This procedure covers the removal and replacement of transmission cooler lines on a 2019-2024 Toyota RAV4 with 2.5L I4 engine, including fluid drainage and refill.

Warnings

Tools required

Parts

• Transmission cooler line set × 1 — Use OEM specification
• Transmission drain plug crush washer × 1 — 90430-12031 or equivalent
• Transmission cooler line seals/O-rings × 1 — Typically included with lines

Fluids

• Toyota WS ATF — 3 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Allow engine and transmission to cool for at least 30 minutes if recently driven
4. Remove engine under covers using 10mm socket
5. Raise and support front of vehicle securely on jack stands at manufacturer lift points
6. Position drain pans under transmission drain plug and cooler line connection points

Procedure

1. 1

   Drain transmission fluid
   Remove the transmission drain plug using a 14mm socket. Allow fluid to drain completely into the drain pan. This will minimize spillage when disconnecting cooler lines. Once drained, reinstall drain plug with new crush washer.
   Torque spec

   Transmission Drain Plug30 Nm (22 lb-ft)
2. 2

   Locate transmission cooler lines
   Identify the two transmission cooler lines running from the transmission housing to the radiator. The lines are steel with rubber sections and quick-disconnect fittings at both ends. Note their routing for proper installation of replacement lines.
3. 3

   Disconnect cooler lines at radiator
   Position drain pan under radiator-side connections. Using line wrenches, carefully loosen the flare nuts connecting the cooler lines to the radiator cooler ports. On this model, these typically use 12mm or 14mm flare nuts. Once loosened, finish removal by hand and allow any remaining fluid to drain. Cap or plug radiator ports to prevent contamination.
4. 4

   Disconnect cooler lines at transmission
   Position drain pan under transmission-side connections. The transmission-side connections use quick-disconnect fittings with retaining clips. Depress the retaining tabs while pulling the lines straight out from the transmission housing. Twist slightly if resistance is encountered. Inspect and remove old O-rings from transmission ports.
5. 5

   Remove cooler lines from vehicle
   Release any mounting clips or brackets securing the cooler lines along their routing path. Note the position of all clips and brackets for reinstallation. Carefully maneuver the old lines out from under the vehicle, avoiding damage to surrounding components.
6. 6

   Prepare new cooler lines
   Unpack new cooler lines and verify they match the old lines in length and fitting types. Install new O-rings onto the transmission-side quick-connect fittings, lubricating them lightly with clean ATF. Ensure all protective caps are removed from fittings before installation.
7. 7

   Route new cooler lines
   Route the new cooler lines along the same path as the original lines, ensuring they do not contact exhaust components, sharp edges, or moving parts. Maintain proper clearance from the exhaust system (minimum 25mm). Secure lines with all original mounting clips and brackets.
8. 8

   Connect lines at transmission
   Push each cooler line firmly into its respective transmission port until you hear and feel a distinct click, indicating the quick-connect fitting has engaged. Tug gently on each line to verify secure connection. The lines should not pull out with moderate force.
9. 9

   Connect lines at radiator
   Remove plugs from radiator cooler ports. Thread flare nuts onto radiator ports by hand to prevent cross-threading. Once hand-tight, use line wrenches to snug fittings. Do not overtighten; these are typically tightened to 20-25 Nm but torque specs are not provided for these connections, so tighten firmly by feel without stripping threads.
10. 10

    Refill transmission fluid
    Using the transmission dipstick tube or fill plug (depending on model variant), add approximately 3 quarts of Toyota WS ATF to replace the fluid lost during the procedure. Use a transmission fluid pump or funnel for filling. Start with 2.5 quarts and check level before adding more.
11. 11

    Check for leaks and verify fluid level
    Start engine and allow to idle. Shift through all gear positions (P-R-N-D-L) pausing 2-3 seconds in each, then return to Park. With engine running and transmission at operating temperature (160-180°F), check fluid level on dipstick or through fill hole. Add fluid as needed to bring to proper level. Inspect all cooler line connections for leaks while engine is running.

Reassembly

1. Verify all cooler line connections are secure and not leaking
2. Ensure all mounting clips and brackets are properly fastened
3. Reinstall engine under covers and torque cover screws per specification
4. Lower vehicle from jack stands
5. Remove wheel chocks

Verification

• Start engine and verify no transmission fluid leaks at cooler line connections
• Allow engine to reach operating temperature and recheck fluid level with engine running in Park
• Test drive vehicle through all gears to verify normal transmission operation
• After test drive, recheck all connections for leaks and verify fluid level again
• Monitor transmission fluid level and condition over the next few days of driving

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