TOYOTA RAV4 2006 Service Repair Manual

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–197
AX
(c) Install the rear planetary sun gear to the rear
planetary gear.
21. INSTALL 2ND BRAKE CLUTCH DISC
(a) Install the 3 discs and 3 plates to the transaxle.
Standard install in order:
P - D - P - D - P - D
HINT:
P = Plate
D = Disc
(b) Temporarily install the snap ring.
(c) Using a vernier caliper, measure the distance
between the disc surface and snap ring surface.
(d) Select an appropriate flange so that the pack
clearance will meet the specified value.
Standard pack clearance:
0.50 to 0.91 mm (0.0197 to 0.0358 in.)
HINT:
Piston stroke = Clearance - Flange thickness - Snap
ring thickness 1.6 mm (0.063 in.)
Standard flange thickness
(e) Temporarily remove the snap ring, attach the
selected flange and restore the snap ring.
NOTICE:
Secure the snap ring so that its gap is visible
through the groove of the transaxle case.
D003587E01
C129390E01
D009163E01
Mark Thickness Mark Thickness
1 3.0 mm (0.118 in.) 5 3.4 mm (0.134 in.)
2 3.1 mm (0.122 in.) 6 3.5 mm (0.138 in.)
3 3.2 mm (0.126 in.) 7 3.6 mm (0.142 in.)
4 3.3 mm (0.130 in) 8 -
D003623E02

AX–198U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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22. INSTALL DIRECT CLUTCH
(a) Install the bearing race to the direct clutch.
Standard bearing race diameter
(b) Install the direct clutch and thrust bearing to the rear
planetary sun gear.
NOTICE:
The disc in the direct clutch should completely
mate with the hub attached outside the rear
planetary sun gear. Otherwise, the rear cover
cannot be installed.
(c) Clean the connector part of the transaxle case and
rear cover.
(d) As shown in the illustration, place a straightedge on
the direct clutch drum and measure the distance
between the transaxle case and the straightedge
using a vernier caliper (Dimension B).
(e) Measure the 2 places of the rear cover as shown in
the illustration. Calculate a dimension C using the
following formula.
HINT:
Dimension C = Dimension (1) - Dimension (2)
(f) Calculate the end play value using the following
formula. Select a thrust bearing which satisfies the
end play value and install it.
End play:
0.198 to 0.936 mm (0.00780 to 0.03685 in.)
NOTICE:
Make sure that the colored race side is facing
the direct clutch assembly.
HINT:
End play = Dimension C - Dimension B
Standard bearing thickness and diameter
D003802E01
Item Inside Outside
Bearing race 30.3 mm (1.193 in.) 46.0 mm (1.811 in.)
D003586E01
D003624E01
D003922E01
Thickness Inside Outside
3.58 mm (0.1409 in.) 53.6 mm (2.110 in.) 69.6 mm (2.740 in.)
3.88 mm (0.1528 in.) 53.6 mm (2.110 in.) 70.18 mm (2.768 in.)

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–199
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23. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Install 2 new governor apply gaskets.
24. INSTALL FRONT CLUTCH APPLY TUBE
(a) Install the clamp to the front clutch apply tube.
NOTICE:
Make sure to install the clamp to the apply pipe
before installing the apply pipe to the transaxle
case. This prevents the apply pipe from being
deformed or damaged.
25. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.
NOTICE:
Make sure to install the clamp to the apply pipe
before installing the apply pipe to the transaxle
case. This prevents the apply pipe from being
deformed or damaged.
(b) Install the 2 apply tubes and to the transaxle with
the bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
NOTICE:
Each pipe should be securely inserted until it
reaches the stopper.
26. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Install 2 new O-rings to the 2 plugs.
(b) Install the 2 plugs to the transaxle rear cover.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
D003591E01
D003923E01
D003923E01
D025510E01
C134984

AX–200U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
27. INSTALL TRANSAXLE REAR COVER SUB-
ASSEMBLY
(a) Using SST and a press, press in the bearing.
SST 09950-60010 (09951-00230, 09952-06010)
Standard depth:
12.05 to 12.75 mm (0.4744 to 0.5020 in.)
NOTICE:
• Face the inscribed mark side of the bearing
race up.
• Repeat the press-fit until the specified value
is obtained.
(b) Apply adhesive to the 2 screws.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or Equivalent
(c) Using a T30 ''torx'' socket wrench, install the
transaxle rear cover plate with the 2 screws.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(d) Coat 2 new oil seal rings with ATF, and install them
to the transaxle rear cover.
(e) Remove any packing material and be careful not to
get oil on the contacting surfaces of the transaxle
rear cover or the transaxle.
(f) Apply FIPG to the cover.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or Equivalent
(g) Coat the needle roller bearing with ATF.
D009193E01
C083140E01
D003584E01
D009946E01

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–201
AX
(h) Apply adhesive to the threads of the bolts labeled A.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or Equivalent
(i) Install the 11 bolts.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A.
25 N*m (255 kgf*cm, 18 ft.*lbf) for other
bolt
SST 09950-60010 (09951-00230, 09952-06010)
28. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC
(a) Install the 3 discs and 3 plates to the transaxle.
Install in order:
P - D - P - D - P - D
HINT:
D = Disc
P = Plate
(b) Using a screwdriver, install the snap ring.
(c) Using a dial indicator, measure the underdrive brake
pack clearance while applying and releasing
compressed air (392kPa, 4.0 kgf/cm
2, 57 psi).
Standard pack clearance:
1.59 to 2.20 mm (0.0626 to 0.0866 in.)
HINT:
Select an appropriate flange from the table below so
that it will meet the specified value.
Standard flange thickness
(d) Temporarily remove the snap ring and attach the
flange. Restore the snap ring.
29. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(See page AX-186)
30. INSTALL UNDERDRIVE 1 WAY CLUTCH ASSEMBLY
(a) Install the outer race retainer to the 1-way clutch.
D009943E01
C129391E01
D008082E01Mark Thickness Mark Thickness
1 3.0 mm (0.118 in.) 3 3.4 mm (0.134 in.)
2 3.2 (0.126 in.) - -
D003907E02

AX–202U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(b) Install the 1-way clutch to the transaxle.
NOTICE:
Make sure that the mark on the 1-way clutch
outer race is visible.
(c) Using a screwdriver, install the snap ring to the
transaxle.
31. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
(a) Coat the bearing and bearing race with petroleum
jelly, and install them onto the underdrive clutch.
Standard race diameter
(b) Install the underdrive clutch to the transaxle.
32. INSTALL UNDERDRIVE PLANETARY GEAR
(a) Install the pawl pin and spring to the parking lock
pawl.
(b) Temporarily install the parking lock pawl, shaft and
spring to the transaxle case as shown in the
illustration.
D003627E03
D003581E02
D003580E02
Item Inside Outside
Bearing 37.73 mm (1.4854 in.) 58.0 mm (2.283 in.)
Race 29.9 mm (1.177 in.) 55.5 mm (2.185 in.)
D009691E02
D009692E01

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–203
AX
(c) Install the underdrive planetary gear to the
transaxle.
NOTICE:
Engage all the discs of underdrive clutch and
the hub splines of the underdrive planetary gear
firmly and assemble them securely.
(d) Install the parking lock pawl shaft.
(e) Install the pawl shaft clamp with the bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
(f) Using a straightedge and vernier calipers as shown
in the illustration, measure the gap between the top
of the differential drive pinion in the underdrive
planetary gear and contact surface of the transaxle
and housing (Dimension D).
NOTICE:
Make a note of dimension D as it is necessary
for the following process.
(g) As shown in the illustration, measure the 2 places of
the transaxle housing. Calculate the dimension E
using the formula.
NOTICE:
Make a note of dimension E as it is necessary
for the following process.
HINT:
Dimension E = Dimension (1) - Dimension (2)
D003579E04
D009693E01
D003576E03
D003875E01
D025511E01

AX–204U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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33. INSTALL MULTIPLE DISC CLUTCH HUB
(a) Install the bearing race to the transaxle while
checking its direction.
Standard bearing race diameter
(b) Coat the thrust bearing and race with petroleum
jelly, and install them onto the multiple disc clutch
hub.
Standard thrust bearing and race diameter
(c) Install the bearing to the multiple clutch hub.
Standard bearing diameter
(d) Install the forward clutch hub to the transaxle.
34. INSTALL FORWARD CLUTCH ASSEMBLY
(a) Install the thrust bearing to the forward clutch.
Standard bearing diameter
NOTICE:
Install the thrust bearing properly so that the
race "B" will be visible.
(b) Install the forward clutch to the multiple clutch hub.
NOTICE:
Align the splines of all discs in the forward
clutch with those of multiple clutch hub to
assemble them securely.
D008087E03
Item Inside Outside
Bearing race 34.5 mm (1.358 in.) 48.5 mm (1.909 in.)
D003628E01
Item Inside Outside
Bearing 36.3 mm (1.429 in.) 52.2 mm (2.055 in.)
D003929E01
Item Inside Outside
Bearing 23.5 mm (0.925 in.) 44.0 mm (1.732 in.)
D011358E01
Item Inside Outside
Bearing 33.85 mm (1.3327 in.) 52.2 mm (2.055 in.)
D003574E03

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–205
AX
35. INSTALL OVERDRIVE BRAKE GASKET
(a) Install 2 new overdrive brake gaskets.
36. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear to the transaxle.
37. INSTALL NO. 2 THRUST BEARING UNDERDRIVE
RACE
(a) Install the thrust bearing race to the underdrive
planetary gear.
38. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Calculate the end play value using the following
formula and values of Dimensions D and E that
were measured when installing cylindrical roller
bearing and underdrive planetary gear. Select an
appropriate underdrive planetary gear thrust
bearing race No. 2 which satisfies the specified end
play value, and instal it.
End play:
0.498 to 0.993 mm (0.0196 to 0.0390 in.)
HINT:
End play = Dimension E - Dimension D - thrust
bearing thickness 3.28mm (0.1291 in.) - underdrive
thrust bearing race thickness.
Standard race thickness
D003573E01
D003577E01
D025506E04
D025505E03
E - D Thickness
Less than 7.64 mm (0.3008 in.) 3.5 mm (0.138 in.)
7.64 mm (0.3008 in.) 3.8 m (0.150 in.)

AX–206U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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Standard bearing and bearing race diameter
39. INSTALL OIL PUMP ASSEMBLY
(a) Install the oil pump to the transaxle with the 7 bolts.
Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
(b) Coat the O-ring of the oil pump with ATF.
40. INSTALL TRANSAXLE HOUSING
(a) Remove any packing material and be careful not to
get oil on the contacting surface of the transaxle
housing.
(b) Apply FIPG to the transaxle.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or Equivalent
(c) Install the transaxle housing to the transaxle with
the 16 bolts.
Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) for bolt A
29 N*m (296 kgf*cm, 21 ft.*lbf) for bolt B
and C
HINT:
Each bolt length is indicated below.
Bolt length:
50 mm (1.969 in.) for bolt A
50 mm (1.969 in.) for bolt B
42 mm (1.654 in.) for bolt C
NOTICE:
Because the bolt labeled A are seal bolts, apply
seal packing to new bolts and tighten them
within 10 minutes after application.
Seal packing:
Toyota Genuine Seal Packing 1281,
Item Inside Outside
Bearing 57.2 mm (2.252 in.) 84.96 mm (3.3449 in.)
Bearing race 56.4 mm (2.220 in.) 83.0mm (3.268 in.)
D003569E08
D003629E03
D003630E07
C126600