This procedure covers removal and replacement of the flexplate on a 2019-2024 Toyota RAV4 with 2.5L I4 gas engine and FWD automatic transmission, requiring transmission removal to access the flexplate.

Warnings

Tools required

Parts

• Flexplate × 1 — Use OEM specification
• Flexplate bolts (if not reusable) × 8 — Use OEM specification
• Transmission gasket/seal × 1 — Use OEM specification
• Engine oil × 1 — Toyota Genuine 0W-20
• Automatic transmission fluid × 1 — Toyota WS ATF

Fluids

• Toyota Genuine 0W-20 — 5 qt
• Toyota WS ATF — 10 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect negative battery terminal and wait 90 seconds for airbag system discharge
3. Raise vehicle and support securely on jack stands at all four corners
4. Remove engine under covers and splash shields
5. Drain engine oil completely and remove oil filter
6. Drain transmission fluid from drain plug and fluid cooler lines
7. Install engine support fixture across engine bay or attach engine hoist to lifting eyes
8. Remove both front wheels for access to subframe mounting points

Procedure

1. 1

   Disconnect transmission cooler lines and electrical connections
   Disconnect transmission fluid cooler lines at the transmission using a flare nut wrench. Cap or plug all openings immediately to prevent contamination. Disconnect all electrical connectors from transmission including shift solenoids, speed sensors, and park/neutral position switch. Label connectors for reassembly.
2. 2

   Remove axle shafts and intermediate shaft
   Remove cotter pins and axle nuts from both front axles. Separate lower ball joints and tie rod ends. Pull both axle shafts from transmission and support out of the way with wire. Remove center support bearing bracket and remove intermediate shaft from transmission. Plug transmission openings to prevent fluid loss.
3. 3

   Disconnect shift cable and starter
   Disconnect shift cable from transmission lever and remove cable bracket from transmission case. Remove starter motor mounting bolts and set starter aside with wiring still connected. Support starter to prevent strain on electrical connections.
4. 4

   Support transmission and remove crossmember
   Position transmission jack under transmission pan with a block of wood to distribute load. Secure transmission to jack with a strap or chain. Remove rear transmission mount bolts and transmission crossmember mounting bolts. Lower crossmember and remove from vehicle.
   Torque spec

   Mounting Bolts47 Nm (35 lb-ft)
5. 5

   Remove torque converter access cover
   Remove the lower torque converter access cover bolts from the transmission bellhousing. This cover provides access to the torque converter-to-flexplate bolts. Keep cover and bolts organized for reinstallation.
   Torque spec

   Cover Bolts16 Nm (12 lb-ft)
6. 6

   Mark and remove torque converter bolts
   Rotate crankshaft using a socket on the crankshaft pulley bolt to access each torque converter bolt through the access opening. Mark the relationship between torque converter and flexplate before removal. Remove all torque converter bolts. Push torque converter back into transmission and secure with wire to prevent it from falling out during transmission removal.
   ⚠Torque converter must be pushed fully into transmission and secured before lowering transmission to prevent damage or injury from falling converter.
   Torque spec

   Torque Converter Bolts50 Nm (37 lb-ft)
7. 7

   Remove transmission-to-engine bolts
   Remove all transmission-to-engine mounting bolts. There are typically multiple bolts of different lengths around the bellhousing perimeter. Note bolt locations and lengths for proper reinstallation. Check for any remaining ground straps, brackets, or wiring before separating.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
8. 8

   Separate and lower transmission
   Carefully pull transmission straight back away from engine to disengage from dowel pins. Ensure torque converter remains in transmission. Slowly lower transmission jack and remove transmission from under vehicle. Handle with care due to weight and size.
   ⚠️Transmission weighs approximately 200 lbs. Ensure transmission jack is secure and have assistance when lowering.
9. 9

   Mark and remove flexplate
   Use a flywheel holder tool or wedge to prevent crankshaft rotation. Mark the flexplate orientation to crankshaft with a paint pen or marker for proper balance during reinstallation. Remove all flexplate mounting bolts in a star pattern. Remove flexplate from crankshaft. Inspect flexplate for cracks, heat damage, or worn ring gear teeth.
   ⚠Flexplate orientation must be marked before removal to maintain engine balance. Improper installation will cause vibration.
   Torque spec

   Flexplate Bolts85 Nm (63 lb-ft)
10. 10

    Inspect crankshaft flange and rear main seal
    Clean crankshaft flange thoroughly with brake cleaner and inspect for damage, cracks, or wear. Check rear main seal for leakage. Replace rear main seal if any seepage is visible. Verify crankshaft dowel pins are intact and properly seated.
11. 11

    Install new flexplate
    Align new or inspected flexplate with crankshaft dowel pins and marks made during removal. Ensure proper orientation with ring gear teeth facing transmission. Install all flexplate bolts hand-tight. Apply medium-strength thread locker to bolt threads if specified. Use flywheel holder to prevent rotation. Torque flexplate bolts to specification in a star pattern, making multiple passes from 30%, 60%, to 100% of final torque.
    ⚠Flexplate bolts must be torqued in proper star pattern sequence. Verify sequence with factory service manual before torquing.
    Torque spec

    Flexplate Bolts85 Nm (63 lb-ft)
12. 12

    Prepare transmission for installation
    Install new transmission front seal if removed or leaking. Ensure torque converter is fully seated in transmission pump by measuring depth from bellhousing face to converter mounting lugs. Converter should be recessed approximately 15-20mm. Apply small amount of transmission fluid to torque converter hub and transmission input shaft splines.
13. 13

    Install transmission
    Raise transmission into position using transmission jack. Align transmission with engine dowel pins and carefully push transmission forward. Ensure torque converter hub engages with flexplate center pilot. Transmission should mate flush with engine without forcing. Install all transmission-to-engine bolts and torque to specification in a cross pattern.
    ⚠Do not use transmission bolts to pull transmission to engine. Transmission must slide forward easily when properly aligned.
    Torque spec

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)
14. 14

    Install torque converter bolts
    Rotate flexplate to align torque converter bolt holes. Install all torque converter-to-flexplate bolts using alignment marks made during removal. Torque bolts to specification while rotating crankshaft to access each bolt through the access opening. Verify torque sequence with service manual.
    Torque spec

    Torque Converter Bolts50 Nm (37 lb-ft)
15. 15

    Reinstall remaining components
    Install torque converter access cover with bolts torqued to specification. Install transmission crossmember and rear mount, torquing all mounting bolts to specification. Remove transmission jack and engine support fixture. Reinstall starter motor, shift cable and bracket, axle shafts with new cotter pins, and all electrical connections. Reconnect transmission cooler lines. Install engine under covers and wheels.
    Torque spec

    Cover Bolts16 Nm (12 lb-ft)

    Mounting Bolts47 Nm (35 lb-ft)

Reassembly

1. Fill transmission with Toyota WS ATF to proper level using dipstick or fill plug procedure
2. Fill engine with Toyota Genuine 0W-20 oil and install new oil filter
3. Reconnect negative battery terminal
4. Torque wheel lug nuts to specification in star pattern
5. Double-check all fluid levels before starting engine

Verification

• Start engine and verify no fluid leaks from transmission or engine
• With engine at operating temperature, verify transmission fluid level is correct using proper checking procedure
• Test drive vehicle and verify smooth engagement of all gears with no unusual vibrations
• Check for proper operation of park, reverse, neutral, and all forward gears
• Re-check all fluid levels after test drive and inspect for any leaks
• Verify no warning lights are illuminated on instrument cluster

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