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Week-end Off-Road Warrior

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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!

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Yes. It also works for almost any Toyota V6 engines. Some brands label their clutch disc as 236mm and other as 240mm. Some says they are all 236mm or 240mm. In fact it does not matter: even if the 1AZ-FE has a 236mm clutch disc, it has plenty room for 4mm more on the flywheel and pressure-plate.

Some adjustment may be needed on the clutch pedal rod (it is adjustable)... but this is already something needed when changing a clutch kit from a different brand.

I would also suggest to install an OEM throw out bearing, because I see so much aftermarket clutch kits sold with a junk TOB that don't last long... or are noisy.
THANK YOU Commando!!!!

I have a complete new clutch now, but sometimes i miss a liiitle bit of clamping force, or maybe a shorter gearing? hahaha
 

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Thanks for the advice about the clutch Commando ! I'll go for the cheap one cause I'm already spending a lot everywhere else haha.

I will also put a skid plate to protect the under carriage, it will be of 2.5mm thick steel. I will order it from an italian factory.

Do you happen to know the angles by which the metal sheet is folded ? (I meed to send a sketch as precise as possible) And if the sketch that you did compensates for it ?
Also, did you have to drill new holes on the frame ?
 

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Discussion Starter · #383 ·
@ Phoenix11: look at Coff33's build thread. It took my sketch and have done a much better job than me with the skid-plate. He seems to tell the angles were right.

 

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Discussion Starter · #384 ·
Yes; another one haha! I just bought this one 400$, and it will be my winter beater. During this time I'll dismantle every parts of my actual RAV4... then build the blue one with all the mods I have done to my actual RAV4.

 
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Discussion Starter · #386 ·
This one is rusted... but much less than my actual RAV4. But the blue one is really clean.... almost like a new! 👌
 

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Discussion Starter · #388 ·
Coff33: Honestly, I don't know haha! It's not me that does the alignment at the shop... it's another technician. He told me that everything was in the manufacturer specs; except the rear camber that is a little off because the rear camber-bolts are seized in the bushings sleeves. It does not matter to me because my rear tires wear normally. In front I had to add camber-bolts to the shock/knuckles assemby to get into the specs.
 

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Guys, I'm finally doing all the work on my rav4. Changing the diff has been one of the most longest and complicated jobs so far. I have good friends helping me, I wouldn't be able to do it alone.
By the way, do you find it easier to remove all the motor or take out the drivetrain/stearing etc and go from below like we did?

White Motor vehicle Automotive tire Aircraft engine Engineering
 

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Discussion Starter · #390 ·
Removing all the transmission + engine all assembled together takes tooooo much time!

I always do like you did.

I let the steering rack in place with shocks, knuckles and brakes. I only drop the subframe with control arms. The only part of the job that is tricky and need assistance of another person, is when it's time to separate the transmission/t-case assembly off the engine (and replace to bolt to the engine).
 

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Tire Sky Car Vehicle Wheel


Allright I'm almost ready!
Got the new exedy clutch, 40mm suspension spacers everywhere, skid plate to protect the carter (3mm steel), hitch hook, new AC compressor + radiator and the rear electromagnetic diff installed!
Took me veeery long to get all this done, even with the help of my friend. I'm almost on my way to Africa now, still a few things to do like put foam inside to make the car less noisy, darken the windows and get a 16mm2 power source cable from the battery directly inside the car for use with a power inverter.
Thanks to everybody who contributed to this topic and especially you Commando, you have been an inspiration!
 

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Discussion Starter · #392 ·
@PhoenixII; is your new clutch kit installed?

You bought the AER rear diff E-locker?
 

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That's right for both!
For multiple RAV4s, or for the center and rear? I'm REALLY interested in a center locking solution for the automatic transmission. I have met the limitations, and have completely been flattened by the viscous center differential. The bigger tires and Torsen LSD really make the problems worse.
 

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"is your new clutch kit installed?

You bought the AER rear diff E-locker? "

for both questions above.

I have only installed the e-locker at the rear diff. Still have the viscous center one and will leave it like this. Also, since I have the VSC/TRC, I had to install a little kill switch to deactivate it on purpose when I engage the locker, so the computer doesn't go mad and doesn't cut the power whenever there is wheel spin.

I'll try to make a video when I am on unconsolidated terrain ;)
 

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Discussion Starter · #397 ·
@ 05RAV; I thought you were dead! You did not post anything on the forum since 6-7 months. I'm happy you're back. ;)

@ DankoRav; a member here did a little video with the rear e-locker installed:

 
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Discussion Starter · #398 · (Edited)
I did a 3 days trip deep in the woods last week end. Hot tenting by the side of a big lake was very relaxing. I had to cut a few fallen trees to get to that lake.











 
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