TOYOTA SIENNA 2007 Service Repair Manual

AX–236U151E AUTOMATIC TRANSAXLE – OIL PUMP
AX
2. INSTALL FRONT OIL PUMP BODY O-RING
(a) Coat new O-ring with ATF, and install it to the oil
pump body.
NOTICE:
Make sure that the O-ring is not twisted or
pinched. Moreover, apply enough ATF to the O-
ring before installation.
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 marked side
facing upward.
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 marked side
facing upward.
5. INSTALL STATOR SHAFT ASSEMBLY
(a) Set the stator shaft and align it with each bolt hole.
(b) Using a "torx" socket (T30), install the 11 bolts.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
6. INSTALL CLUTCH DRUM OIL SEAL RING
(a) Coat 2 new clutch drum oil seal rings with ATF.
(b) Install 2 new clutch drum oil seal rings.
NOTICE:
Do not expand the ring ends excessively.
7. INSPECT OIL PUMP ASSEMBLY
HINT:
(See page AX-234)
C055817E02
C119012E01
D009206E04
D003651E01
D026627E01

AX–244U151E AUTOMATIC TRANSAXLE – FORWARD CLUTCH
AX
REASSEMBLY
1. INSTALL INPUT SHAFT OIL SEAL RING
(a) Compress a new input shaft oil seal ring from both
sides to reduce dimension A.
Dimension A:
5 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the
input shaft.
NOTICE:
Do not expand the end gap of the oil seal ring
too much. Fix the hooks firmly.
2. INSTALL FORWARD CLUTCH PISTON SUB-
ASSEMBLY
(a) Coat the forward clutch piston with ATF, and install it
to the input shaft.
NOTICE:
Be careful not to damage the lip of the forward
clutch piston.
3. INSTALL FORWARD CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Install the return spring to the input shaft.
NOTICE:
Installing the spring sub-assembly, check that
all of the springs are fit in the piston correctly.
(b) Coat the clutch balancer with ATF.
(c) Install the clutch balancer to the input shaft.
NOTICE:
• Be careful not to damage the lip of the
forward clutch balancer.
• Make sure that the clutch balancer is not
pinched and that there are no other defects at
the lip.
• Apply sufficient ATF to the sealing lip before
installation.
D025587E01
D026707E01
D026708E01
D026709E02

U151E AUTOMATIC TRANSAXLE – FORWARD CLUTCHAX–245
AX
(d) Place SST on the clutch balancer, and compress
the clutch balancer with a press.
SST 09387-00020
(e) Install the snap ring with a snap ring expander.
(f) Be sure that the end gap of the snap ring is not
aligned with the spring retainer claw.
NOTICE:
• Stop the press when the spring seat is
lowered to the place 1 to 2 mm (0.039 to 0.078
in.) from the snap ring groove.
• This prevents the spring seat from being
deformed.
• Do not expand the snap ring excessively.
(g) Set the end gap of the snap ring in the piston as
shown in the illustration.
NOTICE:
The end gap of the snap ring should not align
with any of the stoppers.
4. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC
(a) Coat the 5 discs with ATF.
(b) Install the 5 plates, 5 discs and flange input shaft.
NOTICE:
Make sure that the plates, discs, and flange are
installed as shown in the illustration.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not
aligned with one of the cutouts.
NOTICE:
The snap ring should be fully engaged in the
groove of the drum.
5. INSPECT PACK CLEARANCE OF FORWARD
CLUTCH
HINT:
(See page AX-243)
6. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
HINT:
(See page AX-243)
D026418E01
D026788E02
D026415E01
D026753E01

AX–242U151E AUTOMATIC TRANSAXLE – FORWARD CLUTCH
AX
(d) Remove the forward clutch return spring from the
input shaft.
4. REMOVE FORWARD CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Place the forward clutch drum onto the oil pump.
(b) Holding the forward clutch piston by hand, apply
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil pump to remove the forward clutch piston.
HINT:
When the piston cannot be removed as it is slanted,
blow air again with the protruding side pushed, or
remove the piston using the needle nose pliers with
vinyl tape on the tip.
5. REMOVE INPUT SHAFT OIL SEAL RING
(a) Remove the input shaft oil seal ring from the input
shaft.
INSPECTION
1. INSPECT PACK CLEARANCE OF FORWARD
CLUTCH
(a) Install the forward clutch on the oil pump.
NOTICE:
Be careful not to damage the oil seal ring of oil
pump.
(b) Using a dial indicator, measure the forward clutch
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:
1.00 to 1.25 mm (0.0394 to 0.4921 in.)
If the clearance is not as specified, inspect the
discs, plates and flange.
HINT:
If the opening is large, cover it with a shop rug or a
piece of cloth to prevent the compressed air from
being released.
D026708E01
D003664
C056374
D026715E01

U151E AUTOMATIC TRANSAXLE – FORWARD CLUTCHAX–243
AX
2. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
(a) Check if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:
• If the lining of the disc comes off or discolors, or if
a part of the groove is worn, replace all discs.
• Before installing new discs, immerse them in ATF
for at least 15 minutes.
3. INSPECT FORWARD CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Using vernier calipers, measure the free length of
the spring together with the spring seat.
Standard free length:
26.74 mm (1.0528 in.)
4. INSPECT PACK CLEARANCE OF FORWARD
CLUTCH
(a) Using a dial indicator, measure the forward clutch
pack clearance while applying and releasing
compressed air (392 kgf/cm
2, 4.0 kPa, 57 psi).
Pack clearance:
1.00 to 1.25 mm (0.0394 to 0.4921 in.)
If the piston stroke is less than the minimum, parts
may be assembled incorrectly. Check and
reassemble the parts again.
If the clearance is not as specified, select another
flange.
HINT:
There are 5 different thicknesses of flanges
available.
Flange thickness: mm (in.)
5. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
(a) Check if the disc lightly rotates when rotating the
forward clutch assembly after inserting the multiple
disc clutch into it.
NOTICE:
Do not place the forward clutch assembly in a
vise.
D009189
D009211E01
D026715E01
No. Thickness No. Thickness
1 3.00 (0.1181) 4 3.45 (0.1358)
2 3.15 (0.1240) 5 3.60 (0.1417)
3 3.30 (0.1299) - -
D003672

AX–246U151E AUTOMATIC TRANSAXLE – DIRECT CLUTCH
AX
TRANSMISSION
U151E AUTOMATIC TRANSAXLE
DIRECT CLUTCH
COMPONENTS
C119011E02

U151E AUTOMATIC TRANSAXLE – DIRECT CLUTCHAX–247
AX
DISASSEMBLY
1. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
HINT:
(See page AX-249)
2. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
AND OVERDRIVE CLUTCH
HINT:
(See page AX-249)
3. REMOVE DIRECT MULTIPLE DISC CLUTCH DISC
(a) Using a screwdriver, remove the snap ring from the
intermediate shaft.
(b) Remove the flange, 3 discs, 3 plates and cushion
plate from the intermediate shaft.
4. REMOVE OVERDRIVE DIRECT CLUTCH DISC
(a) Using a screwdriver, remove the snap ring from the
intermediate shaft.
(b) Remove the flange, 4 discs and 4 plates from the
intermediate shaft.
5. REMOVE OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Place SST on the clutch balancer and compress the
spring with a press.
SST 09387-00020
(b) Using a snap ring expander, remove the snap ring
from the direct clutch drum.
NOTICE:
• Stop the press when the spring seat is
lowered to the place 1 to 2 mm (0.039 to 0.078
in.) from the snap ring groove.
D026419E01
D026420
D026422
D003677E01

AX–248U151E AUTOMATIC TRANSAXLE – DIRECT CLUTCH
AX
• This prevents the spring seat from being
deformed.
• Do not expand the snap ring excessively.
(c) Remove the clutch balancer from the direct clutch
drum.
(d) Remove the overdrive clutch return spring from the
direct clutch drum.
6. REMOVE OVERDRIVE DIRECT CLUTCH PISTON
(a) Install the intermediate shaft on the transaxle rear
cover.
(b) Holding the direct clutch piston with your hand,
apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the transaxle rear cover to remove the direct
clutch piston.
7. REMOVE OVERDRIVE DIRECT CLUTCH DRUM SUB-
ASSEMBLY
(a) Holding the direct clutch drum by hand, apply
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
transaxle rear cover to remove the direct clutch
drum.
D026424E02
D026423E04
D026463
D026425

U151E AUTOMATIC TRANSAXLE – DIRECT CLUTCHAX–249
AX
8. REMOVE OVERDRIVE DIRECT CLUTCH O-RING
(a) Using a screwdriver, remove the O-ring from the
direct clutch drum.
INSPECTION
1. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the intermediate shaft and needle roller
bearing onto the transaxle rear cover.
(b) Using a dial indicator, measure the reverse clutch
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:
0.60 to 0.82 mm (0.02362 to 0.03228 in.)
If the pack clearance is not as specified, inspect the
discs, plates and flange.
2. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
AND OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch and
overdrive clutch pack clearance while applying and
releasing compressed air (392 kPa, 4.0 kgf/cm
2, 57
psi).
Pack clearance:
0.61 to 0.83 mm (0.02401 to 0.03268 in.)
If the pack clearance is not as specified, inspect the
discs, plates and flange.
D026464E01
D026426E02
D026427E01

AX–250U151E AUTOMATIC TRANSAXLE – DIRECT CLUTCH
AX
3. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC
(a) Check if the sliding surfaces of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:
• If the lining of the disc comes off or discolors, or if
a part of the groove is worn, replace all discs.
• Before installing new discs, immerse them in ATF
for at least 15 minutes.
4. INSPECT OVERDRIVE DIRECT CLUTCH DISC
(a) Check if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:
• If the lining of the disc comes off or discolors, or if
a part of the groove is worn, replace all discs.
• Before installing new discs, immerse them in ATF
for at least 15 minutes.
5. INSPECT OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Using vernier calipers, measure the free length of
the spring together with the spring seat.
Standard free length:
25.91 mm (1.0201 in.)
6. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the intermediate shaft onto the transaxle rear
cover.
(b) Using a dial indicator, measure the direct clutch
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Clearance:
0.60 to 0.82 mm (0.02362 to 0.03228 in.)
If the pack clearance is less than the minimum,
parts may have been assembled incorrectly, so
check and reassemble again. If the clearance is not
as specified, select another flange.
HINT:
There are 7 flanges of different thickness.
Flange thickness: mm (in.)
D026718
D026719
D009211E02
D026426E02
No. Thickness No. Thickness
1 3.0 (0.118) 5 3.4 (0.134)
2 3.1 (0.122) 6 3.5 (0.138)
3 3.2 (0.126) 7 3.6 (0.142)
4 3.3 (0.130) - -