TOYOTA RAV4 1996 Service Repair Manual

1999 MANUAL TRANSMISSIONS
Toyota E250 & E250F 5-Speed Overhaul
APPLICATION
TRANSAXLE APPLICATIONS
IDENTIFICATION
Transmission type is identified by ID label located on driver-side door post.
DESCRIPTION
Transaxle design incorporates transmission, center differential, front differential and transfer case (4WD
models). Transmission is shifted by a pair of push-pull cables. These cables provide positive shift feel and
absorb transmission and engine vibrations. The E250F utilizes a full-time transfer case with a limited slip
viscous coupling. Both the E250 and E250F have a center differential, which compensates for difference
between the rotational speed of the front and rear wheels.
ADJUSTMENTS
LUBRICATION
Remove filler plug from side of transmission. Fluid should be level with bottom of filler opening. If fluid is low,
fill until level is correct. Use SAE 75W/90 API GL-4 or GL-5 gear oil for 2WD models, or SAE 75W/90 API
GL-5 gear oil for 4WD models. Capacity is 4.1 qts. (3.9L) for 2WD models, or 5.3 qts. (5.0L) for 4WD models.
ON-VEHICLE SERVICE
AXLE SHAFTS
See appropriate AXLE SHAFTS article in AXLE SHAFTS & TRANSFER CASES.
TROUBLE SHOOTING
See GENERAL TROUBLE SHOOTING article.
Vehicle ApplicationTransaxle Model
RAV4
2WDE250
4WDE250F
NOTE: No adjustments are necessary.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
Microsoft
Sunday, November 22, 2009 10:48:07 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.
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Sunday, November 22, 2009 10:48:29 AMPage 1 © 2005 Mitchell Repair Information Company, LLC.

REMOVAL & INSTALLATION
See appropriate MANUAL TRANSMISSION REMOVAL article in TRANSMISSION SERVICING.
TRANSAXLE DISASSEMBLY
1. Unbolt transfer case from transaxle housing. Using a plastic hammer, remove transfer case from
transaxle. Screw appropriate bolt and washer into differential side gear intermediate shaft. Using slide
hammer type puller, remove shaft. Remove snap ring from shaft.
2. Remove clutch release fork and bearing. Remove back-up light switch. Remove speedometer adapter.
Remove speedometer driven gear or speed sensor, if equipped. Remove gear selecting bellcrank. Remove
shift and select lever lock bolt. Remove control shaft cover. Remove shift and select lever shaft assembly.
See Fig. 1
.
3. Remove case cover. Unstake output shaft lock nut. Lock transmission in 2 gears. Remove output shaft
lock nut. Unlock transmission. See Fig. 2
.
4. Remove No. 3 shift fork set bolt. Remove No. 3 hub sleeve and No. 3 shift fork. Using puller, remove 5th
driven gear. See Fig. 2
. Measure 5th gear clearances. Record for reassembly reference. Using dial
indicator, measure 5th gear thrust clearance. See Fig. 3
and Fig. 4 . Standard clearance should be .004-
.022" (.10-.57 mm). Service limit is .026" (.65 mm). Remount dial indicator to measure lateral movement
(oil clearance) of 5th gear. Standard clearance should be .0004-.002" (.009-.05 mm). Service limit
is .0028" (.070 mm).
5. Remove input shaft snap ring. Using puller, remove No. 3 clutch hub with synchronizer ring and 5th gear.
Remove needle bearing and spacer. Remove 7 Torx (T45) screws and rear bearing retainer. Remove
adjusting shim.
6. Remove input shaft rear bearing snap ring. Remove shift fork shaft snap rings. Remove plug. Remove
seat, spring and detent ball with a magnet. Remove reverse idler gear shaft retaining bolt.
7. Remove transmission housing. Remove output shaft rear bearing outer race. Remove No. 2 oil pipe.
Remove reverse shift arm bracket. Remove reverse idler gear, thrust washer and shaft. Remove all
remaining plugs, seats, springs and detent balls with magnet.
8. To remove No. 1 shift fork shaft, pull up No. 3 shift fork shaft. Using magnetic finger, remove interlock
roller. Remove No. 2 shift fork shaft, shift head and No. 1 shift fork. Pull out No. 3 shift fork shaft along
with the reverse shift fork. Remove No. 2 shift fork. Remove snap rings from shift fork shafts.
9. Remove output and input shaft assemblies. Remove oil pump drive gear. Remove differential case
assembly. Remove oil pipe and oil pump. See Fig. 1
.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
Microsoft
Sunday, November 22, 2009 10:48:07 AMPage 2 © 2005 Mitchell Repair Information Company, LLC.

Fig. 1: Exploded View Of Transmission Assembly (1 Of 2)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
Microsoft
Sunday, November 22, 2009 10:48:07 AMPage 3 © 2005 Mitchell Repair Information Company, LLC.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
Microsoft
Sunday, November 22, 2009 10:48:07 AMPage 4 © 2005 Mitchell Repair Information Company, LLC.

Fig. 2: Exploded View Of Transmission Assembly (2 Of 2)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 3: Measuring 5th Gear Thrust Clearance

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
Microsoft
Sunday, November 22, 2009 10:48:07 AMPage 5 © 2005 Mitchell Repair Information Company, LLC.

Fig. 4: Measuring 5th Gear Lateral Movement
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
COMPONENT DISASSEMBLY & REASSEMBLY
INPUT SHAFT (MAINSHAFT)
Disassembly
1. For all input shaft clearance measurements, see INPUT SHAFT CLEARANCE SPECIFICATIONS
table. Using feeler gauge, measure 3rd and 4th gear thrust clearances. Secure input shaft in soft-jaw vise.
Using dial indicator, measure 3rd and 4th gear lateral movement (gear oil clearance). If clearance exceeds
maximum specification, replace gear, needle bearing and/or shaft.
INPUT SHAFT CLEARANCE SPECIFICATIONS
ApplicationIn. (mm)
3rd Gear Thrust Clearance
Standard.004-.014 (.10-.35)

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
Microsoft
Sunday, November 22, 2009 10:48:07 AMPage 6 © 2005 Mitchell Repair Information Company, LLC.

2. Remove snap ring from input shaft. Using bearing splitter or appropriate blocks, support 4th gear, and
press input shaft out of rear bearing and 4th gear. Remove needle bearings, spacer and synchronizer ring.
Remove snap ring. Supporting 3rd gear, press input shaft out of No. 2 hub sleeve. Remove synchronizer
ring, needle bearing and 3rd gear. Remove needle bearing. Press input shaft out of front bearing inner
race. See Fig. 5
.
Inspection
1. Inspect all parts for damage and wear. Replace if necessary. Clean all parts in clean solvent and dry.
Lubricate all parts, and ensure oil passages are free of contamination.
2. Measure input shaft at points "A", "B" and "C". See Fig. 6
. Support input shaft on "V" blocks. Using dial
indicator to measure runout, rotate input shaft 2 complete revolutions. Replace input shaft if runout or any
part of shaft is not within service limit. See INPUT SHAFT JOURNAL DIAMETERS
table.
INPUT SHAFT JOURNAL DIAMETERS
Reassembly
1. Install clutch hub and shifting keys to No. 2 hub sleeve. Ensure key spring end-gaps are not in-line.
2. Apply multipurpose grease to needle bearings. Install bearing in 3rd gear. Place synchronizer ring on 3rd
Service
Limit.016 (.40)
4th Gear Thrust Clearance
Standard.004-.022 (.10-.55)
Service
Limit.024 (.60)
3rd & 4th Gear Lateral Movement
Standard.0004-.002 (.009-.05)
Service
Limit.003 (.07)
NOTE: Input shaft inner bearing race is non-reusable and should be replaced whenever
removed..
Application (1) Minimum Diameter - In. (mm)
"A" Shaft Journal Diameter1.100 (27.95)
"B" Shaft Journal Diameter1.415 (35.95)
"C" Shaft Journal Diameter1.415 (35.95)
Runout Limits.002 (.05)
(1)"A", "B", and "C" refer to measuring points indicated in illustration. See Fig. 6 .
NOTE: Input shaft front inner bearing race is non-reusable and should be replaced
whenever removed.

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
Microsoft
Sunday, November 22, 2009 10:48:07 AMPage 7 © 2005 Mitchell Repair Information Company, LLC.

gear, and align ring slots with shifting keys. Using press, install 3rd gear and No. 2 hub sleeve. See Fig.
5 .
3. Select snap ring that will allow minimum axial play on shaft. See SNAP RING APPLICATION
CHART NO. 1 .
SNAP RING APPLICATION CHART NO. 1
4. Install selected snap ring. Recheck 3rd gear thrust clearance. Clearance should be .004-.014" (.10-.35
mm). Install spacer. Place synchronizer ring on 4th gear, and align ring slots with shifting keys. Install 4th
gear. Press on ball bearing. See Fig. 5
.
5. Select 4th gear snap ring that will allow minimum axial play on shaft. See SNAP RING
APPLICATION CHART NO. 2 .
SNAP RING APPLICATION CHART NO. 2
6. Install snap ring. Recheck 4th gear thrust clearance. Clearance should be .004-.022" (.10-.55 mm). Using
press, install input shaft front bearin
g inner race.
Stamped LetterThickness - In. (mm)
H.090 (2.30)
J.092 (2.35)
K.094 (2.40)
L.096 (2.45)
M.098 (2.50)
N.100 (2.55)
P.102 (2.60)
Stamped NumberThickness - In. (mm)
1.092 (2.35)
2.094 (2.40)
3.096 (2.45)
4.098 (2.50)
5.100 (2.55)
6.102 (2.60)
7.104 (2.65)
8.106 (2.70)

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
Microsoft
Sunday, November 22, 2009 10:48:07 AMPage 8 © 2005 Mitchell Repair Information Company, LLC.

Fig. 5: Identifying Input Shaft Components
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 6: Measuring Input Shaft Journals

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
OUTPUT SHAFT

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
Microsoft
Sunday, November 22, 2009 10:48:07 AMPage 9 © 2005 Mitchell Repair Information Company, LLC.

Disassembly
1. For all output shaft clearance specifications, refer to OUTPUT SHAFT CLEARANCE
SPECIFICATIONS table. Using feeler gauge, measure 1st and 2nd gear thrust clearances. Secure output
shaft in soft-jaw vise. Using dial indicator, measure 1st and 2nd gear lateral movement (gear oil
clearance). If clearance exceeds maximum, replace gear, needle bearing and/or shaft.
OUTPUT SHAFT CLEARANCE SPECIFICATIONS
2. Using bearing splitter or blocks, support 4th driven gear, and press output shaft out of rear bearing and
4th driven gear. Remove spacer. Support 2nd gear, and press output shaft out of 3rd driven gear and 2nd
gear. Remove needle bearing, spacer and synchro ring. Remove snap ring. Support 1st gear, and press
output shaft out of No. 1 hub sleeve and 1st gear. Remove synchro ring and needle bearing. See Fig. 7
.
Inspection
1. Inspect all parts for damage and wear. Replace if necessary. Throughly clean all parts in clean solvent,
and dry. Lubricate all parts, and ensure oil passages are free of contamination.
2. Measure output shaft diameter at points "A" and "B". See Fig. 8
. Support output shaft on "V" blocks.
Using a dial indicator to measure runout, rotate output shaft 2 complete revolutions. Replace output shaft
if runout or any part of shaft is not within service limit. See OUTPUT SHAFT JOURNAL
DIAMETERS table.
OUTPUT SHAFT JOURNAL DIAMETERS
ApplicationIn. (mm)
1st Gear Thrust Clearance
Standard.004-.014 (.10-.35)
Service
Limit.016 (.40)
2nd Gear Thrust Clearance
Standard.004-.018 (.10-.45)
Service
Limit.020 (.50)
1st & 2nd Gear Lateral Movement
Standard.0004-.002 (.009-.05)
Service
Limit.003 (.07)
Application (1) Minimum Diameter - In. (mm)
"A" Shaft Journal Diameters1.48 (37.53)
"B" Shaft Journal Diameter1.36 (34.51)
Runout Limits.002 (.06)
(1)"A" and "B" refer to measuring points indicated in illustration. See Fig. 8 .

1999 Toyota RAV4
1999 MANUAL TRANSMISSIONS Toyota E250 & E250F 5-Speed Overhaul
Microsoft
Sunday, November 22, 2009 10:48:07 AMPage 10 © 2005 Mitchell Repair Information Company, LLC.