TOYOTA RAV4 2006 Service Repair Manual

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NOTICE:
Install the thrust bearing properly so that the
non-collared race or blue ink jet race will be
visible.
(c) Install the forward clutch to the transaxle case.
NOTICE:
• Align the splines of all discs in the forward
clutch with those of multiple clutch hub to
install them securely.
• Be careful not to damage the bushing inside
of the forward clutch hub during installation.
45. INSTALL OVERDRIVE BRAKE GASKET
(a) Install 2 new overdrive brake gaskets.
46. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear to the transaxle case.
NOTICE:
Check the position and number of the grooves
on each end face of the differential ring gear.
47. INSTALL NO. 2 THRUST BEARING UNDERDRIVE
RACE
(a) Install the thrust bearing underdrive race to the
underdrive planetary gear.
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48. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Coat the thrust needle roller bearing with ATF.
(b) Calculate the end play value using the following
formula and values of Dimension E and F that were
measured when installing the cylindrical roller
bearing and underdrive planetary gear. Select an
appropriate underdrive planetary gear thrust
bearing race which satisfies the specified end play
value, and install the selected bearing race.
Standard end play:
0.498 to 0.993 mm (0.01961 to 0.03909 in.)
HINT:
End play = Dimension F - Dimension E - thrust
bearing thickness 2.5 mm (0.0984 in.) - underdrive
thrust bearing race thickness.
Standard race thickness
Standard bearing and bearing race diameter
49. INSTALL OIL PUMP ASSEMBLY
(a) Install the oil pump to the transaxle case with the 7
bolts.
Torque: 22 N*m (226 kgf*cm, 16 ft.*lbf)
(b) Coat the O-ring of oil pump with ATF.
NOTICE:
Confirm that the input shaft rotates smoothly by
manual operation after installing the oil pump.
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F - E Thickness
Less than 7.72 mm (0.3039 in.) 3.5 mm (0.138 in.)
7.72 mm (0.3039 in.) 3.8 mm (0.150 in.)
Item Inside Outside
Bearing 57.2 mm (2.252 in.) 84.96 mm (3.345 in.)
Bearing race 56.4 mm (2.22 in.) 83 mm (3.268 in.)
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50. INSTALL TRANSAXLE HOUSING
(a) Remove any packing material and be careful not to
spill oil on the contact surface of the transaxle case
or transaxle housing.
(b) Apply seal packing to the transaxle case.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or Equivalent
(c) Apply adhesive or equivalent to bolts A and D.
(d) Install the transaxle housing and 16 bolts to the
transaxle case.
Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) for bolt A
29 N*m (295 kgf*cm, 21 ft.*lbf) for bolt B
29 N*m (295 kgf*cm, 21 ft.*lbf) for bolt C
22 N*m (226 kgf*cm, 16 ft.*lbf) for bolt D
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or Equivalent
HINT:
Each bolt length is indicated below.
Bolt length:
50 mm (1.97 in.) for bolt A
50 mm (1.97 in.) for bolt B
42 mm (1.65 in.) for bolt C
72 mm (2.84 in.) for bolt D
NOTICE:
Tighten the bolts within 10 minutes of adhesive
application.
51. INSPECT INPUT SHAFT END PLAY
(a) Using a dial indicator, measure the input shaft end
play.
Standard end play:
0.262 to 1.249 mm (0.0100 to 0.0494 in.)
52. FIX AUTOMATIC TRANSAXLE ASSEMBLY
(a) Fix the transaxle.
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53. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Coat a new oil seal with MP grease.
(b) Install the oil seal to the transaxle case.
SST 09950-60010 (09951-00230), 09950-70010
(09951-07100)
Standard depth:
0 +- 0.5 mm (0 +- 0.197 in. )
54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY
(a) Install the parking lock rod to the manual valve lever.
55. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
(a) Install a new spacer and manual valve lever shaft to
the transaxle case.
NOTICE:
Do not damage the oil seal when installing the
shaft to the transaxle case.
(b) Using a pin punch and hammer, drive in a new pin.
(c) Turn the spacer and the lever shaft to align the small
hole (for locating the staking position in the spacer)
with the staking position mark on the lever shaft.
(d) Using a pin punch, stake the spacer through the
small hole.
(e) Check that the spacer does not turn.
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56. INSTALL MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using needle-nose pliers, install the retainer spring.
NOTICE:
Hang the spring on the shaft firmly.
57. INSTALL PARKING LOCK PAWL BRACKET
(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 N*m (205 kgf*cm, 15 ft.*lbf)
HINT:
The bolt length is indicated below.
Bolt length:
25 mm (0.984 in.)
NOTICE:
Make sure that the parking rod is placed
between the parking pawl and the guide of the
parking bracket when the parking bracket is
installed.
58. INSTALL MANUAL DETENT SPRING SUB-
ASSEMBLY
(a) Install the manual detent spring and cover with the 2
bolts.
NOTICE:
Make sure to install the manual detent spring
and cover in this order.
HINT:
Tighten bolt A first, and then bolt B.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) for bolt A
12 N*m (122 kgf*cm, 9 ft.*lbf) for bolt B
HINT:
Each bolt length is indicated below.
Bolt length:
27 mm (1.06 in.) for bolt A
16 mm (0.63 in.) for bolt B
59. INSTALL B-3 ACCUMULATOR PISTON
(a) Coat a new O-ring with ATF, and install it to the B-3
accumulator piston.
NOTICE:
Make sure that the O-ring is not twisted and that
it does not protrude abnormally from the
accumulator piston. Apply sufficient ATF before
installing the O-ring. The O-ring must be
installed in the correct position.
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(b) Install the accumulator piston to the transaxle case.
(1) Coat the piston with ATF.
(2) Install the 2 springs to the piston, and install the
piston (with springs) to the transaxle case.
NOTICE:
Before installing the springs, check the
identification color of each spring.
Standard accumulator spring
60. INSTALL REVERSE CLUTCH ACCUMULATOR
PISTON
(a) Coat 2 new O-rings with ATF, and install them to the
reverse accumulator piston.
NOTICE:
Make sure that the O-ring is not twisted and that
it does not protrude abnormally from the
accumulator piston. Apply sufficient ATF before
installing the O-ring. The O-ring must be
installed in the correct position.
(b) Install the piston to the transaxle case.
(1) Coat the accumulator piston with ATF.
(2) Install the spring to the piston, and install the
piston (with spring) to the transaxle case.
NOTICE:
Before installing the spring, check the
identification color of the spring.
Standard accumulator spring
61. INSTALL C-3 ACCUMULATOR PISTON
(a) Coat a new O-ring with ATF, and install it to the C-3
accumulator piston.
NOTICE:
Make sure that the O-ring is not twisted and that
it does not protrude abnormally from the
accumulator piston. Apply sufficient ATF before
installing the O-ring. The O-ring must be
installed in the correct position.
D025512E02Spring Free length /
Outer diameterIdentification Color
Inner 62.00 mm (2.4409 in.) /
15.50 mm (0.610 in.)Purple
Outer 74.23 mm (2.9224 in.) /
21.70 mm (0.854 in.)
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C092978E03Free length
Outer diameterIdentification Color
60.96 mm (2.3999 in.) /
14.10 mm (0.555 in.)Yellow
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(b) Coat the piston with ATF, install it to the transaxle
case.
NOTICE:
Install the springs to each accumulator piston,
checking the identification color of each spring.
Standard accumulator spring
Standard accumulator spring
(c) Install the spring to the C-3 accumulator piston.
NOTICE:
Install the springs to each accumulator piston,
checking the identification color of each spring.
62. INSTALL CHECK BALL BODY
(a) Coat the check ball body with ATF.
(b) Install the check ball body and spring.
NOTICE:
Be sure to place the spring in the hole in the
check ball body. Be careful of the direction of
the parts.
63. INSTALL BRAKE DRUM GASKET
(a) Coat a new brake drum gasket with ATF, and install
it to the transaxle case.
NOTICE:
Be sure not to damage the lip of the transaxle
case brake gasket when inserting the gasket to
the case. Apply sufficient ATF to the gasket
before installation. Be careful of the direction of
parts.
64. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with
ATF, and install it to the transaxle case.
NOTICE:
Be sure not to damage the lip of the transaxle
case brake gasket when inserting the gasket to
the case. Apply sufficient ATF to the gasket
before installation. Be careful of the direction of
parts.
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Free length
Outer diameterColor
72.20 mm (2.8425 in.) /
19.0 mm (0.748 in.)Colorless
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65. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Coat a new governor apply gasket with ATF, and
install it to the transaxle case.
NOTICE:
Be sure not to damage the lip of the transaxle
case brake gasket when inserting the gasket to
the case. Apply sufficient ATF to the gasket
before installation. Be careful of the direction of
parts.
66. INSTALL TRANSMISSION WIRE
(a) Coat a new O-ring with ATF, and install it to the
transmission wire.
NOTICE:
Make sure that the O-ring is not twisted,
protruded, or pinched when installing the wire
transmission to the transaxle case. Apply
sufficient ATF to the O-ring before installation.
(b) Install the transmission wire retaining bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
67. CONNECT TRANSMISSION WIRE
(a) Coat the O-ring of the ATF temperature sensor with
AT F.
(b) Apply ATF to the bolt.
(c) Install the ATF temperature sensor with the lock
plate and bolt.
Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
(d) Connect the 7 solenoid valve connectors.
68. INSTALL TRANSMISSION VALVE BODY ASSEMBLY
(a) Apply ATF to the 17 bolts.
(b) While positioning the manual valve lever position,
install the valve body to the transaxle case with the
17 bolts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
25 mm (0.984 in.) for bolt A
57 mm (2.244 in.) for bolt B
41 mm (1.614 in.) for bolt C
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NOTICE:
• Push the valve body against the accumulator
piston spring and the check ball body to
install the valve body.
• When installing the valve body to the
transaxle case, do not hold the solenoids.
• Temporarily tighten the bolts marked with (1)
in the illustration first because they are
positioning bolts.
69. INSTALL VALVE BODY OIL STRAINER ASSEMBLY
(a) Coat a new O-ring with ATF and install it to the oil
strainer.
NOTICE:
Make sure that the O-ring is not twisted or
pinched. Apply sufficient ATF to the O-ring
before installation.
(b) Install the oil strainer to the valve body with the 3
bolts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
NOTICE:
Apply ATF to the bolts.
70. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-
ASSEMBLY
(a) Install the 2 magnets to the oil pan.
(b) Install the oil pan and new oil pan gasket to the
transaxle case with the 18 bolts.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
NOTICE:
Completely remove any oil or grease from the
contact surface of the transaxle case and the oil
pan with the gasket before installing the oil pan
to the case.
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71. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Coat 4 new O-rings with ATF, and install them to the
4 plugs.
(b) Install the 4 plugs to the transaxle case.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
72. INSTALL SPEEDOMETER DRIVEN HOLE COVER
SUB-ASSEMBLY
(a) Coat a new O-ring with ATF, and install it to the
cover.
(b) Install the cover with the bolt.
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
73. INSTALL SPEED SENSOR
(a) Coat 2 new O-rings with ATF and install them to the
2 sensors.
(b) Install the 2 sensors to the transaxle case with the 2
bolts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
74. INSTALL OIL COOLER INLET TUBE ELBOW
(a) Coat a new O-ring with ATF, and install it to the
elbow.
(b) Install the elbow to the transaxle case.
Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf)
75. INSTALL OIL COOLER OUTLET TUBE ELBOW
(a) Coat a new O-ring with ATF, and install it to the
elbow.
(b) Install the elbow to the transaxle case.
Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf)
76. INSTALL BREATHER PLUG HOSE
(a) Install the breather plug hose to the transaxle case
firmly.
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