TOYOTA RAV4 2006 Service Repair Manual

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–187
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8. INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Using a caliper gauge, measure the inside diameter
of the forward clutch hub bush.
Standard inside diameter:
23.025 to 23.045 mm (0.9065 to 0.9073 in.)
Maximum inside diameter:
23.09 mm (0.9091 in.)
NOTICE:
• When the diameter is over the maximum,
replace the multiple disc clutch hub with a
new one.
• Check the contact surface of the bush in the
direct clutch shaft. If any scratch or discolor
is identified, replace the direct clutch sub-
assembly with a new one.
If the inside diameter is greater than the maximum,
replace the forward clutch hub.
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REASSEMBLY
1. BEARING POSITION
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Standard bearing position
2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the apply tube and apply tube clamp to the
transaxle housing with the bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
NOTICE:
Make sure to insert the tube to the stopper.
3. INSTALL NO. 2 BREATHER PLUG
4. INSTALL COUNTER DRIVE GEAR HOLE SNAP RING
(a) Using a screwdriver, install the hole snap ring to the
transaxle.
Mark Front Race Diameter Inside /
OutsideThrust Bearing Diameter Inside
/ OutsideRear Race Diameter Inside /
Outside
A - 53.0 mm (2.087 in.) / 78.2 mm
(3.079 in.)52.1 mm (2.051 in.) / 75.5 mm
(2.972 in.)
B - 37.73 mm (1.4854 in.) / 58.0 mm
(2.283 in.)29.9 mm (1.177 in.) / 55.5 mm
(2.185 in.)
C - 33.85 mm (1.3327 in.) / 52.2 mm
(2.055 in.)-
D - 23.5 mm (0.925 in.) / 44.0 mm
(1.732 in.)-
E - 36.3 mm (1.492 in.) / 52.2 mm
(2.055 in.)34.5 mm (1.358 in.) / 48.5 mm
(1.909 in.)
F - 34.6 mm (1.362 in.) / 52.2 mm
(2.055 in.)-
G 40.3 mm (1.587 in.) / 58.0 mm
(2.283 in.)38.6 mm (1.520 in.) / 60.0 mm
(2.362 in.)38.6 mm (1.520 in.) / 58.0 mm
(2.283 in.)
H - 53.6 mm (2.110 in.) / 69.6 mm
(2.740 in.)-
I - 33.7 mm (1.327 in.) / 48.2 mm
(1.898 in.)30.3 mm (1.193 in.) / 46.0 mm
(1.811 in.)
J - 53.6 mm (2.110 in.) / 70.18 mm
(2.763 in.) or 69.6 mm (2.740 in.)-
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AX–190U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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5. INSTALL COUNTER DRIVE GEAR
(a) Using SST and a press, press in the 2 counter drive
gear bearings outer races to the transaxle.
NOTICE:
• Press-fit the bearing race until it contacts the
snap ring.
• Do not apply excessive pressure.
SST 09950-60020 (09951-00890, 09951-07150)
(b) Using SST and a press, press in the tapered roller
bearing to the counter drive gear.
SST 09649-17010
NOTICE:
• Press-fit the bearing inner race until it
contacts the counter drive gear.
• Do not apply excessive pressure.
(c) Using SST and a press, press in the counter drive
gear and bearing to the transaxle.
SST 09950-60020 (09951-00890), 09950-70010
(09951-07150)
NOTICE:
Do not apply excessive pressure.
6. INSTALL 1ST AND REVERSE BRAKE PISTON
(a) Coat 2 new O-rings with ATF.
(b) Install the 2 O-ring to the 1st and reverse brake
piston.
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(c) Coat the 1st and reverse brake piston with ATF, and
install it to the transaxle.
(d) Install the 1st and reverse brake return spring to the
1st and reverse brake piston.
(e) Using SST, a press and snap ring expander, press
the piston return spring and snap ring to the
transaxle.
NOTICE:
• Stop the press when the spring sheet is
lowered to the place 1 to 2 mm (0.039 to 0.078
in.) from the snap ring groove, preventing the
spring sheet from being deform.
• Do not expand the snap ring excessively.
7. INSTALL FRONT PLANETARY RING GEAR
(a) Using a screwdriver, install the front planetary ring
gear and brake hub snap ring to the brake hub.
8. INSTALL FRONT PLANETARY GEAR ASSEMBLY
(a) Install the front planetary gear to the brake hub.
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(b) Using SST and a press, press-fit the front planetary
gear.
NOTICE:
Do not apply excessive pressure to it.
(c) Install the front planetary gear washer, as shown in
the illustration.
(d) Using SST, install the nut.
SST 09387-00030, 09387-00080
Torque: 280 N*m (2,855 kgf*cm, 206 ft.*lbf)
(e) Using SST and a torque wrench, measure the
turning torque of the bearing while rotating SST at
60 rpm. When the measured value is not within the
specified value, gradually tighten the nut until it
reaches the specified value.
SST 09950-60010 (09951-00400), 09950-70010
(09951-07100), 09387-00030, 09387-00080
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Torque: Turning torque at 60 rpm
0.5 to 1.0 N*m (5.1 to 10.0 kgf*cm, 4.4 to
8.7 in.*lbf) for new
0.3 to 0.5 N*m (3.1 to 5.1 kgf*cm, 2.7 to
4.4 in.*lbf) for used
(f) Using a chisel and hammer, stake the front
planetary gear washer.
9. INSTALL INPUT SUN GEAR
(a) Install the 2 thrust bearings, bearing race and front
planetary sun gear to the planetary gear.
Standard bearing race diameter
10. INSTALL REAR PLANETARY GEAR ASSEMBLY
(a) Coat the bearing race with ATF, and install it to the
rear planetary gear.
Standard bearing race diameter
(b) Install the planetary carrier thrust washer to the
planetary gear.
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Item Inside Outside
Bearing 34.6 mm (1.362 in.) 52.2 mm (2.055 in.)
Race 40.3 mm (1.587 in.) 58.0 mm (2.283 in.)
Bearing 38.6 mm (1.520 in.) 60.0 mm (2.362 in.)
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Item Inside Outside
Race 38.6 mm (1.520 in.) 58.0 mm (2.283 in.)
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(c) Install the rear planetary gear to the rear planetary
ring gear.
(d) Using a screwdriver, install the snap ring to the
brake hub.
11. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC
(a) Install the 5 plates and 5 discs.
Install in order:
P - D - P - D - P - D - P - D - P - D
HINT:
P = Plate
D = Disc
(b) Using a vernier caliper, measure the distance
between the disc surface and the contact surface of
the 2nd brake cylinder and transaxle (Dimension A).
(c) Select an appropriate flange so that the piston
stroke will meet the specified value.
Pack clearance:
1.02 to 1.21 mm (0.0402 to 0.0476 in.)
HINT:
Piston stroke = Dimension A - Flange thickness
Standard flange thickness
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Mark Thickness Mark Thickness
1 1.8 mm (0.071 in.) 5 2.2 mm (0.087 in.)
2 1.9 mm (0.075 in.) 6 2.3 mm (0.091 in.)
3 2.0 mm (0.079 in.) 7 2.4 mm (0.094 in.)
4 2.1 mm (0.083 in.) 8 2.5 mm (0.098 in.)

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(d) Install the flange.
12. INSPECT PACK CLEARANCE OF 1ST AND
REVERSE BRAKE
13. INSTALL 1-WAY CLUTCH SLEEVE OUTER
(a) Install the 1-way clutch outer sleeve to the 2nd
brake cylinder.
NOTICE:
Check the positioning direction of the outer
sleeve.
14. INSTALL 1-WAY CLUTCH ASSEMBLY
(a) Install the inner race to the 1-way clutch.
NOTICE:
Check the direction of the inner race.
(b) Check the rotating direction of the 1-way clutch for
the lock or free operation, as shown in illustration.
(c) Install the 1-way clutch and bearing to the 1-way
clutch outer race sleeve.
Standard bearing diameter
NOTICE:
Install the thrust bearing properly so that no
colored race will be visible.
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Item Inside Outside
Bearing 53.6 mm (2.110 in.) 69.6 mm (2.740 in.)

AX–196U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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15. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY
(a) Coat the No. 1 planetary carrier thrust washer with
petroleum jelly, and install it onto the rear planetary
sun gear.
(b) Coat the bearing with petroleum jelly, and install it
onto the rear planetary sun gear.
Standard bearing diameter
(c) Install the rear planetary sun gear to the rear
planetary gear.
16. INSTALL 2ND BRAKE CLUTCH DISC
(a) Install the 3 discs and 3 plates to the transaxle.
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 piston
stroke will meet the specified value.
Standard pack clearance:
0.62 to 0.91 mm (0.0244 to 0.0358 in.)
HINT:
Piston stroke = Clearance - Flange thickness -Snap
ring thickness 1.6 mm (0.063 in.)
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Item Inside Outside
Bearing 33.8 mm (1.331 in.) 48.2 mm (1.898 in.)
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