TOYOTA RAV4 2006 Service Repair Manual

U140F AUTOMATIC TRANSAXLE – OIL PUMPAX–221
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6. INSTALL CLUTCH DRUM OIL SEAL RING
(a) Install the 2 clutch drum oil seal rings.
NOTICE:
Do not expand the ring ends excessively.
7. INSPECT OIL PUMP ASSEMBLY (See page AX-218)
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AX–224U140F AUTOMATIC TRANSAXLE – SECOND BRAKE PISTON
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REASSEMBLY
1. INSTALL 2ND BRAKE PISTON O-RING
(a) Coat the 2 new O-rings with ATF, and install them
into the 2nd brake piston.
2. INSTALL 2ND BRAKE PISTON
(a) Press in the 2nd brake piston into the 2nd brake
cylinder with your hands.
3. INSTALL 2ND BRAKE PISTON RETURN SPRING
SUB-ASSEMBLY
(a) Install the piston return spring.
(b) Place SST on the piston return spring, and
compress the piston return spring with a press.
SST 09387-00060
(c) Using a screwdriver, install the snap ring.
NOTICE:
Be sure the end gap of the snap ring is not
aligned with the piston return spring claw.
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AX–234U140F AUTOMATIC TRANSAXLE – DIRECT CLUTCH
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(d) Remove the piston return spring from the direct
clutch drum.
(e) Install the direct clutch drum on the transaxle rear
cover.
(f) 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.
INSPECTION
1. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
(a) Install the direct clutch and needle roller bearing on
the transaxle rear cover.
(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)
Standard pack clearance:
0.515 to 0.825 mm (0.0203 to 0.0324 in.)
If the pack clearance is not as specified, inspect the
discs, plates and flange.
2. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC
(a) Check to see 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 is peeling off or discolored,
or even if a part of the printed mark is defaced,
replace all discs.
• Before assembling new discs, soak them in ATF
for at least 15 minutes.
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U140F AUTOMATIC TRANSAXLE – DIRECT CLUTCHAX–235
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3. INSPECT DIRECT CLUTCH RETURN SPRING SUB-
ASSEMBLY
(a) Using a vernier caliper, measure the free length of
the spring together with the spring seat.
Standard free length:
22.58 mm (0.8898 in.)
REASSEMBLY
1. INSTALL DIRECT CLUTCH RETURN SPRING SUB-
ASSEMBLY
(a) Coat the direct clutch piston with ATF, and install it
to the direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the
direct clutch piston.
(b) Install the piston return spring to the direct clutch
drum.
(c) Install the clutch balancer to the direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the
direct clutch balancer.
(d) Place SST on the clutch balancer and compress the
piston return spring with a press.
SST 09387-00020
(e) Using a snap ring expander, install the snap ring to
the direct clutch drum.
NOTICE:
• Be sure the end gap of the snap ring is not
aligned with the clutch balancer claw.
• 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.
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AX–236U140F AUTOMATIC TRANSAXLE – DIRECT CLUTCH
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• This prevents the spring sheet from being
deformed.
• Do not expand the snap ring excessively.
2. INSTALL DIRECT MULTIPLE DISC CLUTCH DISC
(a) Install the 3 plates, 3 discs and flange to the direct
clutch drum.
Install in order:
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.
3. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
(a) Install the direct clutch on 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/cm
2, 57 psi).
Standard pack clearance:
0.515 to 0.825 mm (0.0203 to 0.0324 in.)
If the pack clearance is less than the minimum,
parts may have been assembled incorrectly, so
check and reassemble again.
If the stroke is not as specified, select another
flange.
HINT:
There are 6 flanges in different thickness.
Standard flanges in different thickness
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No. Thickness No. Thickness
1 3.0 mm (.118 in.) 4 3.3 mm (0.130 in.)
2 3.1 mm (0.122 in.) 5 3.4 mm (0.134 in.)
3 3.2 mm (0.126 in.) 6 3.5 mm (0.138 in.)

U140F AUTOMATIC TRANSAXLE – DIRECT CLUTCHAX–237
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4. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC
(a) Check that the disc rotates when rotating the disc
after inserting the rear planetary sun gear.
NOTICE:
Do not place the rear planetary sun gear in a
vise.
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U140F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–257
AX
7. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST and hammer, tap out the oil seal.
SST 09950-70010 (09951-07100), 09215-00013
(09215-00471)
8. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and hammer, tap out the oil seal.
SST 09950-70010 (09951-07100), 09608-10010
INSPECTION
1. INSPECT 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
REASSEMBLY
1. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Coat the 2 front differential side gears, 2 side gear
thrust washers, 2 font 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 No. 1 front differential pinion shaft with
ATF, and install it to the differential case.
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Thickness Thickness
1.625 mm (0.0640 in.) 1.825 mm (0.0719 in.)
1.725 mm (0.0679 in.) -
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AX–258U140F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
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3. INSTALL TRANSAXLE CASE STRAIGHT PIN
(a) Using a pin punch and a hammer, tap in the pinion
shaft straight pin.
(b) Using a chisel and a hammer, stake the differential
case.
NOTICE:
Stake it after adjusting the backlash.
4. INSTALL FRONT DIFFERENTIAL CASE REAR
TAPERED ROLLER BEARING
(a) U si ng SST and a pres s, pr es s in the f ron t di fferent ial
case rear tapered roller bearing to the differential
case.
SST 09550-60010, 09950-60020 (09951-00680),
09950-70010 (09951-07100)
(b) Using SST and a hammer, tap in the front
differential case tapered roller bearing front outer
race to the transaxle housing.
SST 09550-60010, 09950-60020 (09951-00680),
09950-70010 (09951-07100, 09951-00890)
5. INSTALL FRONT DIFFERENTIAL CASE FRONT
TAPERED ROLLER BEARING
(a) Using SST and a press, press in the front differential
case rear tapered roller bearing to the differential
case.
SST 09550-60010, 09950-60020 (09951-00680),
09950-70010 (09951-07100, 09951-00890)
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U140F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–259
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(b) Using SST and a hammer, tap in the front
differential case tapered roller bearing front outer
race to the transaxle housing.
SST 09550-60010, 09950-60020 (09951-00680),
09950-70010 (09951-07100, 09951-00890)
NOTICE:
Clearance is not allowed between the bearing
and transaxle housing.
6. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
(a) Install the differential assembly to the transaxle
case.
(b) Clean the matching surfaces of the transaxle case
and transaxle housing.
(c) Install the transaxle housing to the transaxle case
and tighten them with 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 bolts
B and C
HINT:
Each bolt length is indicated below.
Bolt length:
50 mm (1.969 in.) for bolt A
50 m (1.969 in.) for bolt B
42 mm (1.654 in.) for bolt C
NOTICE:
Usually, bolt A is non-reusable bolt. In this case,
however, it can be used after cleaning it.
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AX–260U140F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
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(d) Using SST, return the differential assembly right and
left 2 or 3 times to allow the bearing settle.
SST 09564-32011
(e) Using SST and torque wrench, measure the turning
torque 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)
HINT:
If the turning torque is not within the specified value,
refer to the table below and select a thrust washer
which turning torque is within the specified value.
Standard flange thickness
(f) Remove the 16 bolts and the transaxle housing.
(g) Remove the differential assembly.
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Mark Thickness Mark Thickness
0 2.00 mm (0.0787
in.)9 2.45 mm (0.0965
in.)
1 2.05 mm (0.0807
in.)A 2.50 mm (0.0984
in.)
2 2.10 mm (0.0827
in.)B 2.55 mm (0.1004
in.)
3 2.15 mm (0.0846
in.)C 2.60 mm (0.1024
in.)
4 2.20 mm (0.0866
in.)D 2.65 mm (1.1043
in.)
5 2.25 mm (0.0886
in.)E 2.70 mm (0.1063
in.)
6 2.30 mm (0.0906
in.)F 2.75 mm (0.1083
in.)
7 2.35 mm (0.0925
in.)G 2.80 mm (0.1102)
8 2.40 mm (0.0945
in.)H 2.85 mm (0.1122
in.)
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