TOYOTA RAV4 2006 Service Repair Manual

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–207
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Three Bond 1281 or Equivalent
41. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Install 2 new O-rings to the 2 plugs.
(b) Install the 2 plugs to the transaxle housing.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
42. INSPECT INPUT SHAFT END PLAY (See page AX-
184)
43. FIX AUTOMATIC TRANSAXLE ASSEMBLY
44. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Coat a new oil seal with ATF.
(b) Install the oil seal to the transaxle.
45. INSTALL PARKING LOCK ROD SUB-ASSEMBLY
(a) Install the parking lock rod to the manual valve lever.
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46. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
(a) Install a new spacer and manual valve lever shaft to
the transaxle.
(b) Using a pin punch and hammer, tap in a new pin.
(c) Turn the spacer and lever shaft to align the small
hole for locating 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.
47. INSTALL MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using needle-nose pliers, install the retainer spring.
48. 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)
Bolt length:
25 mm (0.984 in.)
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49. INSTALL MANUAL DETENT SPRING SUB-
ASSEMBLY
(a) Install the manual detent spring with the 2 bolts.
NOTICE:
Make sure to install the manual detent spring
and cover in this order.
Torque: 20 N*m (204 kgf*cm, 16 ft.*lbf) for bolt A
12 N*m (122 kgf*cm, 9 ft.*lbf) for bolt B
HINT:
Each bolt length is indicated below.
27 mm (1.063 in.) for bolt A
16 mm (0.630 in.) for bolt B
50. INSTALL B-3 ACCUMULATOR PISTON
(a) Coat a new O-ring with ATF, and install it to the B-3
accumulator piston.
(b) Coat the piston with ATF, install it to the transaxle.
Standard accumulator spring
51. INSTALL C-1 ACCUMULATOR PISTON
(a) Coat 2 new O-rings with ATF, and install them to the
C-1 accumulator piston.
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Spring Free length
Outer diameterColor
B-3 Inner 60.24 mm (2.3716 in.)
15.9 (0.626 in.)Yellowish green
B-3 Outer 74.61 mm (2.9374 in.)
21.7 mm (0.854 in.)Blue
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A X –210U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(b) Coat the piston with ATF, and install it to the
transaxle.
Standard accumulator spring
52. INSTALL C-3 ACCUMULATOR PISTON
(a) Coat a new O-ring with ATF, and install it to the C-3
accumulator piston.
(b) Coat the piston with ATF, install it to the transaxle
case.
Standard accumulator spring
(c) Install the spring from the C-3 accumulator piston.
53. INSTALL CHECK BALL BODY
(a) Install the check ball body and spring.
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Spring Free length
Outer diameterColor
C-1 81.53 mm (3.2098 in.)
18.5 mm (0.728 in.)Pink
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Spring Free length
Outer diameterColor
C - 3 90.49 mm (3.5626 in.)
19.2 mm (0.756 in.)White
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U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–211
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54. INSTALL BRAKE DRUM GASKET
(a) Coat a new brake drum gasket with ATF, and install
it to the transaxle.
55. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with
ATF, and install it to the transaxle.
56. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Coat a new governor apply gasket No. 1 with ATF,
and install it to the transaxle.
57. INSTALL TRANSMISSION WIRE
(a) Coat a new O-ring with ATF, and install it to the
transaxle solenoid wire.
(b) Install the solenoid wire retaining bolt
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
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58. INSTALL TRANSMISSION VALVE BODY ASSEMBLY
(a) Align the groove of the manual valve with the pin of
lever.
(b) Install the 17 bolts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
NOTICE:
• Push the valve body against the accumulator
piston spring and the check ball body to
install it.
• Tighten the bolts marked by * in the
illustration first temporarily because they are
positioning bolts.
HINT:
Each bolt length is indicated below.
Bolt length:
25 mm (0.984 in.) for bolt A
41 mm (1.614 in.) for bolt B
45 mm (1.771 in.) for bolt C
(c) Connect the 5 solenoid connectors.
(d) Coat the O-ring of the temperature sensor with ATF.
(e) Install the ATF temperature sensor with the lock
plate and bolt.
Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
59. INSTALL VALVE BODY OIL STRAINER ASSEMBLY
(a) Coat a new O-ring with ATF.
(b) Install the O-ring to the oil strainer.
(c) Install the oil strainer with the 3 bolts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
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60. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-
ASSEMBLY
(a) Install the 3 magnets in the oil pan.
(b) Install a new oil pan gasket to the oil pan.
(c) Install the oil pan to the transaxle with the 18 bolts.
Torque: 7.6 N*m (77 kgf*cm, 67 in.*lbf)
NOTICE:
Because the bolts are seal bolts, apply seal
packing to new bolts and tighten them within 10
minutes after application.
61. 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)
62. INSTALL SPEED SENSOR
(a) Coat 2 new O-rings with ATF, and install them to the
2 sensors.
(b) Install the 2 sensors with the 2 bolts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
63. INSTALL OIL COOLER INLET TUBE UNION
(a) Coat a new O-ring with ATF, and install it to the
union.
(b) Install the union to the transaxle.
Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf)
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64. INSTALL OIL COOLER OUTLET TUBE UNION
(a) Coat a new O-ring with ATF, and install it to the
union.
(b) Install the union to the transaxle.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
65. INSTALL BREATHER PLUG HOSE
66. INSTALL PARK/NEUTRAL POSITION SWITCH
ASSEMBLY
(a) Install the park/neutral position switch to the manual
valve shaft.
(b) Temporarily install the 2 bolts.
(c) Install a new lock plate and tighten the manual valve
shaft nut.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
(d) Temporarily install the control shaft lever.
(e) Turn the lever counterclockwise until it stops, and
then turn it clockwise 2 notches.
(f) Remove the control shaft lever.
(g) Align the groove with neutral basic line.
(h) Hold the switch in this position and tighten the 2
bolts.
Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
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U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–215
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(i) Using a screwdriver, stake the nut with the lock
plate.
(j) Install the control shaft lever with the washer and
nut.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
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AX–220U140F AUTOMATIC TRANSAXLE – OIL PUMP
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REASSEMBLY
1. INSTALL FRONT OIL PUMP OIL SEAL
(a) Using SST and a hammer, install a new oil seal to
the pump.
SST 09350-32014 (09351-32140)
HINT:
The seal end should be flat 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 the 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 marked 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 marked side
facing up.
5. INSTALL STATOR SHAFT ASSEMBLY
(a) Set the stator shaft by aligning each bolt hole.
(b) Using a T30 ''trox'' socket, install the 11 bolts.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
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