Description of the variator on Toyota RAV4: resource, design and operation of the box

Author: Victor

Due to the fact that CVTs have appeared recently and finding specialists to repair them is problematic, it is believed that such a unit is not very reliable. In this article we will tell you what the resource of the Toyota Rav 4 variator is and what needs to be taken into account when operating it in order to prevent premature failure.

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Design and principle of operation

A CVT gearbox is the only type of unit that allows you to continuously change the gear ratio between the transmission and the power unit. The vehicle picks up speed without increasing engine speed.

The design of CVT cars of Toyota Rav 4 2010, 2011, 2013 and other years of production includes two sliding shafts. They interact with each other through a strap stretched between them. One of these pulleys is connected to the power unit and is considered the drive, and the second - the driven - is connected to the drive wheels. Both pulleys consist of two halves. When these elements move together, the strap is pushed out, and when they move apart, it falls in. As a result of a synchronous change in the radii of the parts along which the strap moves, the diameter of one shaft increases and the other decreases. This contributes to a smooth change in gear ratio. If the drive shaft is smaller than the driven shaft, the vehicle moves at a reduced speed. With equal pulley diameters, the car drives in direct gear. If the driven shaft size is smaller, the machine moves at higher speed.

Toyota CVT transmission

A torque converter device is used as a clutch in Toyota Rav 4 2014, 2015, 2016, 2021 gearboxes. This unit is large in size and weight. Its presence in the design allows for smooth starting of the car and eliminates jerking during acceleration. Thanks to the use of a torque converter device, the vehicle shifts faster from a low gear to a higher one if the driver presses the gas pedal hard. To allow the car to move backwards, the transmission uses a planetary gear.

The operation of the CVT transmission is controlled by a control system, which includes a central processor, a controller, and a shaft control unit. The control module receives information about the speed of the vehicle, the speed of the power unit, as well as the position of the gas pedal. In accordance with these data, the central processor selects the gear ratio for a specific driving mode. If the information about the rotation of the primary and secondary pulleys does not match, then the control module sends a command to the hydraulic system to change the size of the shafts. The operating pressure in the system is provided by a pumping device. The same unit lubricates the internal parts of the gearbox.

You can learn more about the operating principle of a CVT transmission from a video filmed by the Toyota Russia channel.

The pressure parameter in the system is usually not determined by the speed of the power unit, but is maintained proportional to the developing torque. As this indicator increases, the discs are compressed more strongly, which helps prevent the strap from slipping. The amount of pressure generated by the pumping device determines the speed of the CVT gearbox. The larger this parameter is, the faster the gear ratio will change. To lubricate internal parts and components, a special lubricant is used, intended for Toyota Rav 4 CVTs and produced by the car manufacturer.

Life time

Now let’s look at how long continuous variable transmissions last on average. According to reviews from owners, the unit is reliable and on average lasts about 100-150 thousand kilometers, without causing any inconvenience to the motorist. Only after this interval are the first malfunctions of the gearbox possible.

How does the Toyota RAV4 with CVT differ from the version with manual transmission and automatic transmission?

A box with constantly variable gears - even today this phrase strikes fear into inexperienced car enthusiasts unfamiliar with the structure and operating principle of a continuously variable transmission. We are accustomed to the fact that conventional gearboxes use a planetary gear shift mechanism, but in a variator such gears are physically absent. Its design is based on two pulleys with cones, connected to each other by a chain or belt. It would seem to be a simple design with a limited set of mechanisms, which means there is nothing to break in it. But, unfortunately, the first modifications of the CVT turned out to be unsuccessful, hence unreliable. The noise of bearings that appeared after 50 thousand km terrified car enthusiasts. One part of the drivers continued to operate the car even with extraneous noise, while the other was forced to urgently go to a service station for diagnostics.

With 2021 outside the window, much more information is known about the CVT. And many drivers, from their own experience during this time, have been able to verify that CVT gearboxes on modern car models have become quieter, more efficient, and more productive. There are no longer widespread complaints about gear slippage, increased noise (shaft bearings hum only on the Nissan Qashqai) and inaccuracies in selecting the optimal gear ratio. In practice, it was found that a Rav4 with a CVT transmission consumes on average 20% less fuel than the same car, but with an automatic transmission. Low gasoline consumption is due to optimal transmission of torque and power.

A crossover with a CVT always moves in the right gear, which cannot be said about an automatic transmission, much less a manual transmission. In addition, the CVT gearbox is much lighter than competitive gearboxes, which has a beneficial effect on the overall weight of the car. We know a simple formula: the lighter the vehicle, the less fuel it consumes. This is an additional plus for saving fuel. Of course, this type of transmission is not ideal, and is capable of turning even an explosive, impulsive car into an obedient toy.

The disadvantages of Rav4 with CVT are as follows:

• boring character: the modification is suitable for those who prioritize economy, comfort, calm and leisurely operation;
• high cost of maintenance: you will have to pour only high-quality transmission fluid into the box, install only high-quality filters and constantly clean the magnets;
• the presence of a large number of expensive electronic components that can fail, which negatively affects the cost of repairs;
• difficulties in finding professional craftsmen and specialized services in small towns;
• There is no possibility to tow a car with a CVT gearbox.

If you previously owned a Toyota RAV4 with a manual or at least an automatic transmission, then with the new modification, which includes a continuously variable transmission, you will have to reconsider your driving style. There is an opinion among car enthusiasts that a CVT is the ideal gearbox for city cars. She does not like overheating and frequent heavy loads. That is, driving such a car out of town and loading it with off-road conditions is a serious mistake that can seriously hit your pocket. If you like, the Rav4 with CVT resembles a toaster for toasting bread. After all, the frying process itself does not evoke any emotions. This is the case with a car, which, after installing a continuously variable transmission, actually loses some of its functional capabilities.

Basic faults

Transmission problems do not always appear gradually. Therefore, if the variator breaks down, it can quickly lead to the inability to control the car.

Damaged metal variator belt

Failed differential flange

Worn damaged support bearing

CVT repair

What problems are typical for CVT and how to repair the box in a car with a 2-liter engine or another volume:

1. Failure of the planetary gear set. When the unit operates under high load conditions, this leads to the destruction of the gear axes, and as a result, their teeth break. In this case, the teeth must be replaced.
2. Oil starvation. In the absence of lubrication and the engine operating at high speeds, when the car is used off-road, damage to the planetary gear occurs. You can see such a malfunction when replacing the filter device. The magnets installed in the tray collect wear products in the form of metal shavings; you need to inspect them. If the vehicle's mileage is more than 150 thousand km, and the size of the steel chips is more than 1 mm, this indicates that a chain reaction of gear destruction occurs during the operation of the unit. If you do not take any action, the gearbox planetary gear may damage the pumping device and other components of the gearbox. In this case, repairs will be expensive.
3. Front gear failure. When operating a vehicle in aggressive conditions, damage to this part occurs. The wear products of the element ultimately damage the ring gear. If you do not solve the problem in time, the presence of metal shavings can damage the rear planetary gearbox. As a result, the clutches will fail.
4. With intensive use, especially in off-road conditions, rapid wear of the support bearing devices occurs. We are talking about parts located on the primary and secondary shafts. Fixing this problem is quite difficult, since you will not find bearings for Toyota CVTs on sale. CVT parts are not available on the aftermarket. Therefore, to solve the problem, you will have to look for bearings at a car disassembly or buy similar ones in size and turn them on a lathe to fit the dimensions of the installed parts. This repair option is considered the cheapest.
5. Sensor failures. CVT transmissions are equipped with a large number of different electronic controllers designed to read data and transmit it to the control unit. The failure of one sensor can affect the functionality of the CVT as a whole. If the diagnostics show a failure of the controller, it is necessary to carry out a detailed check of it. It is necessary to check the connectors and contacts. Often the cause of malfunction lies in damage to the plug.
6. Malfunctions in the operation of the control system. If the central processor fails, the transmission will not work. If the control module is malfunctioning, but is still functioning, the gearbox will work, but intermittently. It is better to entrust the solution to problems in the operation of the control unit to professionals. Sometimes it is necessary to reflash the unit, but it is almost impossible to do it at home.
7. Broken drive belt. Due to rapid wear and improper use, the drive belt may break. Its links can scatter throughout the gearbox and damage other components of the variator.

Damage to the differential flange is especially dangerous. The drive for the so-called transfer transmission passes through a flange on the differential housing. This element has thin walls and in practice problems often occurred when the part burst due to operation under constant high loads. This leads to lubricant leakage. If it is not detected and resolved in a timely manner, the transmission fluid may completely drain from the box. In addition, the flange will crumble in the system and its fragments will fall on the gears of the transmission, which will lead to damage to transmission parts. The difficulty of repair lies in the fact that differentials for CVT gearboxes cannot be found on sale.

The car owner has the option of purchasing a new complete unit, which will cost more than 15 thousand dollars. The problem can be solved by installing a contract variator, but finding such a unit on sale is problematic. Moreover, the cost of such a unit will be quite high. The best way to solve the problem is at the stage of oil leaks and cracks. In this case, any suitable tightening sleeve must be pressed over the damaged flange and traces of leakage must be removed. But keep in mind that it is impossible to give exact guarantees about the durability of such a solution. Usually, after such manipulations, car owners try to sell the vehicle as quickly as possible.

The Automatic Transmission Technology channel has published a video showing the process of repairing a Rav 4 transmission with a broken belt.

What kind of CVTs are installed on Toyota RAV4

Toyota is unique in that it installs exclusively boxes from the manufacturer Aisin on its cars, including Lexus. This is a machine-building enterprise specializing in the production of transmissions for vehicles. A Japanese company dependent on Toyota, but not directly controlled by it. Only approximately 42% of Aisin shares belong to Toyota. In general, a fairly reliable and well-known manufacturer of gearboxes, one of the so-called “Big Three” - ZF, Borg-Warner, Aisin. Transmissions from Aisin can be found in many competitive Toyota brands of cars. The company decided to encourage the supply of actually its own gearboxes to other people's conveyors.

The Japanese manufacturer is known for its conservatism, so the company's management decided to purchase a CVT gearbox from Jatco, rework it a little and adapt it to the technical characteristics of the RAV4. Many structural parts, such as a metal belt or chain, are still interchangeable today, that is, you can use these items from a variator from one manufacturer and use them on a continuously variable transmission from another manufacturer. The installation of CVT on the Rav4 was done slowly and deliberately, having first tested this functional gearbox on other models. After successful testing on Verso, Avensis, Opa, it was decided to assemble a crossover with all-wheel drive and a two-liter gasoline engine.

Modification of the variator on Toyota RAV4 – Aisin K111/K111F. The transmission has been tested for a long time on cars intended for the domestic market. Only after five years of operating cars with Aisin K111/K111F did Toyota enter the international arena. All CVTs are divided into conditional groups, each group is focused on a specific torque. The K111/K111F modification is part of the “hundredth” series, produced for 2.0 and 2.4-liter engines. The only difference between K111/K111F is that the F index indicates that it is intended for all-wheel drive vehicles.

Rules of operation and maintenance

What nuances should be taken into account in order not to reduce the resource of the Toyota Rav 4 variator:

1. Do not start moving from a standstill by pressing the gas pedal all the way. The structural elements of the gearbox are subject to high loads, which will lead to damage to parts.
2. Do not tow other vehicles. Towing trailers is also not recommended. CVT gearboxes are designed to work with a certain vehicle weight and cannot be increased.
3. Reverse gear cannot be engaged or disengaged until the car has come to a complete stop.
4. Try to drive less at top speed. This may cause the engine speed to fluctuate.
5. Avoid wheel slip. Cars often slip when they get stuck in mud or snowdrifts. You should not try to drive out of an obstacle while rocking, alternately turning on modes R and D. This will lead to a decrease in the service life of the CVT transmission. It is better to put the car in neutral and ask someone to pull the car out of the obstacle.
6. When the emergency mode is turned on, the car owner needs to turn off the power unit of the car and try to start it again. If the box works normally after restarting the engine, you can continue to use it. If the emergency mode remains, then diagnostics of the unit is required, and it is advisable to perform it as quickly as possible.
7. During the cold season, always warm up the transmission. The car engine heats up faster than the transmission, so when the engine warms up, you cannot assume that the transmission has also warmed up. At low negative temperatures, it will take at least 10 minutes to fully warm up the unit. Only after this is it possible to drive at normal speed. To warm up the transmission faster, you can turn on all modes on the gearbox selector one by one, staying in each of them for a few seconds. This will allow the oil to circulate faster through the channels of the transmission system.
8. During the operation of the vehicle, we must not forget about the need to regularly check the oil level. If diagnostics show that the lubricant in the system is less than normal, you need to check the condition of the gearbox. The cause may be a fluid leak. If wear debris is visible in the oil, and there is also a burning smell coming from it, the lubricant must be replaced. Please review the service book before performing this task. According to the regulations, the manufacturer prohibits the use of any oil other than Toyota Genuine CVT Fluid TC or Toyota Genuine CVT Fluid FE in transmissions. The use of consumables from other manufacturers may cause problems with the transmission. You may feel vibrations in the area of ​​the gear selector, and the lever itself may jam. In some cases, complete failure of the unit is possible if the quality of the lubricant does not meet the standard.
9. You cannot turn on the neutral gear mode at every short stop, in a traffic jam, at traffic lights, etc. If you know that you will be standing for a long time, turn on the parking sensors mode. Neutral speed is considered an emergency speed. It can be turned on if the car needs to be pulled out of a snowdrift.
10. Avoid off-road driving. Toyota RAV4 belongs to the class of crossovers, but the CVT transmission installed on these cars is not intended for regular operation on bad roads or rural areas.

The Automatic Transmission Technology channel provided a video, the author of which talked about what nuances to take into account during operation in order to increase the service life of the CVT gearbox.

Maintenance of Toyota Rav4 variator

The most important thing to consider is that the consumables for the CVT are not tied to the model/make of the car, but to the CVT modification. Drivers are often interested in what kind of transmission oil should be poured into the gearbox and what filters are best to install. First of all, you need to find out the model and modification of the variator installed on the car. You can find out by looking at a special plate that is found in every car with a CVT, including the Toyota Rav4. Typically, the mark is placed on the door post. A car with a 2.0 liter engine was delivered to Russia, so it can have both K111 and K111F, it all depends on the type of drive.

As for ATF fluid, it is recommended to fill this box only with an original and high-quality product - Toyota CVT Fluid TC/FE. The filter installed in the unit pan (in a metal casing) does not need to be changed during the first gear oil change. It is enough to wash it, but a new one should be installed at the time of subsequent maintenance and oil change in the box. Its catalog number is 35330-0W040, marked “Made In USA” or “Made in Japan”. The pan gasket is designated by the index 35168-20010. In total, the driver will need about 9 liters of transmission fluid to completely replace it. The manufacturer recommends changing the oil every 60 thousand kilometers.

But you need to keep in mind that the recommendations are given without taking into account your character and driving style. This figure is calculated for vehicles operating under “ideal conditions.” If you take into account that the CVT is a “delicate” gearbox, purely for a quiet ride, then any movements in the start-stop style, towing, and off-road conquest are already an abnormal operating environment for it. If possible, the regulated frequency of oil changes should be reduced to 35-40 thousand kilometers. As mentioned above, it is advisable to inspect the belt, consisting of metal plates, each time simultaneously with replacing the ATF fluid and change it as often as possible. If it starts to destroy the cones - one of the most expensive parts of the variator - then you will have to spend money on replacing them, and this is much more expensive than the cost of a new copy. The cones are not ground, but are usually replaced with new products.

Advantages and disadvantages

To understand which is better - a CVT or an automatic, you need to understand the pros and cons of CVT transmissions.

Advantages:

1. Lower fuel consumption compared to automatic transmissions. Due to the absence of actual gear shifting and constant operation at the optimal speed, engines with CVT gearboxes operate more economically. The volume of harmful substances released into the atmosphere with exhaust gases is also reduced.
2. Smooth gear changes while driving. Thanks to this, when the vehicle speed increases, there are no jerks or shocks. Because of this, the service life of individual gearbox components also increases.
3. Reliability of the unit.
4. Good car dynamics.
5. Light weight gearbox.

Flaws:

1. Noisy. The effect of a CVT transmission can be compared to the noise a trolleybus makes while driving.
2. Transmission sensitivity. When using cars with CVT gearboxes, you must strictly adhere to the operating and maintenance rules. Otherwise, it may damage the structural elements of the gearbox and affect the service life.
3. Expensive and difficult to repair. If the structural components of the gearbox break down, it is problematic to find new parts. They are not always on sale.

Advantages and disadvantages of a CVT gearbox

The positive aspects of the transmission are the following parameters:

• the driver does not feel the shocks and jerks that occur when changing gears on an automatic transmission;
• acceleration is smooth;
• silent;
• economical and environmentally friendly.

But there are also negative aspects of a CVT transmission:

• high cost of repairs;
• does not tolerate extreme conditions;
• expensive restoration;
• expensive components for CVT.

Despite the disadvantages, many car owners prefer the Rav 4 SUV with a CVT transmission.

Video “How to change the oil in a Rav 4 CVT transmission?”

User Andrey Florida in his video explained in detail and showed how to change the lubricant in the CVT gearbox of a Toyota Rav 4.

Do you have any questions? Specialists and readers of the AUTODVIG website will help you ask a question

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Why do RAV4 CVTs break?

Experts identify several reasons why a continuously variable transmission begins to malfunction and breaks down:

• Radiator contamination, due to which the engine regularly heats up;
• Inconsistent operation of pulleys;
• Resource development of cone bearings;
• Worn seat of the oil pump gearbox valve.

Since the operating parameters of the transmission systems are recorded by the electronic control module, it will put the car into emergency mode. Thanks to it, you can safely get to the nearest car service center. Another situation is also possible: the car may stop in the middle of the road, and in this case you cannot do without a tow truck.

Repair and replacement of Toyota RAV 4 variator

The most common problems with a car transmission and how to fix them:

• The planetary gear set does not work. This malfunction occurs due to high load, as a result of which the gear axes are destroyed, followed by their teeth breaking. The repair consists of replacing the gear teeth.
• Insufficient oil supply. If there is no lubrication and the engine operates at high speeds when driving off-road, the planetary gear is damaged. This defect becomes visible when the filter elements are replaced.
• Magnets that are installed on the pallet attract metal shavings. Consider it. If, with a mileage of more than 150 thousand km, metal wear products in the form of steel chips have a size of more than 1 mm, then the gears are destroyed. Expensive repairs or replacement will be required if nothing is done. After all, the planetary gear set of the variator can damage the pump unit and other gearbox parts.
• Malfunction in the front gear. This element may be damaged due to driving in aggressive conditions. Metal chips affect the ring gear and ultimately damage it. If measures are not taken in a timely manner (repair or replacement), the rear planetary gear set of the gearbox becomes unusable, followed by the clutches.
• Support bearing devices wear out especially quickly during intensive use in off-road conditions. These RAV 4 parts are located on the primary and secondary pulleys. If such a problem arises, you will not be able to cope with it on your own, since variator bearings for Toyota RAV-4 are not sold on the aftermarket, and replacing them is difficult. To resolve the issue, look for parts at car dismantling centers or purchase similar parameters. They will need to be turned on a machine and adjusted to the dimensions of already installed elements. This option is the cheapest.
• The sensors are broken and require replacement. RAV 4 CVTs are equipped with a variety of electronic controllers, the function of which is to read information and transmit it to the central control unit. If a malfunction occurs in one of the sensors, the operation of the variator as a whole is disrupted. If diagnostic measures reveal a breakdown of the control part, it must be carefully checked and, if necessary, replaced. In addition, all connectors and contacts are checked. The cause of most breakdowns is a damaged plug that requires replacement.
• There is a problem with the control central processor, without which the gearbox will not function. In case of temporary malfunctions in the functioning of the control module, the variator operates intermittently. Experts will help you deal with the problem. In some cases, it is necessary to flash the unit, which cannot be done on your own.
• The drive belt breaks due to rapid wear due to incorrect operation. The belt breaks into links that scatter throughout the variator, which can damage the gearbox. This item requires replacement.
• It is extremely dangerous if the differential flange through which the transfer transmission drive passes is damaged. This part has thin walls, so it sometimes breaks under regular increased loads. As a result, lubricant leaks. If this process goes unnoticed, all the transmission lubricant will pour out of the box.

Transmission elements may be damaged due to fragments of the crumbled flange getting into the variator gears. It is difficult to repair the breakdown due to the fact that it is extremely difficult to purchase differentials for the Toyota RAV-4 variator and replace them due to their lack of availability on sale.

There is an alternative option - replacing the variator on a Toyota RAV-4, but the price will be quite high (more than $15,000).

You can install a contract variator on a Toyota, but it is also difficult to buy, and it will not be cheap.

The optimal solution is to eliminate the problem at the stage of the appearance of a crack through which oil leaks. To do this, a sleeve of suitable dimensions is attached to the damaged flange by pressing on it. However, the durability of such a “patch” cannot be guaranteed. Therefore, the car owner sets the goal of quickly selling the Toyota RAV-4 and buying himself a new one.

How does CVT Toyota Rav 4 work?

The main operating principle of the box is stepless gear shifting while driving. Occurs due to pulleys and a belt connecting and disconnecting from each other. CVT Toyota Rav 4 since 2011 has a V-belt drive.

Variator device:

• driving and driven shafts;
• belt or metal chain depending on the modification of the box;
• hydraulic unit;
• filter.

The process of switching speeds occurs as follows:

1. By pressing the gas, the driver increases the number of engine revolutions, and the speed of the drive shaft connected to the engine increases accordingly.
2. Torque is transmitted to the belt, which in turn drives the second shaft.
3. As the speed increases, the shafts converge with each other and the pulleys take on a wedge shape. The gears are growing and the speed is increasing.
4. When the speed decreases, the belt fails and the shafts diverge. Speed ​​decreases, gears drop. The belt also relaxes.

Virtual gears are needed to specifically create the effect of lowering or increasing speeds. And the Rav 4 vehicle in any generation contains six virtual gears.

How to extend the operation of a continuously variable transmission?

In fact, reliability depends on operating conditions and modes of operation. For some drivers, the transmission lasts 300 thousand km, while for others it lasts less than a hundred. Expensive maintenance is also noted.

Variator belt (https://www.transakpp.ru/uslugi/cvt-ill.html)

To maintain the reliability and smooth operation of the variator, you should adhere to the following recommendations:

• Periodically check the oil level and cleanliness.
• Perform preheating at sub-zero temperatures.
• Do not load the variator until the oil temperature reaches sixty degrees.
• Avoid overheating of the transmission mechanism, especially those that have served most of the resource declared by the manufacturer. To solve the problem, you will need to install an additional radiator.
• Do not pull other cars on a cable and do not tow the Rav 4.
• Adhere to posted speed limits.
• In accordance with technical recommendations and when primary signs of malfunction appear, change consumables.