GF2A (TRANSFER / 4WD / AWD): TRANSFER ASSEMBLY: DISASSEMBLY; 2020 - 2025 MY RAV4 [10/2019

Last Modified: 05-08-2025	6.11:8.1.0	Doc ID: RM100000001N9OA
Model Year Start: 2020	Model: RAV4	Prod Date Range: [10/2019 - ]
Title: GF2A (TRANSFER / 4WD / AWD): TRANSFER ASSEMBLY: DISASSEMBLY; 2020 - 2025 MY RAV4 [10/2019 - ]

DISASSEMBLY

CAUTION / NOTICE / HINT

NOTICE:

When replacing the rear drive pinion companion flange and rear transfer case oil seal, be sure to check the preload.
If the output shaft companion flange sub-assembly and rear transfer case oil seal were replaced without checking the preload, replace the transfer assembly.
Before installation of each part, thoroughly clean and dry it. Then apply grease or oil as necessary. Do not use alkaline chemicals to clean aluminum parts, rubber parts or precoated bolts. Also, do not use non-residue solvent or other cleaning oils to clean oil seals or rubber parts.

PROCEDURE

1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT

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

2. SECURE TRANSFER ASSEMBLY

(a) Secure the transfer assembly to the overhaul attachment.

3. REMOVE TRANSFER CASE STRAIGHT PIN

(a) Remove the 2 transfer case straight pins.

4. REMOVE NO. 1 TRANSFER CASE PLUG

(a) Remove the No. 1 transfer case plug and gasket.

5. REMOVE TRANSFER DRAIN PLUG

(a) Using a 10 mm socket hexagon wrench, remove the transfer drain plug and gasket.

6. REMOVE TRANSFER FILLER PLUG

(a) Using a 10 mm socket hexagon wrench, remove the transfer filler plug and gasket.

7. REMOVE NO. 2 TRANSFER CASE PLUG

(a) Using a 10 mm socket hexagon wrench, remove the No. 2 transfer case plug and gasket.

8. REMOVE NO. 1 4 WHEEL DRIVE POSITION SWITCH

(a) Remove the No. 1 4 wheel drive position switch.

9. REMOVE TRANSFER CASE BREATHER PLUG

(a) Remove the transfer case breather plug.

10. REMOVE TRANSFER CASE OIL SEAL

Click here

11. REMOVE TRANSFER CASE OIL SEAL RH

(a) Using SST, remove the transfer case oil seal RH from the electro magnetic cont clutch sub-assy.

SST: 09308-00010

NOTICE:

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

*1	Transfer Case Oil Seal RH

12. INSPECT TOTAL PRELOAD

NOTICE:

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.

(a) Using a torque wrench, check the starting torque (total preload) with the teeth of the driven pinion and ring gear in contact.

HINT:

The torque wrench should be installed as shown in the illustration.
Record the measured value as it is used during assembly.

13. REMOVE OUTPUT SHAFT COMPANION FLANGE NUT

(a) Place a matchmark on the output shaft companion flange sub-assembly as shown in the illustration.

HINT:

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

Matchmark

(b) Using a screwdriver and hammer, unstake the output shaft companion flange nut.

NOTICE:

Completely unstake the output shaft companion flange nut.
Do not damage the threads of the transfer gear.

14. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

(a) Using SST, remove the output shaft companion flange sub-assembly.

SST: 09950-30012

09951-03010

09953-03010

09954-03010

09955-03030

SST: 09956-03090

*a	Turn
*b	Hold

15. REMOVE NO. 2 TRANSFER CASE OIL SEAL

Click here