This procedure covers removal and replacement of the torque converter on a 2019-2024 Toyota RAV4 with 2.5L I4 engine and FWD transmission, requiring transmission removal from the vehicle.

Warnings

Tools required

Parts

• Torque converter × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Transmission oil seal (front) × 1 — Use OEM specification
• Flexplate inspection cover gasket × 1 — Use OEM specification
• Engine mount fasteners × 1 — Inspect and replace if damaged

Fluids

• Toyota WS ATF — 10 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Disconnect negative battery cable and wait 90 seconds for airbag system to discharge
3. Raise vehicle and support securely on jack stands at frame contact points
4. Remove front wheels to access subframe area
5. Remove engine under covers and splash shields
6. Install engine support fixture to prevent engine from dropping when transmission is removed
7. Mark driveline components for reassembly alignment reference

Procedure

1. 1

   Drain transmission fluid
   Place drain pan under transmission pan. Remove the transmission pan bolts gradually in a cross pattern to allow controlled draining. Once drained, remove pan completely and clean magnet. Inspect fluid for metal debris or burning smell indicating internal damage.
   Torque spec

   Pan Bolts16 Nm (12 lb-ft)
2. 2

   Disconnect electrical connectors and cooling lines
   Disconnect all transmission electrical connectors including shift solenoids, speed sensors, and temperature sensor. Label each connector for reassembly. Disconnect transmission cooler lines at the radiator and cap open ends to prevent contamination. Remove sensor bolts as needed.
   ⚠Residual ATF will drain from cooler lines. Have drain pan ready.
   Torque spec

   Sensor Bolts11 Nm (8 lb-ft)
3. 3

   Remove exhaust components and heat shields
   Disconnect exhaust system at front flex pipe. Remove any heat shields attached to transmission or blocking access. Support exhaust system with wire or stand to prevent damage to hangers.
   ⚠Exhaust components may be extremely hot. Allow adequate cooling time.
4. 4

   Remove shift cable and linkage
   Disconnect shift cable from transmission lever. Remove cable bracket mounting bolts. Secure cable out of work area to prevent damage during transmission removal.
   Torque spec

   Mounting Bolts61 Nm (45 lb-ft)
5. 5

   Disconnect axle shafts
   Remove both front axle shaft retaining nuts. Using appropriate pry bar, carefully separate axle shafts from transmission differential. Cap open differential ports with clean shop rags to prevent fluid loss and contamination. Support axles with wire to prevent CV joint damage.
   ⚠Do not allow axle shafts to hang unsupported as this will damage CV boots and joints.
6. 6

   Remove starter motor
   Disconnect starter electrical connections. Remove starter mounting bolts and remove starter from bellhousing. This provides access to flexplate and torque converter bolts.
   Torque spec

   Mounting Bolts61 Nm (45 lb-ft)
7. 7

   Remove flexplate inspection cover
   Remove the flexplate inspection cover screws from the bottom of the bellhousing. This exposes the torque converter bolts. Mark flexplate and torque converter position for reassembly reference.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
8. 8

   Remove torque converter to flexplate bolts
   Rotate crankshaft using 19mm socket on crankshaft pulley bolt to access each torque converter bolt through inspection opening. Remove all torque converter bolts. There are typically 6 bolts. Push torque converter back into transmission to separate from flexplate.
   ℹ️Mark bolt positions if bolts are different lengths. Keep torque converter pushed into transmission during removal.
   Torque spec

   Torque Converter Bolts50 Nm (37 lb-ft)
9. 9

   Support transmission and remove mounts
   Position transmission jack securely under transmission oil pan with wood block to distribute load. Remove rear transmission mount bolts and crossmember. Remove transmission mount bolts on both sides. Support transmission weight on jack before removing final mount bolts.
   Torque spec

   Mounting Bolts61 Nm (45 lb-ft)
10. 10

    Remove transmission to engine bolts
    Remove all bellhousing bolts securing transmission to engine. Note bolt lengths and positions as they vary. Support transmission securely on jack and ensure torque converter is held in place with retention tool or wire to prevent it from sliding out.
    ⚠️Ensure transmission jack is properly positioned and locked before removing final bolts. Transmission will shift weight as it separates from engine.
    Torque spec

    Mounting Bolts61 Nm (45 lb-ft)
11. 11

    Remove transmission from vehicle
    Carefully pull transmission straight back from engine, ensuring torque converter remains fully engaged in transmission pump. Lower transmission on jack and roll out from under vehicle. Keep transmission level during removal to prevent torque converter from sliding out.
    ⚠️Have assistant guide transmission and monitor clearance during removal. Do not allow torque converter to fall out.
12. 12

    Remove torque converter from transmission
    With transmission on bench, carefully pull torque converter straight out of transmission. Note depth of engagement before removal. Measure from transmission case to torque converter hub and record for installation verification. Drain remaining fluid from torque converter into appropriate container.
    ℹ️Torque converter should slide out with moderate resistance. If stuck, do not pry on transmission case.
13. 13

    Inspect and prepare for installation
    Inspect transmission front pump seal and replace if worn or damaged. Clean transmission bellhousing mating surface. Check flexplate for cracks or damaged ring gear teeth. Inspect crankshaft pilot bearing. Verify new torque converter pilot hub is not damaged and rotates freely.
    ⚠Any flexplate damage requires replacement before installing transmission.
14. 14

    Install new torque converter
    Install new torque converter into transmission by rotating while pushing straight in. Torque converter must engage pump drive gear, then turbine shaft, then stator. Feel for three distinct engagement clicks. Verify converter is fully seated by measuring engagement depth against previously recorded measurement. Distance from converter to bellhousing face should match specification or old converter measurement.
    ⚠️Torque converter MUST be fully seated before transmission installation. Improper seating will cause pump failure when transmission is bolted to engine.
15. 15

    Install transmission to engine
    Apply thin film of high-temp grease to torque converter pilot hub. Using transmission jack, carefully raise transmission to engine. Align transmission with dowel pins and slide forward. Transmission should slide easily to engine if torque converter is properly seated. Install all bellhousing bolts and tighten in cross pattern. Rotate crankshaft to verify torque converter rotates freely before proceeding.
    ⚠️If transmission does not mate easily to engine, STOP. Do not force with bolts. Remove and verify torque converter engagement.
    Torque spec

    Mounting Bolts61 Nm (45 lb-ft)
16. 16

    Install transmission mounts and torque converter bolts
    Install and torque transmission mount bolts and crossmember. Rotate crankshaft to access torque converter bolt holes through inspection opening. Align marks made during disassembly. Install and tighten torque converter bolts evenly in star pattern to prevent warping flexplate. Verify all bolts are tight.
    Torque spec

    Mounting Bolts61 Nm (45 lb-ft)

    Torque Converter Bolts50 Nm (37 lb-ft)

    Flexplate Bolts85 Nm (63 lb-ft)
17. 17

    Reinstall flexplate cover and starter
    Install new flexplate inspection cover gasket and cover. Tighten cover screws. Reinstall starter motor and connect electrical connections.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

    Mounting Bolts61 Nm (45 lb-ft)
18. 18

    Reconnect axles and components
    Remove protective caps from differential. Install axle shafts into transmission, ensuring they fully engage with circlips. Reconnect shift cable and adjust as needed. Install exhaust system and heat shields. Reconnect all electrical connectors and transmission cooler lines.
    Torque spec

    Sensor Bolts11 Nm (8 lb-ft)
19. 19

    Install transmission pan and fill with fluid
    Install new transmission pan gasket and pan. Tighten pan bolts in cross pattern. Using transmission fluid pump, add approximately 4 quarts of Toyota WS ATF through dipstick tube or fill plug. Start engine and add remaining fluid while cycling through gears.
    ⚠Do not overfill transmission. Check fluid level with engine running at operating temperature in Park position.
    Torque spec

    Pan Bolts16 Nm (12 lb-ft)

Reassembly

1. Reinstall all under covers and splash shields
2. Install front wheels and torque lug nuts to specification
3. Remove engine support fixture
4. Reconnect negative battery cable
5. Lower vehicle from jack stands

Verification

• Start engine and verify no fluid leaks from transmission pan, cooler lines, or axle seals
• With engine at idle and brake applied, shift through all gear ranges verifying smooth engagement
• Check transmission fluid level with engine at operating temperature in Park position and adjust as needed
• Road test vehicle verifying proper shift points, no slipping, and no abnormal noises
• Recheck fluid level after road test and inspect for leaks
• Verify no diagnostic trouble codes are present using scan tool

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