What are your goals? What is your budget?
If you're looking for a project, and have money to burn, then this is an interesting project. However, the car will be worth less than when you started, have less utility, but will be more fun to drive.
If you have a shop do the swap it's going to be really expensive, like close to how much the car is worth now.
Going off the top of my head, here's what you would need.
- 5speed (C59) or 6speed (C60) Transmission (6-speeds are cheaper and more fun).
- Clutch + clutch cable.
- Master Cylinder / Salve Cylinder / Hydraulic lines
- Pedals (Brake and Clutch)
- Gear shifter, shift boot, and knob
- shift cables to go from the transmission to the shifter
- both front axles
- ECU for a manual with ABS, because the AWD ecu watches what the rear wheels are doing and will throw codes.
- Various Fluids / nuts / bolts / clips / other little things.
Things to think about
- The FWD ECU might have issues with the pre-cat in the AWD's exhaust manifold.
If this is a problem you can swap in the FWD manifold and exhaust.
- The rear wheel bearings might need to be swapped for FWD rear bearings, because when the rear axles are removed there will be a hole.
- After the rear drive train is removed the rear factory spring rates will be a bit off.
Not having done this I'm certainly missing things.
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Everything above this line is possible to do, because 2003-2008 Vibes\Matrix\Corollas are constructed with these parts, and you can LEGO them together.
Now starts the speculation.
2000-2005 RAV4 4x4 came standard with a 5-speed manual (most in the US sold with the optional 4-speed auto). Find out if it bolts up to the Vibe 1ZZ-FE. Most transmission only bolt to the bell housing, unfortunately, AWD Toyota transmissions also bolt to the side of the block.
If it bolts up, you'll need to investigate the following.
- The front axle output holes are likely in a different spot than the AWD Vibe. If so you will need custom axles.
- The rear output hole on the transmission is likely in a different spot than the AWD Vibe (also they have different wheel bases). You will need a custom drive shaft.
- Verify the Final Drive ratio on the rear differential is the same as on the Rav4.
If not
1. Find out if the rear differential from the Rav4 fits. If it does but it's a different diameter, you will need custom axles. If it does, but the axle inputs are different, you will need custom axles.
2. Find out if the Vibe rear diff will accept custom gears.