TOYOTA RAV4 2006 Service Repair Manual

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLYAX–177
AX
8. INSTALL FRONT ENGINE MOUNTING BRACKET
(a) Install the mounting bracket with the 4 bolts.
Torque: 64 N*m (657 kgf*cm, 47 ft.*lbf)
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) for filler
tube bolt
9. INSTALL REAR ENGINE MOUNTING BRACKET
(a) Install the mounting bracket with the 3 bolts.
Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf)
10. INSTALL TRANSMISSION OIL COOLER HOSES AND
TUBE
(a) Install the transmission oil cooler hoses and tube
(see page AX-152).
11. CONNECT WIRE HARNESS
(a) Connect the wire harness clamps.
(b) Connect the 2 speed sensor connectors.
(c) Connect the transaxle wire connector.
(d) Connect the park/neutral position switch connector.
12. INSTALL STARTER ASSEMBLY
(a) Install the starter with the 2 bolts.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
(b) Connect the starter connector.
(c) Install the terminal nut and cover the nut with the
cap.
Torque: 9.8 N*m (100 kgf*cm, 88 in.*lbf)
13. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the engine with transaxle (see page EM-31).
14. ADD AUTOMATIC TRANSAXLE FLUID
Fluid type:
Toyota Genuine ATF WS
C134977
C134975
C134973
A126955
A126954

AX–178U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY
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15. INSPECT AUTOMATIC TRANSAXLE FLUID
(a) Inspect the automatic transaxle fluid (see page AX-
126).
16. PERFORM RESET MEMORY
(a) Perform the RESET MEMORY procedures (A/T
initialization) (see page AX-20).

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–189
AX
DISASSEMBLY
1. REMOVE PARK/NEUTRAL POSITION SWITCH
ASSEMBLY
(a) Remove the nut, washer and control shaft lever.
(b) Using a screwdriver, pry off the lock plate.
(c) Remove the nut and lock plate.
(d) Remove the 2 bolts and pull out the switch.
2. REMOVE BREATHER PLUG HOSE
(a) Remove the breather plug hose from the transaxle
case.
3. REMOVE OIL COOLER OUTLET TUBE ELBOW
(a) Remove the elbow.
(b) Remove the O-ring from the elbow.
4. REMOVE OIL COOLER INLET TUBE ELBOW
(a) Remove the elbow.
(b) Remove the O-ring from the elbow.
C140280
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AX–190U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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5. REMOVE SPEED SENSOR
(a) Remove the 2 bolts and the 2 speed sensors from
the transaxle.
6. REMOVE SPEEDOMETER DRIVEN HOLE COVER
SUB-ASSEMBLY
(a) Remove the bolt and cover.
(b) Remove the O-ring from the cover.
7. REMOVE NO. 1 TRANSAXLE CASE PLUG
(a) Remove the 4 plugs from the transaxle case.
(b) Remove the 4 O-rings from the 4 plugs.
8. FIX AUTOMATIC TRANSAXLE ASSEMBLY
(a) Fix the transaxle.
9. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-
ASSEMBLY
(a) Remove the 18 bolts, oil pan and gasket.
(b) Remove the 2 magnets from the oil pan.
D030672E06
C136368
D009176E01
C091925E01
C086316E02

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–191
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10. INSPECT TRANSMISSION OIL CLEANER MAGNET
(a) Remove the magnets and use them to collect any
steel chips. Examine the chips and particles in the
pan and on the magnet to determine what type of
wear has occurred in the transaxle.
Result:
Steel (magnetic):
Wear of the bearing, gear and plate
Brass (non-magnetic):
Wear of the bush
11. REMOVE VALVE BODY OIL STRAINER ASSEMBLY
(a) Remove the 3 bolts and oil strainer.
(b) Remove the O-ring from the oil strainer.
12. REMOVE TRANSMISSION WIRE
(a) Remove the 7 connectors from the shift solenoid
valves.
(b) Remove the bolt, lock plate and temperature
sensor.
(c) Remove the bolt and transmission wire from the
transaxle case.
AT00103E01
C091931E02
C091932E02
C134996E01
D003547E07

AX–192U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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13. REMOVE TRANSMISSION VALVE BODY ASSEMBLY
(a) Support the valve body and remove the 17 bolts and
valve body.
14. REMOVE NO. 1 GOVERNOR APPLY GASKET
(a) Remove the gasket from the transaxle case.
15. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET
(a) Remove the gasket from the transaxle case.
16. REMOVE BRAKE DRUM GASKET
(a) Remove the gasket from the transaxle case.
17. REMOVE CHECK BALL BODY
(a) Remove the check ball body and spring from the
transaxle case.
C091933E07
C083127E01
C083128E01
C083129E01
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U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–193
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18. REMOVE C-3 ACCUMULATOR PISTON
(a) Remove the spring from the C-3 accumulator
piston.
(b) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the oil hole and remove the C-3 accumulator
piston.
NOTICE:
• Applying compressed air may cause the
piston to jump out. When removing the
piston, hold it using a waste cloth.
• Take care not to splash ATF when applying
compressed air.
(c) Remove the O-ring from the C-3 accumulator
piston.
19. REMOVE REVERSE CLUTCH ACCUMULATOR
PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the oil hole and remove the reverse accumulator
piston and spring.
NOTICE:
• Applying compressed air may cause the
piston to jump out. When removing the
piston, hold it using a waste cloth.
• Take care not to splash ATF when applying
compressed air.
(b) Remove the 2 O-rings from the reverse clutch
accumulator piston.
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AX–194U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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20. REMOVE B-3 ACCUMULATOR PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the oil hole and remove the B-3 accumulator
piston and 2 springs.
NOTICE:
• Applying compressed air may cause the
piston to jump out. When removing the
piston, hold it using a waste cloth.
• Take care not to splash ATF when applying
compressed air.
(b) Remove the O-ring from the B-3 accumulator
piston.
21. REMOVE MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using needle-nose pliers, remove the manual valve
lever shaft retainer spring.
22. REMOVE MANUAL DETENT SPRING SUB-
ASSEMBLY
(a) Remove the 2 bolts, manual detent spring and
cover.
23. REMOVE PARKING LOCK PAWL BRACKET
(a) Remove the 2 bolts and parking lock pawl bracket.
D003558E01
D003904E05
D003559E01
D003560E03
C056727E01

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–195
AX
24. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY
(a) Using a chisel and hammer, cut off and remove the
spacer.
(b) Using a pin punch (
35 mm) and hammer, drive out
the pin.
HINT:
Slowly drive out the pin so that it does not fall into
the transaxle case.
(c) Remove the manual valve lever shaft and manual
valve lever.
25. REMOVE PARKING LOCK ROD SUB-ASSEMBLY
(a) Remove the parking lock rod from the manual valve
lever.
26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Using a screwdriver, pry out the oil seal from the
transaxle case.
NOTICE:
Do not apply excessive force when removing
the oil seal.
27. FIX AUTOMATIC TRANSAXLE ASSEMBLY
(a) Fix the transaxle case in place with the oil pump
side facing up.
28. INSPECT INPUT SHAFT ENDPLAY (See page AX-212)
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AX–196U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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29. REMOVE TRANSAXLE HOUSING
(a) Remove the 16 bolts.
(b) Tap on the circumference of the transaxle housing
with a plastic-faced hammer to remove the
transaxle housing from the transaxle case.
NOTICE:
The differential may be accidentally removed
when the transaxle housing is removed.
30. REMOVE OIL PUMP ASSEMBLY
(a) Remove the 7 bolts and oil pump from the transaxle
case.
31. REMOVE THRUST NEEDLE ROLLER BEARING
(a) Remove the thrust needle roller bearing from the
underdrive planetary gear.
32. REMOVE NO. 2 THRUST BEARING UNDERDRIVE
RACE
(a) Remove the thrust bearing race from the underdrive
planetary gear.
33. REMOVE DIFFERENTIAL GEAR ASSEMBLY
(a) Remove the differential gear from the transaxle
case.
C115282
D003569E03
D025505E03
D025506E04
D026450E09