Output shaft seal TOYOTA RAV4 1996 Service Repair Manual

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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November-03-08 10:30:29 AMPage 22 © 2005 Mitchell Repair Information Company, LLC.

REASSEMBLY
1. Assembly is reverse order of disassembly. Remove output shaft. Install oil pump drive gear. Install input
and output shaft assemblies, and shift fork assemblies as single unit. Install shift fork shaft locking balls,
springs, seats and plugs. Install reverse idler gear and shaft. Align referencing marks on idler gear and
clutch housing. Place reverse shift fork pivot into reverse shift arm, and install reverse shift arm bracket to
clutch housing. Install No. 2 oil pipe. Install NEW gasket to oil pipe. See Fig. 1
.
2. Apply Three Bond (1281) sealant to transmission housing. Install transmission housing to clutch housing.
Install reverse idler gear shaft retaining bolt. Install shift shaft locking ball, spring, seat and plug. Install
snap rings onto shift fork shafts.
3. Install output shaft rear bearing outer race. Install correct adjusting shim. Install snap ring onto input shaft
rear bearing. Install rear bearing retainer. Install spacer, needle bearing and 5th gear. Install synchro ring
and key spring to No. 3 clutch hub. Using Installer (09310-17010), install No. 3 clutch hub with
synchronizer ring and key spring. See Fig. 2
.
4. Select a snap ring that will allow minimum axial play and install snap ring onto shaft. Snap rings are
available in thicknesses of .068" (1.75 mm) to .084" (2.15 mm) in .002" (.05 mm) increments. Shims are
stamped "A"-"J". See Fig. 2
.
5. Recheck 5th gear thrust clearance. Standard clearance is .004-.022" (.10-.57 mm). Install 5th driven gear.
Install No. 3 hub sleeve and No. 3 shift fork. Lock transmission in 2 gears. Install and tighten NEW lock
nut to 90 ft. lbs. (123 N.m). Stake lock nut. Unlock transmission.
6. Apply Three Bond (1281) sealant to transmission case cover. Install cover. Install shift and select lever
shaft. Install control shaft cover. Install lock bolt. Install boot onto control shaft oil seal. Ensure boot is
installed in correct direction. Position air bleed of boot downward. Install selecting bellcrank. Install
back-up light switch and speedometer driven gear. Install side gear intermediate shaft. Distance from end
of shaft to clutch housing should be 10.06" (255.5 mm).
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS NOTE: This transmission does not use gaskets between major housings, use
Three Bond (1281) sealant. Assemble housing within 20 minutes after
applying liquid gasket. Allow 30 minutes curing time before filling with oil.
ApplicationFt. Lbs. (N.m)
Back-Up Light Switch30 (40)
Bellcrank Bolt14 (20)
Clutch Release Fork Bolt35 (47)
Differential Case Bolt46 (63)
Differential Ring Gear Bolt91 (123)
Drain & Filler Plug36 (49)
Elbow-To-Transaxle Bolt20 (27)
Oil Cooler Tube-To-Elbow Bolt25 (34)
Oil Pipe Clamp13 (17)

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