4WD)
1. Manufacturer recommends removing engine and transaxle as an assembly and then remove transaxle
from engine. See 2.0L 4-CYLINDER article in ENGINES for engine removal.
2. With engine and transaxle removed, remove starter. Remove bolts and stiffener plate. Stiffener plate fits
between side of cylinder block and front of transaxle.
3. Remove torque converter cover from front of transaxle. Remove torque converter bolts. Remove bolts
and center stiffener plate. Center stiffener plate fits between top of transaxle and cylinder block.
4. Remove the 2 transfer case-to-cylinder block bolts. Remove transaxle-to-cylinder block bolts. Separate
transaxle from engine.
Installation
1. Before installing transaxle, use dial indicator to check drive plate runout. Drive plate runout should be
checked right next to the starter ring gear on the drive plate. Replace drive plate if runout
exceeds .0079" (.200 mm).
2. Install torque converter on transaxle. To ensure torque converter is fully seated, torque converter depth
should be checked. Using straightedge and caliper, measure torque converter depth from torque converter
bolt lug on torque converter to the surface on transaxle. See Fig. 1
.
3. Torque converter depth should be more than .539" (13.70 mm). If torque converter depth is less than
specified, check for improperly seated torque converter.
4. To install, reverse removal procedure. Tighten all bolts/nuts to specification. See TORQUE
SPECIFICATIONS When installing torque converter bolts, apply Loctite to torque converter bolt
threads before installing. Ensure the Dark Green torque converter bolt is installed first before installing
the remainin
g torque converter bolts.

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
Installation

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5. Once engine and transaxle are installed, adjust all cables and fill with ATF. See appropriate
TRANSMISSION SERVICING article.
Removal (Sienna)
1. Disconnect negative battery cable. Remove hood. Remove wiper arms. Remove hood-to-cowl top seal.
Remove cowl panel hole cover. Remove clips and left and right side cowl top ventilator louvers.
Disconnect washer hoses. Remove 2 washer nozzles from cowl top ventilator louvers. Remove 11 bolts
and outer front cowl top panel.
2. Remove battery, battery tray, air cleaner assembly and air cleaner case. Disconnect throttle valve cable
from throttle body. Remove cruise control actuator with mounting bracket from the body.
3. Raise and support vehicle. Disconnect necessary electrical connectors and ground cables for transaxle
removal. Remove starter. Disconnect shift cable and oil cooler lines at transaxle. Remove shift cable
clamp bracket from transaxle.
4. Remove front (radiator side) engine mount shock absorber-to-lower frame assembly bolts. Remove front
(radiator side) engine mount-to-lower frame assembly bolts/nuts.
5. Remove front (radiator side) exhaust manifold brace from rear of exhaust manifolds. Brace fits between
rear of exhaust manifold and front of transaxle.
6. Remove the 5 upper transaxle-to-cylinder block bolts. Support engine with hoist. Steering gear assembly
must be supported in place during transaxle removal. Secure steering gear assembly to the engine hoist
using an attaching strap placed at each end of steering gear assembly.
7. Remove front wheels. Remove engine undercover. Remove front exhaust pipe located between exhaust
manifolds and rear exhaust pipe. Drain transaxle fluid. Remove axle shafts from transaxle. See FWD
AXLE SHAFTS article in DRIVE AXLES.
8. Disconnect shift control cable from mounting bracket. Remove rear (firewall side) engine mount-to-lower
frame assembly bolts/nuts. Remove transaxle mount-to-transaxle bolts/nuts at driver's side end of
transaxle.
9. Remove stabilizer bar mount bracket-to-lower frame assembly bolts. Remove steering gear assembly-to-
lower frame assembly bolts/nuts. Support lower frame assembly with floor jack. Lower frame assembly is
located below the engine and transaxle.
10. Disconnect power steering reservoir pipe mounting brackets from lower frame assembly. Remove lower
frame assembly mounting brackets. Lower frame assembly mounting brackets are located on the front
and rear of lower frame assembly attaching the lower frame assembly to the body. Remove lower frame
assembly.
11. Support transaxle with transmission jack. Remove torque converter bracket and cover bolts and nuts from
front of transaxle. Remove torque converter bolts. Remove remaining transaxle-to-cylinder block bolts.
Lower transaxle from vehicle.
Installation
NOTE: Wiper/washer components and output front cowl top panel must be
removed for clearance during transaxle removal and installation.

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
Installation

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1. Before installing transaxle, use dial indicator to check drive plate runout. Drive plate runout should be
checked right next to the starter ring gear on the drive plate. Replace drive plate if runout
exceeds .0079" (.200 mm).
2. Install torque converter on transaxle. To ensure torque converter is fully seated, torque converter depth
should be checked. Using straightedge and caliper, measure torque converter depth from torque converter
bolt lug on torque converter to the surface on transaxle. See Fig. 1
.
3. Torque converter depth should be more than .539" (13.70 mm). If torque converter depth is less than
specified, check for improperly seated torque converter.
4. To install, reverse removal procedure. Tighten all bolts/nuts to specification. See TORQUE
SPECIFICATIONS When installing torque converter bolts, apply Loctite to torque converter bolt
threads before installing. Ensure the Black torque converter bolt is installed first before installing the
remaining torque converter bolts.
5. Use NEW gaskets and NEW nuts when installing front exhaust pipe. Adjust all cables and fill with ATF.
See appropriate TRANSMISSION SERVICING article.
Removal (Supra)
1. Disconnect negative battery cable. Remove transmission oil dipstick, dipstick tube and "O" ring.
Disconnect throttle valve cable from throttle body.
2. Raise and support vehicle. Remove lower engine cover. Remove exhaust pipes and heat insulators as
necessary for access to transmission. Remove floor crossmember brace located between each side of the
body and is directly below the drive shaft.
3. Place reference marks drive shaft flanges for reassembly reference. Remove drive shaft. Disconnect
necessary electrical connectors and oil cooler pipes for transmission removal. Remove shift control rod
located between gearshift and the shift lever on side of transmission.
4. Remove starter. On Turbo models, remove intercooler pipe located below the radiator. On all models,
support transmission with transmission jack. Remove transmission crossmember located below the
transmission. Remove torque converter bolts. Remove transmission-to-cylinder block bolts. Lower
transmission from vehicle.
Installation
1. Before installing transmission, use dial indicator to check drive plate runout. Drive plate runout should be
checked right next to the starter ring gear on the drive plate. Replace drive plate if runout
exceeds .0079" (.200 mm).
2. Install torque converter on transaxle. To ensure torque converter is fully seated, place straightedge on
torque converter bolt mounting lugs on torque converter with straightedge extending out over cylinder
block mounting surface on transmission.
3. Using feeler gauge, measure distance between straightedge and cylinder block mounting surface on
transmission. The distance should be less than .0040" (.100 mm). If distance is more than specified, check CAUTION: When removing drive shaft, DO NOT remove the bolts that hold the
drive shaft on the flange. Remove only the bolts that fasten the
flange on drive shaft to the flange on rear differential.

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
Installation

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for improperly seated torque converter.
4. To install, reverse removal procedure. Tighten all bolts/nuts to specification. See TORQUE
SPECIFICATIONS When installing torque converter bolts, apply Loctite to torque converter bolt
threads before installing. Adjust shift linkage and fill with ATF. See appropriate TRANSMISSION
SERVICING article.
Removal (Tacoma 2WD 2.4L 4-Cyl.)
1. Manufacturer recommends removing engine and transmission as an assembly and then remove
transmission from engine. See 2.4L & 2.7L 4-CYLINDER article in ENGINES for engine removal.
2. With engine and transmission removed, remove starter. Remove bolts and stiffener plates. Stiffener plate
fits between each side of cylinder block and front of transmission.
3. Remove torque converter cover from front of transmission. Remove torque converter bolts. Remove
transmission-to-cylinder block bolts. Separate transmission from engine.
Installation
1. Before installing transmission, use dial indicator to check drive plate runout. Drive plate runout should be
checked right next to the starter ring gear on the drive plate. Replace drive plate if runout
exceeds .0079" (.200 mm).
2. Install torque converter on transmission. To ensure torque converter is fully seated, torque converter
depth should be checked. Using straightedge and caliper, measure torque converter depth from torque
converter bolt lug on torque converter to the surface on transmission. See Fig. 1
.
3. Torque converter depth should be more than 1.250" (31.75 mm). If torque converter depth is less than
specified, check for improperly seated torque converter.
4. To install, reverse removal procedure. Tighten all bolts/nuts to specification. See TORQUE
SPECIFICATIONS When installing torque converter bolts, apply Loctite to torque converter bolt
threads before installing. Once engine and transmission are installed, adjust all cables and fill with ATF.
See appropriate TRANSMISSION SERVICING article.
Removal (Tacoma 2WD 2.7L 4-Cyl. & 3.4L V6)
1. Manufacturer recommends removing engine and transmission as an assembly and then remove
transmission from engine. See 2.4L & 2.7L 4-CYLINDER article or 3.4L V6 article in ENGINES for
engine removal.
2. With engine and transmission removed, remove transmission oil dipstick, dipstick tube and "O" ring.
Remove oil cooler pipes and brackets from engine and transmission. Disconnect necessary wiring
connectors from transmission.
3. Remove torque converter cover from front of transmission. Remove torque converter bolts. Remove
transmission-to-cylinder block bolts. Separate transmission from engine.
Installation
1. Before installing transaxle, use dial indicator to check drive plate runout. Drive plate runout should be
checked ri
ght next to the starter ring gear on the drive plate. Replace drive plate if runout

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
Installation

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exceeds .0079" (.200 mm).
2. Install torque converter on transmission. To ensure torque converter is fully seated, torque converter
depth should be checked. Using straightedge and caliper, measure torque converter depth from torque
converter bolt lug on torque converter to the surface on transmission. See Fig. 1
.
3. Torque converter depth should be more than .707" (17.95 mm). If torque converter depth is less than
specified, check for improperly seated torque converter.
4. To install, reverse removal procedure. Tighten all bolts/nuts to specification. See TORQUE
SPECIFICATIONS When installing torque converter bolts, apply Loctite to torque converter bolt
threads before installing. Ensure the Green torque converter bolt is installed first before installing the
remaining torque converter bolts.
5. Once engine and transmission are installed, adjust all cables and fill with ATF. See appropriate
TRANSMISSION SERVICING article.
Removal (Tacoma 4WD)
1. Disconnect negative battery cable. Remove transmission oil dipstick. Disconnect throttle valve cable from
throttle body.
2. Raise and support vehicle. Remove lower engine cover. Remove fan shroud from radiator. Remove rear
console box, located between the seats. Remove screws from front console, located near transfer case and
transmission shift levers.
3. Remove front console with transfer case shift lever knob. Disconnect electrical connectors for removal of
transmission shift lever assembly. Disconnect shift linkage at transmission shift lever assembly. Remove
transmission shift lever assembly.
4. Remove snap ring and transfer case shift lever from transfer case. Remove transmission oil dipstick tube
and "O" ring. Place reference marks on drive shaft flanges for reassembly reference. Remove drive shafts.
5. Remove exhaust pipes as necessary for access to transmission and transfer case. Disconnect speedometer
cable and necessary electrical connectors for transmission and transfer case removal. Remove
transmission oil cooler pipes and brackets as necessary.
6. Remove starter and stabilizer bar. Remove torque converter cover from front of transmission. Remove
torque converter bolts. Front differential assembly rear mount must be removed for transmission removal.
Rear mount is located on front differential assembly, just behind the drive shaft flange.
7. Support front differential assembly with jack. Remove front differential assembly rear mount-to-
crossmember nut. Slightly raise front differential assembly. Remove the 2 front differential assembly rear
mount bolts.
8. Support transmission with transmission jack. Remove transmission mount-to-transmission crossmember
bolts. Remove transmission crossmember, located below transmission and transfer case. Remove
transmission-to-cylinder block bolts. Lower transmission with transfer case from vehicle.
Installation
1. Before installing transmission, use dial indicator to check drive plate runout. Drive plate runout should be
checked right next to the starter ring gear on the drive plate. Replace drive plate if runout
exceeds .0079" (.200 mm).
2. Install torque converter on transmission. To ensure torque converter is full
y seated, torque converter

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
Installation

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depth should be checked. Using straightedge and caliper, measure torque converter depth from torque
converter bolt lug on torque converter to the surface on transmission. See Fig. 1
.
3. Torque converter depth should be more than 1.250" (31.75 mm) on 2.7L 4-cylinder or .707" (17.95 mm)
on 3.4L V6. If torque converter depth is less than specified, check for improperly seated torque converter.
4. To install, reverse removal procedure. Tighten all bolts/nuts to specification. See TORQUE
SPECIFICATIONS When installing torque converter bolts, apply Loctite to torque converter bolt
threads before installing. Ensure the Green torque converter bolt is installed first before installing the
remaining torque converter bolts.
5. Apply grease to transfer case shift lever before installing. Use NEW gasket when installing exhaust pipe.
Adjust all cables, shift linkages and fill with ATF. See appropriate TRANSMISSION SERVICING
article.
Removal (Tercel)
1. Disconnect negative battery cable. Remove battery. Disconnect throttle valve cable from throttle body.
Remove air cleaner assembly along with air intake duct to air cleaner.
2. Remove starter. Remove the 2 upper transaxle-to-cylinder block bolts, located at top of transaxle. Raise
and support vehicle. Remove lower engine covers.
3. Support engine with hoist. Remove front wheels. Drain transaxle fluid. Remove axle shafts from
transaxle. See FWD AXLE SHAFTS article in DRIVE AXLES.
4. Disconnect necessary electrical connectors, ground cables, speedometer cable, control cables and oil
cooler lines for transaxle removal. Remove exhaust pipe as necessary for access to transaxle.
5. Support transaxle with transmission jack. Remove the 2 vertical bottom bolts from front (radiator side)
transaxle mount.
6. Remove through-
bolt and rear (firewall side) engine mount assembly for transaxle removal. Remove plug
from front of transaxle for access to torque converter bolts. Remove torque converter bolts. Remove
remaining transaxle-to-cylinder block bolts. Lower transaxle from vehicle.
Installation
1. Before installing transaxle, use dial indicator to check drive plate runout. Drive plate runout should be
checked right next to the starter ring gear on the drive plate. Replace drive plate if runout
exceeds .0079" (.200 mm).
2. Install torque converter on transaxle. To ensure torque converter is fully seated, torque converter depth
should be checked. Using straightedge and caliper, measure torque converter depth from torque converter
bolt lug on torque converter to the surface on transaxle. See Fig. 1
.
3. Torque converter depth on 3-speed transaxle should be more than .512" (13.00 mm). Torque converter
depth on 4-speed transaxle should be more than .538" (13.40 mm). If torque converter depth is less than
specified, check for improperly seated torque converter.
4. To install, reverse removal procedure. Tighten all bolts/nuts to specification. See TORQUE
SPECIFICATIONS . Tighten the lower transaxle-to-cylinder block bolts to specification as indicated.
See Fig. 9
and Fig. 10 .
5. When installing torque converter bolts, apply Loctite to torque converter bolt threads before installing.
Ad
just all cables and fill with ATF. See appropriate TRANSMISSION SERVICING article.

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
Installation

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Fig. 9: Identifying Transaxle-To-Cylinder Block Bolt Tightening Specifications (Tercel 3-Speed)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
Installation

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November-03-08 10:30:29 AMPage 27 © 2005 Mitchell Repair Information Company, LLC.

Fig. 10: Identifying Transaxle-To-Cylinder Block Bolt Tightening Specifications (Tercel 4-Speed)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (T100 2WD)
1. Manufacturer recommends removing engine and transmission as an assembly and then separating
transmission from engine. See 2.4L & 2.7L 4-CYLINDER article or 3.4L V6 article in ENGINES for
engine removal.

1998 Toyota Avalon XLS
TRANSMISSION SERVICING - A/T 1997-98 TRANSMISSION SERVICING Toyota - Transmission Removal &
Installation

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November-03-08 10:30:29 AMPage 28 © 2005 Mitchell Repair Information Company, LLC.