TOYOTA RAV4 2006 Service Repair Manual

U241E AUTOMATIC TRANSAXLE – OIL PUMPAX–221
AX
REASSEMBLY
1. INSTALL FRONT OIL PUMP OIL SEAL
(a) Using SST, install a new oil seal to the pump.
SST 09350-32014 (09351-32140)
HINT:
The seal end should be flush with the outer edge of
the oil pump.
(b) Coat the lip of the oil seal with petroleum jelly.
2. INSTALL FRONT OIL PUMP BODY O-RING
(a) Coat a new O-ring with ATF, and install it to the oil
pump body.
3. INSTALL FRONT OIL PUMP DRIVEN GEAR
(a) Coat the front oil pump driven gear with ATF, and
install it to the oil pump body with the maked side
facing up.
4. INSTALL FRONT OIL PUMP DRIVE GEAR
(a) Coat the front oil pump drive gear with ATF, and
install it to the oil pump body with the maked side
facing up.
5. INSTALL STATOR SHAFT ASSEMBLY
(a) Set stator shaft by aligning each bolt hole.
(b) Using a T30 ''torx'' socket, install the 11 bolts.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
D003654E01
C055817E03
D009206E08
D009206E09
D003651E02

AX–222U241E AUTOMATIC TRANSAXLE – OIL PUMP
AX
6. INSTALL CLUTCH DRUM OIL SEAL RING
NOTICE:
Do not expand the ring ends excessively.
(a) Install the 2 clutch drum oil seal rings.
7. INSPECT OIL PUMP ASSEMBLY (See page AX-219)
D003655E01

AX–230U241E AUTOMATIC TRANSAXLE – FORWARD CLUTCH
AX
REASSEMBLY
1. INSTALL INPUT SHAFT OIL SEAL RING
(a) Compress the oil seal ring from both sides to reduce
dimension A.
Dimension A:
5.0 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the
input shaft.
2. INSTALL FORWARD CLUTCH PISTON O-RING
(a) Coat 2 new O-rings with ATF, and install them to the
forward clutch piston.
3. INSTALL FORWARD CLUTCH PISTON SUB-
ASSEMBLY
(a) Install the forward clutch piston to the forward clutch
drum.
4. INSTALL FORWARD CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Place the forward clutch return spring onto the
forward clutch piston.
(b) Place SST on the return spring, and compress the
return spring with a press.
SST 09350-32014 (09351-32070)
(c) Install the snap ring with a snap ring expander. Be
sure the end gap of the snap ring is not aligned with
the spring retainer claw.
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.
C083535E01
D003669E01
D003670E01
D003663E01
D003662E01

U241E AUTOMATIC TRANSAXLE – FORWARD CLUTCHAX–231
AX
• This prevents the spring sheet from being
deformed.
• Do not expand the snap ring excessively.
5. INSTALL FORWARD CLUTCH FLANGE HOLE SNAP
RING
(a) Install the 5 plates, 5 discs and flange.
Install order:
P - D - P - D - P - D - P - D - P - D - F
HINT:
P = Plate
D = Disc
F = Flange
(b) Using a screwdriver, install the snap ring.
(c) Check that the end gap of the snap ring is not
aligned with one of the cutouts.
6. INSPECT PACK CLEARANCE OF FORWARD
CLUTCH (See page AX-228)
7. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
(a) Inspect the clutch disc rotation.
(1) After inserting the multiple disc clutch into the
multiple disc clutch hub, rotate the forward
clutch and check that the disc lightly rotates.
NOTICE:
Do not place the forward clutch in a vise.
C129392E01
D003660E01
D003672E01

U241E AUTOMATIC TRANSAXLE – VALVE BODYAX–253
AX
REASSEMBLY
1. INSTALL MANUAL VALVE
(a) Install the manual valve to the valve body.
2. INSTALL SHIFT SOLENOID VALVE S4
(a) Install the shift solenoid valve S4 to the valve body
with the bolt.
Torque: 11 N*m (112 kgf*cm, 9 ft.*lbf)
3. INSTALL SHIFT SOLENOID VALVE SL2
(a) Install the shift solenoid valve SL2 to the valve body
with the bolt and plate.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
4. INSTALL SHIFT SOLENOID VALVE DSL
(a) Install the shift solenoid valve DSL to the valve body
with the bolt.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
5. INSTALL SHIFT SOLENOID VALVE SL1
(a) Install the shift solenoid valve SL1 to the valve body
with the bolt and plate.
Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
C134992
C134991
C134990
C134989

AX–254U241E AUTOMATIC TRANSAXLE – VALVE BODY
AX
6. INSTALL SHIFT SOLENOID VALVE SLT
(a) Install the shift solenoid valve SLT to the valve body
with the bolt and plate.
Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
C134988

U241E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–257
AX
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the 2 front differential pinions, 2 pinion
thrust washers, 2 front differential side gears and 2
side gear thrust washers from the differential case.
7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Place the transaxle case in a vise.
(b) Using SST, remove the oil seal.
SST 09308-00010
8. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Place the transaxle housing in a vise.
(b) Using SST, remove the oil seal.
SST 09308-00010
INSPECTION
1. INSPECT FRONT DIFFERENTIAL SIDE GEAR
BACKLASH
(a) Using a dial indicator, measure the backlash of the
side gear.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0070 in.)
Standard thrust washer thickness
C083136E01
D025600E03
D025599E04
C083138E01Thickness Thickness
1.0 mm (0.0394 in.) 1.2 mm (0.0472 in.)
1.1 mm (0.0433 in.) 1.3 mm (0.0512 in.)

AX–258U241E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
AX
REASSEMBLY
1. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Coat the 2 front differential side gears, 2 side gear
thrust washers, 2 front differential pinions and 2
pinion thrust washers with ATF, and install them to
the differential case.
2. INSTALL NO. 1 FRONT DIFFERENTIAL PINION
SHAFT
(a) Coat the front differential pinion shaft with ATF, and
install it to the differential case.
3. INSPECT FRONT DIFFERENTIAL SIDE GEAR
BACKLASH (See page AX-257)
4. INSTALL FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch and hammer, tap in the pinion
shaft straight pin.
(b) Using a chisel and hammer, stake the differential
case.
5. INSTALL FRONT DIFFERENTIAL CASE REAR
TAPERED ROLLER BEARING
(a) Using SST and a press, press in the front differential
case tapered roller bearing rear inner race to the
differential case.
SST 09608-06041
C083137E01
C083135E01
C060005E01
C060006E01
D025218E03

U241E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–259
AX
(b) Using SST and a hammer, tap in the case washer
and front differential case tapered roller bearing rear
outer race to the transaxle case.
SST 09950-60020 (09951-00710), 09950-70010
(09951-07100)
6. INSTALL FRONT DIFFERENTIAL CASE FRONT
TAPERED ROLLER BEARING
(a) Using SST and a press, press in the front differential
case tapered roller bearing front inner race to the
differential case.
SST 09608-06041
(b) Using SST and a hammer, tap in the front
differential case tapered roller bearing front outer
race to the transaxle housing.
SST 09950-60020 (09951-00680), 09950-70010
(09951-07100), 09950-60010 (09951-00340)
7. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring
gear to 90 to 110
C (194.0 to 230.0F).
(b) Clean the contact surface of the front differential
case.
(c) Align the matchmarks, and install the front
differential ring gear case quickly.
D025219E02
D025216E01
D025217E01
D025215E03
C083132E02

AX–260U241E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
AX
(d) Tighten the 10 bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
8. INSPECT TAPERED ROLLER BEARING PRELOAD
(a) Install the differential assembly to the transaxle
case.
(b) Install the transaxle housing to the transaxle case.
(c) Install 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 (1.97 in.) for bolt A and B
42 mm (1.65 in.) for bolt C
(d) Using SST, turn the differential.
SST 09564-32011
(e) Using SST and torque wrench, measure the preload
of the differential.
SST 09564-32011
Torque: Standard turning torque at 60 rpm
0.20 to 0.69 N*m (2.0 to 7.0 kgf*cm, 1.8
to 6.1 in.*lbf) for new
0.10 to 0.35 N*m (1.0 to 3.6 kgf*cm, 0.9
to 3.1 in.*lbf) for used
C083133E01
C083139E01
C050259E01
C083572E01
C083572E01