[Hadmatt54]

Also for you members across the pond... I've got a new 39 tooth 5th, gear part # 33336-42030 for sale, see the classifieds.

 

[gruntz]

Hello guys.

My fifth gear just started popping out. :S I will replace it in a month or so. I have two questions:

When i take my gearbox apart, are the worn parts visible with necked eye? Will i be able to tell which parts need to be replaced just by looking at them? How would i know, which parts to change?

My second question is - I am about to travel with my car next week. I am about to drive 200 km on highway, and then 200 more on the way back after a week. Should I be worried to drive on forth gear? What speed do you recommend? When I am driving on 4th gear, the noise at 3200 rpm is really bothering me, and I guess that the engine will reach even higher rpm. Is my car going to rise it`s temperature or something?

Thank you for your help.

 

[Hadmatt54]

Hi gruntz:
I'll answer your second question first. My 98 rav at 110 Kmh (70 mph) normally revs about 3200 in 5th. gear. My transmission has a OD ratio of 0.775. The same speed in 4th gear it revs about 3800. It's only 600 rpm, but when you are used to driving in fifth it sounds like it is screaming. I had to go away for work after my transmission started acting up and I drove about the same distance as you and it didn't hurt a thing! I did however drop my speed down to around 100 Kmh just so it didn't sound so bad.
Now your first question, there is noticeable wear on the parts I took off, but you really can't see it until you compare the old parts to the new parts. The hub had some wear not a lot but it wasn't like new, the 5th.gear as similar. I think the main problem is the needle bearings under the 5th. gear wear causing the 5 th gear to deflect and disengage.
The replacement parts that Toyota engineered have compensated for this. The new 5th. gear is of larger bore and the needle bearings that it sits on are larger to take up the added space between the gear and the shaft. Since they are larger they are stronger and probably less likely to wear.
As I said before I ordered the wrong 5th. gear and just got the right one today, I just finished putting it back together, so I'll take it for a test drive in the morning! Another thing that I noticed was with 279000 Km. on my Rav my motor mounts were shot and my engine was moving a lot, before 5th. started popping out the shift lever would move 1.5 cm (3/4") just by letting off on the fuel. The new mounts made a big difference, it's rock solid now.

As you can see I'm Canadian, but I buy my parts in the US. Even with the Canadian dollar the way it is I'm still saving big money. For example the 5th. gear is $99.02 US, I priced it at my local Toyota Stealership (no I didn't spell it wrong) and they wanted $279.00 Canadian. I just about passed out!
The parts that Toyota says you need are:
Hub, Transmission Clutch No. 3 -- 33393-42010 $73.31
Sleeve, Transmission Hub, No. 3 --33395-42012 $67.97
Bearing, Needle Roller (for 5th. gear) -- 90364-28023 $19.10
Retainer, Bearing, Rear (MTM) -- 33151-28020 $62.90
Gear 5th. 39 teeth (European) -- 33336-42030 $99.02
Shipping and Handling $31.01

Total $353.31 US
A lot of guys don't, but I replaced all of the parts $63.00 US is not worth the hassle of having to tear it apart at a later date and there was some wear on the retainer, not a lot , but some. It changes the work a little you will have to remove the driven 5 th, gear and the retaining nut. you will need a bearing puller for this. Toyota says the nut is not a reusable part, but I just put it on with high strength thread locker torqued it to 90-92 ft-lbs and restaked it.
As a footnote the 5th. gear 40 teeth (US) -- 33336-42040, is what my Rav had in it, but according to what I read on this topic, the Canadian Ravs had the same gear as the European Ravs...mine didn't. So I've got the 39 tooth one for sale, check and see if that is the one you need and PM me if your interested.

 

[gruntz]

Thank you, Hadmatt54.

Your post was very helpful and complete.

Thank you for your kind offer about the fifth gear, but the shipping to here (Bulgaria, Europe) will be a lot, and I don`t even know how to pay you

I will check the prices here, and then I will start thinking from where to buy.

Regards.

 

[Hadmatt54]

Well see what kind of prices you are able to get in Europe, if they are too expensive like the ones here in Canada, then this gear shipped to you may be the cheapest option!

 

[mickster69]

iv just started getting this problem on my 2003 model iv been quoted £595 just for the parts to do it myself abit expensive i thought considering i read about a guy in Scotland some were only paid just over £300 for the parts and the labour

 

[jetwhine]

I just wanted to do a praise report. I did the job on my 1997 Rav 5 speed and it worked like a champ. Thanks to Hardrocker for the pictures as I did mine in reference to yours and had very little trouble with the job. Like you said putting the sencros back together with those clips needed a few colorful metaphors to get the hang of it, but it is all back together and shifts into 5th nicely and no more popping out. Yahoo. Oh by the way I had talked to an auto care provider and they wanted to charge me 1600 dollars for the job. 300 dollars later and some labor and back on the road with a nicely running Rav.
Thanks again for the post with pics.

Jet

 

[gruntz]

Hello guys.

I check the prices of the parts that I need to repair my fifth gear. It seems to be very expensive here in Bulgaria :S

33393, HUB, TRANSMISSION CLUTCH, NO.3 $148.10
33395, SLEEVE, TRANSMISSION HUB, NO.3 $138.22
33336A, BEARING, NEEDLE ROLLER (FOR 5TH GEAR) $87.45
33336, GEAR, 5TH $285.19
331151D, Retainer, Bearing, Rear (MTM) I decided not to replace the retainer, so I didn`t asked about it

They wanted $659.10 total for all the parts.

That seems to be too steep. Do You know any way to buy the parts online from USA. It seems that is cheaper there. My repair will cost twice as much as Hadmatt54 had paid :S

Hadmatt54, how can I check if my car have 39 or 40 teeth on the gear, and do you still have that part for sail? ( When I wrote the details bellow, I noticed the EUR in my Vehicle Details, so I guess that it is European mode. Anyway, I decide to keep the details bellow just for reference )

Here are some details about my car:
Catalog Name: Rav4 - SXA1#(9404-0008) [662210]
Model: SXA10L-AZMGKW
Vehicle Details: SXA10..3SFE..MtM..HT..LHD..EUR..3D [199][FR14]
VIN: JT171SC1000166476
Reg. No. AR538CN
Build Date: 01.05.1997

I was thinking to get second hand parts from crashed car, but there is no guarantee that the fifth gear will not be already broken, or will broke after a while.

Do you know a way that I can buy the parts from USA or Canada, or any place that is cheaper? Or can someone of You buy the parts and send them to me ( I will pay in advance ).

Regards.

 

[jetwhine]

You will need a credit card to purchase parts from dealers here in the USA. Your markup is quite high compared to US prices. But I think as you said the shipping is going to kill the good deal. Or maybe not you need to check.

 

[Kittiquel]

I was having the same issue with my 5th gear. I got into a wreck about 2 years ago in my '99 rav4 and a few months later, my rear engine mount failed. Luckily the only real damage done to the car was 5th gear no longer engaging properly and popping out of fifth gear after I had replaced the rear engine mount.

This thread was insanely helpful, but I ran into a slight issue when attempting the repair the first time. My rav4 is one of those unlucky 3rd generations with the slightly smaller shaft diameters (27.997mm or 1.1013"... roughly 28mm). Apparently Toyota fabricated some 3rd generation rav4's with two different shaft diameters. In order to streamline their part fabrication processes, they stopped making the 5th gear for the smaller shaft diameter (everything else about the gears are the same with the exception of the inner diameter of the gear). For some reason, Toyota only updated the gear part number for the VINs, but not the bearing (the needle roller bearing associated with these rav4's are the smaller, original ones and will not fit properly into the newer gear with the larger inner diameter). I have noticed that a few other people had the same issue with this repair on their rav4's, so I have decided to post my resolution.

I pestered Corp. Toyota for over 2 weeks and finally got to their engineering department. I gave them the size of the bearing I needed since they couldn't find anything on the research and they were able to supply me with a part number. It has been roughly a week since I have done the repair and my car is driving perfectly. These following part numbers are for the parts that I replaced, though I know that some people don't have a need to replace the hub, etc.:

33336-42040 - 40 tooth 5th gear
90364-28023 - larger split needle roller bearing that fits into the fifth gear and the smaller shaft diameters (the old bearing was 90364-28013)
33393-42010 - No. 3 Hub
33395-42012 - No. 3 Hub sleeve

When I called the corp. parts specialist to thank him for helping me out with this, he stated that the Corp. Toyota's Engineering Dept. will be issuing a TSB within the next 6 months for the 3rd gen rav4's with the smaller shaft diameter. They just need to find out exactly which VINs are affected by this situation.

 

[dago]

diesel gearbox

have only had my 2001 a week and it's started jumping out of 5th,this didn't show up on test drive private sale so no comeback,is the gearbox the same on the diesel,and where's the best place to order the parts from in the uk, very informative thread this looks like a top site cheers :crying

 

[Rav4Ron]

I'm not knowledgeable with the diesel model at all. Also the overseas version may be completely different. I would take the steps performed here to a mechanic you can trust and let him read and then decided. Sorry I wasn't very helpful.

 

[dago]

diesei 5th gear

just done the 5th gear fix on my uk diesel the 5th gear is different to the petrol's has 41 teeth part no:33336-42020 the rest is the same,held the syncro together as i pulled it off then held it in place on 5th gear as i tapped it on all works fine thanks for the guide took about 2 hours cheers

 

[fifth]

In terms of what 5th gear size is needed, I got this off of Toyota Parts Overstock - Dependable, Proven Quality Toyota Parts Online For the 3342842040 part #:
TOYOTA RAV 4 2000CC 16-VALVE DOHC EFI, MANUAL HARDTOP, 2-DOOR 1996, 1997, 1998, 1999, 2000 TOYOTA RAV 4 2000CC 16-VALVE DOHC EFI, MANUAL HARDTOP, 4-DOOR 1996, 1997, 1998, 1999, 2000 TOYOTA RAV 4 2000CC 16-VALVE DOHC EFI, MANUAL SOFTTOP, 2-DOOR 1996, 1997, 1998, 1999, 2000 TOYOTA RAV 4 2400CC 16-VALVE DOHC EFI, MANUAL 2003, 2004, 2005
For Part number 3342842030 got:
TOYOTA RAV 4 2000CC 16-VALVE DOHC EFI, MANUAL 2001, 2002, 2003, 2004 TOYOTA RAV 4 2400CC 16-VALVE DOHC EFI, MANUAL 2001, 2002, 2003, 2004, 2005
I don't know how accurate this info is, but will find out when I pop under the car next week. I'm in the US with a 2001 RAV4.

 

[tuftyclub]

Just did my 80k '98 Rav 4 GX as I bought it knowing 5th wouldn't stop in. Only had to replace 5th, the sleeve and the split bearing. Hub seemed to have little or no wear.


Did find the gear cover had a blocked oil feed hole - it had been like it since new as it was black paint over the small end of the pipe that I had to pierce through.


Thorough clean out, new semi-synthetic 75-90 and it's changing real smooth and holding 5th with no gearstick movement.


Bit annoyed it had been stripped, emptied of oil and chucked back together by the garage that sold it. Obviously didn't want to pay the cost of the parts (cost me £283 inc' VAT).

 

[ddsmith]

I thought I would provide a little input to this thread now that I am doing this to my 2000 RAV4. It is great that there was so much information from people who have trail blazed this repair. I did run into something that I haven't seen mentioned in any of the threads I have read on this. While I had 5th gear removed, I inspected the 5th driven gear as the book calls it. It is the one with the special nut on it, that is staked in place. When I grabbed on to this gear. It was loose. I could rock it back and forth far more than it should have moved and I could actually rock the gear in and out some. The staked nut was not tight but was staked and it could not be rotated without un-staking it. The manual said that this nut should be torqued to 90 foot pounds. I ended up disassembling it for an inspection. I did not see anything abnormal with the bearing, so I reinstalled it and torqued it to 90 foot pounds. After doing this, the gear is solid like I expected it to be when I took it apart in the first place. The normal replaced parts for the 5th gear pop out issue didn't look bad. Not like some of the picture previous folks have posted. So this may be a good thing to check when you are in there. I just couldn't put it back together with that gear being so sloppy. I knew I would be revisiting it, if I did. Tomorrow, I will take it out for a drive and see if all this fun has cured it's problem.

 

[fifth]

Thanks to Hardrocker and the subsequent posters for all the great information. Based on all this info, I was able to fix my manual transmission on my 2001 RAV4. Despite the second generation RAV, still the same fix. Jacked the car up, took off the driver side mud guard and accessed the transmission from there after taking off the transmission cover. About 700ml of tansmission oil dripped out;have a drain pan ready. The parts I replaced were:
Qty Product # Price EA
1 GEAR, 5TH 3333642030 $100.21
1 SLEEVE, TRANSMISSION HUB, NO.3 3339542012 $70.46
1 BEARING, NEEDLE ROLLER (FOR 5TH GEAR) 9036428023 $19.79

I believe that first generation RAVs use 5th gear part #3342842040. Used a harmonic balancer to pull off the syncro which came apart as I took it off. That was a pain as it took some time to figure out how it went back together, but after some tinkering it only fit back together one way. Did not need to replace the retainer (no movement) or the syncro clutch hub as the gears were a little worn but nothing major. The problematic wear is clearly visible on the inside sleeve hub and the matching gears on fifth gear. It's obvious to see how this caused fifth to pop out of gear and why you could hold it in by keeping pressure on the gear shifter. Used a 12mm X 70mm, 1.5mm pitch bolt (a must have), washers and pipe connector to use as a pusher to get the syncro hub back on the gear shaft. Ends of shifting fork were a bit worn but has not been a problem. Applied gasket sealer to the end cap, put it back on, waited a day, then filled up the transmission with gear oil. Took it out for a drive and fifth shifts perfectly, and stays in gear with no movement at all. Perfect fix. Figure I saved my self at least $2000. I've already driven 1000 miles since the repair and still perfect with no issues. Amazes me that this fix isn't more published or obvious, that so many mechanics say the transmission has to be replaced, rebuilt or at least removed from the car to do this simple fix on just fifth gear. Besides a few minor mishaps, very easy job that can easily be done in under three hours. But this forum was the key to my success and money savings. Thanks everyone!!

 

[harno]

Request for help from Germany

Hi everybody

I hope to find some help regarding my fifth gear problem. I need 2 sets of those listed parts (for myself and a friend of mine) in order to get our RAV4 Convertible’s fixed.
Problem is that those parts are very expensive here in Germany. So I hope to find someone that can help me to order those parts and get them shipped to Germany.

I took the part number information from the early start of this 5th Gear D.I.Y.
So maybe pricing isn’t current. But I hope to find someone that could supply those parts to me. I assume a “UK-Source” would be a good alternative, since shipping to Germany should be easy.
But “worst case” I can also provide a US address. In this case it will take a while until I get the parts, but ….

33393-12022 Hub Transmission clutch no 3 64.51 US$
33395-12021 sleeve Transmission hub no 3 58.27 US$
33336-12061 5th gear 86.00 US$
90364-28023 bearing, needle roller 18.86 US$
33151-28020 retainer bearing rear 62.04 US$



PS: I read somewhere here that the “Retainer Bearing Rear” doesn’t need to get changed, since it doesn’t “do anything” and doesn’t show any “wear” marks. According to the German dealer it is very likely that the “thickness” of this retainer was changed in order to reduce/tighten the clearance.



Many Thanks in advance!
Harno

 

[rns]

Hi,

try quote from Amayama.com.

At least one set of these comes very competive price.


I changed only these 3 parts in my 3rd gen manual Rav4 with same gearbox as 1st gen. I got my parts from Teilexpress but for a higher price.


What you might to want change too is the Fork, gear shift. My case it looked clearly worn but I did not have it.

I had this problem in 2006 Rav4 so the “thickness” of this retainer have to have been changed after that if it has been changed.

Hi everybody

I hope to find some help regarding my fifth gear problem. I need 2 sets of those listed parts (for myself and a friend of mine) in order to get our RAV4 Convertible’s fixed.
Problem is that those parts are very expensive here in Germany. So I hope to find someone that can help me to order those parts and get them shipped to Germany.

I took the part number information from the early start of this 5th Gear D.I.Y.
So maybe pricing isn’t current. But I hope to find someone that could supply those parts to me. I assume a “UK-Source” would be a good alternative, since shipping to Germany should be easy.
But “worst case” I can also provide a US address. In this case it will take a while until I get the parts, but ….

33393-12022 Hub Transmission clutch no 3 64.51 US$
33395-12021 sleeve Transmission hub no 3 58.27 US$
33336-12061 5th gear 86.00 US$
90364-28023 bearing, needle roller 18.86 US$
33151-28020 retainer bearing rear 62.04 US$

Many Thanks in advance!
Harno

 

[2003Rav4Lover]

Well I just read through all 18 pages and now I'm stressed out...

This is my first ever post on Rav4World, I literally just signed up. Two days ago I purchased a 2003 Rav4 L 5 speed with 115,000 miles. Car is in excellent condition. So when can I expect my 5th gear to go?? lol. Pretty upset about this.

I guess first and foremost is to drop the gear oil and get some fresh in her. What do people recommend? I am like a sponge and want to learn as much as I can about this girl. She's sexy and I want to keep her that way!