Replacing 5th gear in-chassis on a Toyota E series
Narrow Case PNs
.775 - Driven 33428-42040, Driving 33336-42040
.731 - Driven 33428-42020, Driving 33336-42020
.690 - Driven 33428-20080, Driving 33336-20090
Please read note at the end of the post before proceeding
1. Drain transmission. There are two (2!) 24mm drain plugs you need to remove, one is visibly draining in the picture, the other is on the bottom of the transfer case. If you have a 2wd car, you won't have a transfer case to drain. (Side note: this may be possible to do without draining the fluid, if you only jack up one side of the car)
2. Remove 5th gear cover. There are 10 12mm bolts to remove. I recommend a small impact gun with an extension. There is one more 12mm bolt holding the shift fork onto the shift rod, remove that too.
3. Remove the 5th gear synchro hub C clip. Two screwdrivers, one on each end of the C, and a light tap with a mallet will pop it right off.
4. Remove synchro hub. I just used a harmonic balancer puller, and some M8x1.25 bolts right in the hub. Careful, the synchro may fall apart. It’s pretty obvious how it goes back together but it’s not the easiest thing to do.
5. 5th gear is now free to come off. be careful, there are roller bearings underneath, don’t lose them. (IF YOU ARE NOT REPLACING THE DRIVEN, SKIP TO STEP 9)
6. Remove the staked nut. I recommend a stubby 1/2” impact gun, that makes it easy without having to double-engage the gears.
7. Use a gear puller to remove the driven 5th gear.
8. Install the new driven 5th gear. I used a big socket and a solid sledgehammer to get it all the way down. Cooking the gear in a small toaster oven at 350F for 10 minutes will make this easier, and potentially even a slip fit.
9. Reinstall driving 5th, synchro hub, and shift fork. Again, big socket and hammer. Once that’s in place, reinstall the shift fork bolt (17 lb*ft), and now is a good time to install the staked nut (90lb*ft). If you need help holding the shaft in place, put the transmission in 4th gear and have a friend press the brakes HARD. Stake the nut, and then reinstall the synchro hub C clip.
10. Clean, FIPG, then reinstall the 5th gear cover plate. Use blue loctite on the bolts, torque to 22 lb*ft.
11. No pictures for this step, but refill the transmission with proper fluid. In the case of the 4WD Rav4, use GL-5 75W90 WITHOUT any LSD additive. Best oil I’ve found for this is Redline GL-5 75W90NS. HAS to be NS, not the regular 75W90. Takes 5 quarts. Just order 2x gallon containers. For a 2wd transmission, use GL-4. The best I’ve found for that is Redline MT90
NOTE: It has since come to my attention that certain years of RAV4s as well as other cars with this transmission platform used a different 5th gear needle bearing which is smaller in diameter. If you run into this you will see a lot of play in the 5th gear (see below video) and you MUST replace the needle bearing with the newer part number before reassembly, or you will damage your new 5th gear. The updated part is Toyota PN 90364-28023.
