Yep its in, but man it was a mission. The hardest part of the whole swap was mating the gearbox to the engine it's an awkward, back breaking ballet. Toyota engineered the E-series transmission to be a tank of a gearbox for high horsepower and torque applications, add the centre diff and the unit weighs an F-tonne. On a side note, I would hate to do a clutch with the engine in the car, I don't think it's possible being that to access one of the bolts holding the centre differential to the gearbox is conveniently hidden away in between the engine, gearbox and differential - BAH!
Here is a photo of the E-series gearbox and centre diff mated together, this then has to be mated onto the engine as a complete unit. The trick with any gearbox installation is to directly line the gearbox input shaft with the centreline of the crankshaft. The problem we had was neither of us could carry and manoeuvre 100kg of unbalanced gearbox and centre diff weight, while the other person braced the engine from sliding around on the floor.
It was Saturday and we had one job for the day, mate the gearbox and engine, then install it into the RAV4 engine bay. The plan was to start at 8:00am and be done by 12:00pm for lunch, beers and high fives.... It was 7pm before we had lunch...
Onto something easier, the old and tired RAV4 stock fuel pump wouldn't cut it for the 3SGTE fuel supply demands, so it got ditched for the good old proven Walbro 255 L/PH.
Its so good when everything just fits, all that needed was to tie down the sucker with cable ties.
A nice little upgrade for the RAV4 was using the Caldina Brake callipers (top right) and retaining the RAV4 302mm brake rotor (ST205 Caldina front rotors are 275mm). The benefits to this is the longer lever arm and greater surface area (from the 302mm brake rotor) and more friction material from the bigger pads from the Caldina brake calliper. Fun fact: the Cadlina brake pads are the same as the SW20 MR2.
Update: not recommended! more on this later.
Last piece of the puzzle was making a custom throttle cable bracket to mount the RAV4 stock throttle cable to the 3SGTE throttle body. The custom bracket utilise the OEM 3SGTE throttle cable bolt holes while having a rearward offset to correctly mount the throttle cable.
On the street the RAV4 is so much fun to drive. Driving around town you totally forget that it has a 3SGTE until you stop at a set of lights and blast a WRX (LOL). On a race track the RAV4 looks totally out of place but at the same time completely hilarious and entertaining to watch as it holds ground against the lower faster sportier cars, more on this in the next update.