This procedure covers replacement of the transmission pan gasket on a 2019-2024 Toyota RAV4 with 2.5L I4 engine, including draining and refilling transmission fluid.

Warnings

Tools required

Parts

• Transmission pan gasket × 1 — Use OEM specification
• Transmission drain plug crush washer × 1 — Use OEM specification

Fluids

• Toyota WS ATF — 4.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Warm engine and transmission to normal operating temperature by driving vehicle for 10-15 minutes
4. Turn off engine and allow to sit for 5-10 minutes to let fluid settle
5. Raise front of vehicle with floor jack and support securely on jack stands
6. Position drain pan under transmission pan area

Procedure

1. 1

   Remove transmission drain plug
   Locate the transmission drain plug on the bottom of the transmission pan. Slowly loosen and remove the drain plug, allowing fluid to drain into the collection pan. Keep drain plug and inspect the crush washer for damage.
   Torque spec

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

   Remove transmission pan bolts
   Once fluid has drained to a slow drip, locate all transmission pan bolts (typically 16-19 bolts around perimeter). Loosen bolts in a criss-cross pattern, leaving two bolts at opposite corners partially threaded. Carefully break the pan seal and allow remaining fluid to drain.
   ⚠Additional fluid will drain when pan is loosened. Be prepared with drain pan positioned correctly.
   Torque spec

   Pan Bolts16 Nm (12 lb-ft)
3. 3

   Remove transmission pan
   Remove the final two bolts and carefully lower the transmission pan. Tilt pan as needed to drain remaining fluid. Set pan aside and allow to drain completely.
4. 4

   Clean pan and mating surface
   Remove old gasket material from transmission pan using plastic scraper. Clean pan interior thoroughly, removing any debris or metal particles. Inspect magnet if equipped and clean thoroughly. Clean transmission case mating surface completely, ensuring no old gasket material remains. Use brake cleaner and lint-free rags for final cleaning.
   ⚠Do not use metal scrapers on aluminum mating surfaces. Use only plastic scrapers to avoid gouging sealing surface.
5. 5

   Inspect transmission pan and filter
   Inspect transmission pan for cracks or damage. Look inside transmission for visible filter screen. Note any excessive debris or metal particles as this may indicate internal transmission wear. Check filter screen if visible and accessible.
6. 6

   Install new gasket
   Position new transmission pan gasket onto the pan. Ensure gasket is properly seated in pan groove or channel. Verify all bolt holes align correctly with pan holes.
   ℹ️Some gaskets may have adhesive backing. If using non-adhesive gasket, hold carefully during installation to prevent shifting.
7. 7

   Install transmission pan
   Carefully lift transmission pan with gasket into position against transmission case. Start all pan bolts by hand, ensuring gasket remains properly positioned. Thread all bolts 2-3 turns before tightening any bolt.
8. 8

   Torque transmission pan bolts
   Tighten transmission pan bolts in a criss-cross pattern starting from the center and working outward. Torque all bolts to specification in multiple passes: first to 6 Nm, then final pass to 12 Nm (9 lb-ft).
   Torque spec

   Pan Bolts16 Nm (12 lb-ft)
9. 9

   Install drain plug with new washer
   Install new crush washer onto drain plug. Thread drain plug into transmission pan by hand, then torque to specification.
   Torque spec

   Transmission Drain Plug30 Nm (22 lb-ft)
10. 10

    Refill transmission fluid
    Locate transmission fill plug on side of transmission case. Remove fill plug. Using fluid transfer pump or funnel adapter, add approximately 4.0 quarts of Toyota WS ATF through fill hole. Fluid should begin to overflow from fill hole when properly filled. Install fill plug and torque to specification.
    ℹ️Fill procedure requires transmission to be at specific temperature (95-113°F or 35-45°C). Use infrared thermometer on transmission case if available for accuracy.
    Torque spec

    Transmission Drain Plug30 Nm (22 lb-ft)
11. 11

    Lower vehicle and check for leaks
    Lower vehicle from jack stands to ground. Start engine and allow to idle. Shift through all gear positions (P-R-N-D), pausing 3 seconds in each position. Return to Park.
12. 12

    Verify fluid level
    With engine running and transmission at operating temperature (95-113°F), remove fill plug. Small amount of fluid should drip out if level is correct. If no fluid drips, add small amounts of ATF until slight overflow occurs. Install fill plug and torque to specification.
    ⚠Engine must be running during fluid level check. Ensure vehicle is on level ground and parking brake is engaged.
    Torque spec

    Transmission Drain Plug30 Nm (22 lb-ft)

Reassembly

1. Ensure all bolts are torqued to proper specification
2. Verify no fluid leaks from pan or drain plug
3. Wipe down transmission case exterior to allow for leak detection during test drive

Verification

• Check for fluid leaks around transmission pan gasket and drain plug with engine running
• Test drive vehicle through all gears to verify proper transmission operation
• Re-check fluid level after test drive following same overflow procedure
• Inspect under vehicle after test drive for any signs of leakage
• Verify smooth shifting in all gears with no slipping or delayed engagement

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