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Peekeen

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Discussion starter · #1 ·
Hi everyone. I’m a new customer to Toyota. I have a 2003 RAV4 4WD. I’ve always worked on my own 4WDs in the past, but I have a problem I’d like to ask help with. I cannot access the front differential filler plug! It’s in a very tight spot where the exhaust passes right in front of the filler plug, therefor blocking access to it. Is there a special tool I need to access the filler plug? It just seems a bit excessive to remove the front section of the exhaust to do a front differential fluid change. Any help or suggestions would be much appreciated.
Many thanks!
 
#3 · (Edited)
It is called a transfer case on this vehicle. That one is a very difficult one to reach because it is smack in the middle under the car. Also hard to reach with the exhaust pipe in the way. Then on top of that the filler bolt has a thin head which can be rounded easily. You would need a shallow socket (3/8 drive) which in itself is hard to find in that size (I think 27mm?) . With that in mind I decided to get a shop to do it. So I found a shop that was not busy and was friendly. Total cost was $20 cash with me bringing my own fluid. It beats buying that unique socket for $15 and getting frustrated.

It is possible to remove this plug but if you had a pit it would be perfect. Jacking up the car and getting under in an awkward position with the exhaust in the way is going to be painful.
 
Discussion starter · #4 ·
Thanks for your reply. I’ve had the vehicle for a couple of days only and I’m trying to gather information about the Toyota drivetrain.
The filler plug has a label on it for API GL-5 SAE 90 hypoid gear oil. I can’t find any information for automatic transmission fluid? The transfer case also mentions GL-5 SAE 90. It’s booked into Toyota garage for Wednesday to get the front prop shaft/differential seal replaced as its leaking, I wanted to top it up a little to last a couple of days. It looks like gear oil, not ATF. But as I mentioned the exhaust is right in the way of the filler plug and I can’t access it with a normal socket or spanner.

many thanks
 
Discussion starter · #5 ·
Thankyou for both replies. Much appreciated. I think I’ll wait until Wednesday and let the Toyota mechanics deal with it!
I’m used to Jeep Dana differentials!
Can I please clarify then that the front diff and transfer box are integrated in the 2003 Toyota RAV4? They are the same unit?

many thanks
 
#6 ·
Peekeen said:
Thanks for your reply. I’ve had the vehicle for a couple of days only and I’m trying to gather information about the Toyota drivetrain.
The filler plug has a label on it for API GL-5 SAE 90 hypoid gear oil. I can’t find any information for automatic transmission fluid? The transfer case also mentions GL-5 SAE 90. It’s booked into Toyota garage for Wednesday to get the front prop shaft/differential seal replaced as its leaking, I wanted to top it up a little to last a couple of days. It looks like gear oil, not ATF. But as I mentioned the exhaust is right in the way of the filler plug and I can’t access it with a normal socket or spanner.

many thanks
Click to expand...
When I had a 2005 model I used 75W 90 Mobil 1 Synthetic gear oil for transfer case and rear differential. The ATF is Toyota Type IV. I use Valvoline MaxLife Synthetic ATF. Don't bother killing yourself trying to get the front transfer case filler bolt out. Pay someone to do it.
 
#7 ·
Peekeen said:
Can I please clarify then that the front diff and transfer box are integrated in the 2003 Toyota RAV4? They are the same unit?
Click to expand...
No, they are not the same.

The front differential is co-located within the transaxle.

The transfer case, aka center differential in this model RAV, is what you can drain/fill independently of the transaxle and takes gear oil. Don't put ATF in the transfer case. Don't put gear oil in the transmission.
 
#8 ·
Peekeen said:
Thankyou for both replies. Much appreciated. I think I’ll wait until Wednesday and let the Toyota mechanics deal with it!
I’m used to Jeep Dana differentials!
Can I please clarify then that the front diff and transfer box are integrated in the 2003 Toyota RAV4? They are the same unit?

many thanks
Click to expand...
No front differential unless it is FWD. On 4WD it is a transfer case.
 
Discussion starter · #9 ·
Yes mine is 4WD. Manual gearbox. So it’s just the rear diff and front transfer case, Is that correct?
The leak is coming from the transfer box where the the front propshaft attaches to it. I’ll take some photos tomorrow in the daylight.
Thanks again for the replies.
 
#11 ·
Peekeen said:
Yes mine is 4WD. Manual gearbox. So it’s just the rear diff and front transfer case, Is that correct?
Click to expand...
Yes.

And congrats on the manual gearbox, don't let that one go!

I unbolt the mid-pipe to gain access. When doing so on both my RAVs I had to replace the OE bolts that were badly corroded.

And have the rear differential changed while you're at it (y)
 
Discussion starter · #12 ·
Peekeen said:
Hi everyone. I’m a new customer to Toyota. I have a 2003 RAV4 4WD. I’ve always worked on my own 4WDs in the past, but I have a problem I’d like to ask help with. I cannot access the front differential filler plug! It’s in a very tight spot where the exhaust passes right in front of the filler plug, therefor blocking access to it. Is there a special tool I need to access the filler plug? It just seems a bit excessive to remove the front section of the exhaust to do a front differential fluid change. Any help or suggestions would be much appreciated.
Many thanks!
Click to expand...
05RAV said:
Yes.

And congrats on the manual gearbox, don't let that one go!

I unbolt the mid-pipe to gain access. When doing so on both my RAVs I had to replace the OE bolts that were badly corroded.

And have the rear differential changed while you're at it (y)
Click to expand...
Yup that’s the plan. They can change the rear diff and gearbox oil while they’re at it. I’ll worry about it next time in another 30,000 miles. I do like a manual gearbox. I’ve had Jeeps & BMWs in the past with auto boxes. Im enjoying the RAV4 much more though. Of course much more economical than the 4.7L V8 Jeep. Petrol here is £1.67 per litre at the moment so got to be careful. It’s only done 70,000 miles in 19 years, and apart from the leaking oil seal it’s mint condition. Bargain!
 
#13 ·
Welcome to the forum.

We have a manual tranny too on our 4.3, and I have just changed all 3 boxes for the second time at 62k miles. Yours is super low mileage, so defo worth looking after.

I would also look at the coolant (initial change at 10 years, then every 5 years after), and also the brake fluid - I do our brake fluid every 5 years for our climate
 
#14 ·
Peekeen said:
Yes mine is 4WD. Manual gearbox. So it’s just the rear diff and front transfer case, Is that correct?
The leak is coming from the transfer box where the the front propshaft attaches to it. I’ll take some photos tomorrow in the daylight.
Thanks again for the replies.
Click to expand...
So if you have a manual gear box then it does not use ATF.
 
#15 ·
There is a second fill plug much higher on the t-case.. . I don't remember if it has better access. But it is important to NOT get the fluid level up to this plug!

 
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#16 ·
Fellow manual here. When I serviced mine I used Motul 300 Gear for everything, it's a synthetic that meets the spec for all of the drivetrain fluids.
The rear diff plugs did not want to come out so I held off on that one until I got new ones. The shop had to trash the old ones to get them out.
And it's a lot easier to do this on a lift.
 
Discussion starter · #17 ·
Hi NY Rav. Thanks for your input. I’ve dropped my RAV4 at Toyota now so they will take car of the fluid changes this time, and the leaking oil seal. But I’ll do the next fluid changes. I’ll order replacement plugs to have on standby, no doubt I’ll need them. I’ve been given some tips about the centre diff access, which has been suggested to unbolt the mid pipe so it’s out of the way. So I’ll order replacement bolts for that too and have them ready.
Thanks for everyone’s information on this topic 👍
 
#18 ·
When we serviced my center diff/transfer case we didn't have to disconnect anything although I do recall it was a bit tight getting in there. Definitely a matter of having the right tools plus the convenience of a lift. Disconnecting any part of the exhaust was not an option as it's pretty much held together by rust at this point, it's fine as long as it's left alone.
 
Discussion starter · #19 ·
Hi guys. I thought I’d post an update with the whining noise. So I got the car back from Toyota today. They have replaced rear diff fluid, changes the leaking oil seal from transfer case and replaced the fluid there. However I can still hear a very audible whining noise in 1st, 2nd and 3rd gear whilst accelerating. The whining gets higher pitched as the car speeds up, then fades away after 3rd gear. Or becomes to high pitched to hear. The only fluid that hasn’t been changed is the manual gearbox fluid. Maybe I should change this fluid and see what happens? I have a couple of sound recordings I will try and post later this evening. If anyone has any more thoughts please reply.
Many thasks!
 
#20 ·
Well there's only one way to find out. ;)
If the fluid has never been changed it's long overdue based on time alone if not mileage. Go ahead and change it, make note of how much old fluid comes out and what it looks like. The level shouldn't have dropped unless there is a leak and the fluid should be fairly clean and not thinned out or contaminated with metal bits, water or anything else.
If the noise goes away with fresh fluid, great. If it's still there you'll need to investigate further.
Does it happen only under load when accelerating, or also when coasting? If coasting, in gear only or in neutral as well?
For reference I don't have any such noises in my '02 MT. When the fluid was changed what came out was very clean and I'm pretty sure it was the original fluid @130K as the plugs did not appear to have been disturbed.
 
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05RAV
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