2004 toyota rav4 repair manual free download

The engine and gearbox can now be eased forward to release the front prop shaft joint from the transfer box. It is advisable to plug the driveshaft holes when the driveshafts have been removed, to stop any excess oil dripping and to stop anything going into the transfer box, then the support bracket for the transfer box to the engine can be removed (see below). Now drain the oil out of the gearbox and transfer box and, once the oil has drained, remove the O/S/F driveshaft by sliding out of the transfer box and store in a safe and clean area (see below). Support the front sub-frame with a transmission jack and remove the sub- frame retaining bolts, lower the transmission jack and remove the front sub-frame (see below) and then remove the gearbox cross member/cradle. Now we need to remove the front sub-frame, so disconnect the anti- roll bar clamps, remove the front gearbox mounting, disconnect both bottom ball joints, and take out the two bolts that hold the steering rack to the front sub-frame (see below) and secure the steering rack to the engine bay to hold in place. With the vehicle on the floor, slacken the wheel bolts and the O/S/F hub nut, raise the ramp to waist height and remove both front wheels, the O/S/F hub nut, the N/S/F wheel arch splash guard (see below) and the N/S/F under tray. At this point, we can remove the top bell housing bolts and then slacken the top gearbox mounting ready for removal later. You’ll also need to remove the plate that is mounted with the slave cylinder.

Now remove the gear linkage assembly and then unbolt the clutch slave cylinder that is located on the front of the gearbox, retained by 2 x 13mm nuts, and stow safely (the hydraulics do not have to be disconnected).

2004 toyota rav4 repair manual free download