[Commando]

I'm frequently going off road with my 2001 RAV4. It's lifted 40mm, has a ST205 torsen in the rear diff... and the tires are BF all terrain K02 (LT225/75/16). My friends, who are ''true 4x4'' guys, are often surprised how my trucklet is capable of. The main difference with their vehicule, is the lack of low range on the RAV4. Even if I take my time, I'm going everywhere so rapidly compared to them... always waiting for them! But in long and very inclined hills, the power to the wheels is insufficient and the engine wants to die. I sometimes have to ''clutch-kick'' if I want to avoid the engine to stall in first gear going up-hill. I know that the RAV4.1 has a better transmission ratio with the E250F (4.93 compared to my 4.56). It would suit better for my application. Another advantage to me is the transfer-case that has a true lock compared to the viscous central diff in the second generation. I already get stuck in the mud with only the front wheels spinning... so I sometimes cross fingers hoping this to not happen again!


So here is my question: does someone here did that tranny/t-case swap in a second generation RAV4? Does the first generation bigger t-case clear 1AZ/2AZ block?


Thanks guys!

 

[jspec rsx]

Can't answer your question about the tcase but was wondering what you used to lift your 4.2 there are some post on here but not so current. Thanks

 

[Commando]

I wanted to buy the OME lift kit, but at this time 850$ (Canada) was not in my budget. So I saw a very cheap kit on ebay, and bought it. When I received it, I was not sure how long the front strut spacers would last... but finally I still don't have any problem. If they break, I will make a copy in aluminum... but 2 inches instead of 40mm.


Toyota RAV4 2000-2005 Lift kit 40mm | eBay

 

[Commando]

 

[Commando]

This was before the lift and wheel spacers.

 

[jspec rsx]

Very nice thanks for the info. Are you still using oem or oem replacement shocks?

 

[Commando]

Are you still using oem or oem replacement shocks?

Yes, and rear shocks are long enough for more lift.

 

[RAV4EVR]

Do you have the differential locker in your RAV4.
My First gen has it and it comes very handy. I also have BFGs. With the locker and the BFGs it is very capable.
I never even had to lift it.

However the low range was missed on some occasions only because I had my vehicle loaded down with so much weight and climbing steep grades out of canyons was a struggle.

Love you RAV. I had 3 2nd gens about 10 years ago but I didn't get the locker in anyone of them. I don't think USA had that option at least.

 

[Commando]

Unfortunately, Canada never had lockers on 4.2, that's why I want a tranny + transfer-case from a 4.1.

 

[Commando]

This is last weekend:

 

[Commando]

Did not find any answer to my main question about the E250F tranny + transfer case on a 4.2. So I found a complete ''running'' RAV4.1 for cheap. I will keep all parts that are interchangeable with 4.2, and check if the tranny and t-case could fit mine.

When I bought my RAV4, I was surprised that there was no tow hook at all in the rear. So I made a steel plate with weld-on shackle mounts, and bolted it to the factory fixing points for a hitch. I like the look it gives to my RAV4... and they were very useful. Up to now, the shackles were more used to tow other vehicules than used to pull mine from embarassing situations! Haha

 

[Commando]

The donor vehicle: 98 RAV4 side by side with my 4.2!

 

[Commando]

This is a couple hours later... the 98 is going to to the scrap yard (the pic was taken trough a dirty window!).

This is the transmission assembly with t-case.

And this is the tranny and t-case separated.

 

[Commando]

4.1 (left) vs 4.2 (right) front/center differentials:

 

[Commando]

My ''hybrid'' transmission is done! Because the E250F don't bolt to the AZ engines, I needed to swap the bellhousing (front half of the transmission) coming from the E352F.


👉 EDIT 2022: THE RAV4.1 E250F TRANSMISSION CAN BOLT TO 1AZ/2AZ ENGINES!!!! 👈 You can see this at page 17: Week-end Off-Road Warrior


My clutch was slipping when I was stuck in mud, so I ordered an Exedy clutch kit (it was cheaper than the Aisin kit).


I also bought a 2AZ (2,4) coming from a wrecked 2005 Camry to get some more low-end torque over the 1AZ (2.0) that is actually in my RAV4.


Because the 4.1 transfer case is bigger than the 4.2 t-case, it does not clear the AZ block and intake manifold. Some buffing on the t-case will make it clear.... but the lock sensor on the t-case have to be removed to clear the intake. The big lock vacuum actuator can't be used for the same reason. So I'm thinking of engage the lock lever with a ''choke cable'' instead.

 

[Commando]

The RAV4.1 transfer-case is ''so big'', that I had to grind both t-case and engine block to allow clearance.

Impossible to install the facory vacuum actuator because there is absolutly no room with the 1AZ/2AZ intake manifold.

So I made a custom fab actuator using an automatic transmission cable from a 2006 Mazda 3!

And we can see how the lock engage:

 

[Commando]

Something I hate about my RAV4, is the low output of the back-up lights... I see almost nothing. It becomes frustrating off road when I don't see what's behind (trees, rocks, etc). I was so happy with the result of the front led bar, that I wanted to add one at rear.

So I bought a roof basket, and mounted the led bar on it. It's a 20'' curved with combo lights (spot and flood) with an output on 120W. For now it lights only when I'm in reverse. But I will later plug it with a switch to put it on whenever I need. Yes: it's a night and day difference!

Now I need to fab a lockable jerry cans holder into the basket to put my fuel and water jerry cans.

 

[Commando]

The last ''expedition'' and camping ride. We found a nice spot to install our tents.

 

[Commando]

A little spot at 5 minutes from my home. Me and kids love to go there.

 

[kempy535]

Great project! I love these kinda threads