[michaelorr94]

Hi folks. Been doing repairs on my mother in laws 2005 Rav4 2.0 D4D (1CD-FTV) 5 speed manual. And while under it I've noticed a pipe that loops out and back into the gearbox in a U shape that has rotted away and is leaking transmission oil out quite badly. Can anyone avail me with a part number or better yet know where I can source one? I'll also need to replace the gearbox oil as a lot has been lost and even more when I had the propshaft off to replace the carrier bearing so while I'm here I'll ask what the correct oil viscosity and volume required for the box is? Any help massively appreciated 🙏

 

[NY RAV]

I haven't been under mine in a while (manual but not diesel as we didn't get those in the US), but it looks like someone may have installed that pipe in place of the drain and fill plugs. Perhaps the plugs got damaged and they came up with this as a "fix". I'd have to look at the service diagrams to be sure but if that's the case all you need are new plugs and gaskets as long as the threads are ok.

 

[michaelorr94]

I don't think that exists on the US/North American spec manuals, I don't recall seeing one on mine when I was under there. May be unique to the diesel which we never got over here.
Usually an external line like that means there is a pump which is not typical for manual gearboxes

From what I have gathered so far the petrol models have an oil cooler there which isn't necessary on the diesel models so the pipe simply returns back in to the box as opposed to feeding into the cooler and back in. Just can't seem to find any reference to it online or find a replacement unfortunately.

 

[NY RAV]

I would assume that the cooler is for the automatic and not the manual, as manual gearboxes are splash-lubricated and don't have pumps to circulate the fluid.

 

[NY RAV]

So it appears you are correct, I am looking at the service manual and it shows that pipe as "Transmission Oil Cooler Tube Sub Assembly". So you would need to replace that tube. As long as the elbows and seals are ok you can probably leave them alone.
I'd think you could just remove the pipe and take it to a plumbing, radiator, HVAC etc shop and have them make you a new one.

 

[Commando]

I would assume that the cooler is for the automatic and not the manual, as manual gearboxes are splash-lubricated and don't have pumps to circulate the fluid.

Toyota E series manual gearboxes are all equipped with an oil pump. If not, the 5th gear would die very quickly because it is in a ''separate'' compartment and higher than the oil level.

The RAV4.1 manual transmission use an oil cooler, but Toyota installed a metal loop instead for the RAV4.2.

 

[Commando]

I'd think you could just remove the pipe and take it to a plumbing, radiator, HVAC, hydraulic etc shop and have them make you a new one.

X2

 

[NY RAV]

Didn't know that about the pump, it's unusual to see that in an MT. Since it's been some time since I had eyes on mine I didn't remember seeing that pipe.
Good luck and let us know how you make out.