TOYOTA RAV4 2006 Service Repair Manual

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–227
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34. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Coat 4 new O-rings with ATF.
(b) Install the 4 O-rings to the 4 plugs.
(c) Install the 4 plugs to the transaxle rear cover.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
35. INSTALL TRANSAXLE REAR COVER SUB-
ASSEMBLY
(a) Remove any packing material and be careful not to
spill oil on the contact surfaces of the transaxle rear
cover or the transaxle case.
(b) Apply FIPG to the cover.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or Equivalent
NOTICE:
Make sure that the seal packing is applied in a
bead (section diameter:
1.2 mm (0.047 in.)) so
that the entire sealing surface will be evenly
sealed. The seal packing should also protrude
slightly from the flange after the installation of
the cover has been completed.
(c) Apply adhesive to the threads of bolt A.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or Equivalent
(d) Install the cover with the 11 bolts.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A
25 N*m (255 kgf*cm, 18 ft.*lbf) for other
bolts
36. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs, 4 plates and flange to the
transaxle case.
NOTICE:
Be careful of the order of the discs, plate and
flange.
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(c) Using a screwdriver, install the snap ring.
NOTICE:
The snap ring should be fully engaged in the
groove of the drum.
37. INSPECT PACK CLEARANCE OF UNDERDRIVE
BRAKE
(a) Using a dial indicator, measure the underdrive brake
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Standard pack clearance:
1.81 to 2.20 mm (0.0713 to 0.0866 in.)
HINT:
Select an appropriate flange from the table below so
that it will meet the specified value.
Standard flange thickness
(b) Temporarily remove the snap ring, attach the
selected flange and reinstall the snap ring.
(c) Reinstall the snap ring.
38. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the underdrive clutch to the 1-way clutch.
(b) Check that the underdrive 1-way clutch locks when
turned clockwise and rotates freely when turned
counterclockwise as shown in the illustration.
If the result is not as specified, replace the
underdrive 1-way clutch.
39. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the outer race retainer to the 1-way clutch.
NOTICE:
Fix the outer race retainer to the external tooth
of the 1-way clutch firmly.
D026466E01
D008082E01
Mark Thickness Mark Thickness
1 3.0 mm (0.118 in.) 4 3.1 mm (0.122 in.)
2 3.2 mm (0.126 in.) 5 3.3 mm (0.130 in.)
3 3.4 mm (0.134 in.) - -
D003925E01
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(b) Install the 1-way clutch to the transaxle case.
NOTICE:
Make sure that the mark on the 1-way clutch
outer race is visible.
(c) Using a screwdriver, install the snap ring to the
transaxle case.
NOTICE:
The snap ring should be fully engaged in the
groove of the transaxle case.
40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
(a) Coat the bearing and bearing race with petrolatum,
and install them onto the underdrive clutch.
Standard bearing and bearing race diameter
(b) Install the underdrive clutch to the transaxle case.
NOTICE:
Do not damage the oil seal when installing the
underdrive clutch drum.
41. INSTALL PARKING LOCK PAWL
(a) Install the pawl pin and spring to the parking lock
pawl.
D003627E02
D003581E02
D003580E02
Item Inside Outside
Bearing 37.73 mm (1.4854 in.) 58.0 mm (2.2835 in.)
Race 29.9 mm (1.1772 in.) 55.5 mm (2.185 in.)
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AX–230U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(b) Temporarily install the parking lock pawl, shaft and
spring to the transaxle case, as shown in the
illustration.
42. INSTALL UNDERDRIVE PLANETARY GEAR
ASSEMBLY
(a) Install the underdrive planetary gear to the transaxle
case.
NOTICE:
• Fully engage all the discs of underdrive
clutch and hub splines of the underdrive
planetary gear and install them securely.
• Check the position and number of the
grooves on each end face of the differential
drive pinion gear.
(b) Install the parking lock pawl shaft.
(c) Install the pawl shaft clamp with the bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
(d) Using a straightedge and vernier caliper as shown
in the illustration, measure the gap between the top
of the differential drive pinion in the underdrive
planetary gear and the contact surface of the
transaxle case and housing (Dimension E).
NOTICE:
Record dimension E for the following process.
D026386E01
C140286
D009693E01
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(e) As shown in the illustration, measure the 2 places of
the transaxle housing, and calculate dimension F
using the formula below.
NOTICE:
Record dimension F for the following process.
HINT:
Dimension F = Dimension (1) - Dimension (2)
43. INSTALL MULTIPLE DISC CLUTCH HUB
(a) Install the thrust bearing race to the transaxle case
while checking its direction.
Standard bearing race diameter
(b) Coat the thrust needle roller bearing and race with
yellow petrolatum, and install them onto the multiple
disc clutch hub.
Standard thrust bearing and race diameter
(c) Coat the needle roller bearing with ATF.
(d) Install the needle roller bearing to the multiple clutch
hub.
Standard bearing diameter
(e) Install the multiple clutch hub to the transaxle case.
44. INSTALL FORWARD CLUTCH ASSEMBLY
(a) Coat the thrust needle roller bearing with ATF.
(b) Install the thrust needle roller bearing to the forward
clutch.
Standard thrust bearing diameter
D025511E01
D008087E03
Item Inside Outside
Bearing race 39.5 mm (1.555 in.) 45.8 mm (1.803 in.)
D026710E04
Item Inside Outside
Thrust Bearing 36.4 mm (1.433 in.) 52.2 mm (2.055 in.)
D026711E04
Item Inside Outside
Bearing 23.6 mm (0.929 in.) 44 mm (1.732 in.)
D003820E02
Item Inside Outside
Thrust Bearing 33.58 mm (1.3220 in.) 51.9 mm (2.043 in.)

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NOTICE:
Install the thrust bearing properly so that the
non-collared race or blue ink jet race will be
visible.
(c) Install the forward clutch to the transaxle case.
NOTICE:
• Align the splines of all discs in the forward
clutch with those of multiple clutch hub to
install them securely.
• Be careful not to damage the bushing inside
of the forward clutch hub during installation.
45. INSTALL OVERDRIVE BRAKE GASKET
(a) Install 2 new overdrive brake gaskets.
46. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear to the transaxle case.
NOTICE:
Check the position and number of the grooves
on each end face of the differential ring gear.
47. INSTALL NO. 2 THRUST BEARING UNDERDRIVE
RACE
(a) Install the thrust bearing underdrive race to the
underdrive planetary gear.
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D003573E01
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48. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Coat the thrust needle roller bearing with ATF.
(b) Calculate the end play value using the following
formula and values of Dimension E and F that were
measured when installing the cylindrical roller
bearing and underdrive planetary gear. Select an
appropriate underdrive planetary gear thrust
bearing race which satisfies the specified end play
value, and install the selected bearing race.
Standard end play:
0.498 to 0.993 mm (0.0196 to 0.0391 in.)
HINT:
End play = Dimension F - Dimension E - thrust
bearing thickness 2.5 mm (0.0984 in.) - underdrive
thrust bearing race thickness.
Standard race thickness
Standard bearing and bearing race diameter
49. INSTALL OIL PUMP ASSEMBLY
(a) Install the oil pump to the transaxle case with the 7
bolts.
Torque: 22 N*m (226 kgf*cm, 16 ft.*lbf)
(b) Coat the O-ring of oil pump with ATF.
NOTICE:
Confirm that the input shaft rotates smoothly by
manual operation after installing the oil pump.
D025505E03
F - E Thickness
Less than 7.72 mm (0.3039 in.) 3.5 mm (0.138 in.)
7.72 mm (0.3039 in.) 3.8 mm (0.150 in.)
Item Inside Outside
Bearing 57.2 mm (2.252 in.) 84.96 mm (3.345 in.)
Bearing race 56.4 mm (2.22 in.) 83 mm (3.268 in.)
D003569E03
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50. INSTALL TRANSAXLE HOUSING
(a) Remove any packing material and be careful not to
spill oil on the contact surface of the transaxle case
or transaxle housing.
(b) Apply seal packing to the transaxle case.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or Equivalent
(c) Apply adhesive or equivalent to bolts A and D.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or Equivalent
(d) Install the transaxle housing and 16 bolts to the
transaxle case.
Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) for bolt A
29 N*m (295 kgf*cm, 21 ft.*lbf) for bolt B
29 N*m (295 kgf*cm, 21 ft.*lbf) for bolt C
22 N*m (226 kgf*cm, 16 ft.*lbf) for bolt D
HINT:
Each bolt length is indicated below.
Bolt length:
50 mm (1.97 in.) for bolt A
50 mm (1.97 in.) for bolt B
42 mm (1.65 in.) for bolt C
72 mm (2.84 in.) for bolt D
NOTICE:
Tighten the bolts within 10 minutes of adhesive
application.
51. INSPECT INPUT SHAFT END PLAY
(a) Using a dial indicator, measure the input shaft end
play.
Standard end play:
0.262 to 1.249 mm (0.0100 to 0.0494 in.)
52. FIX AUTOMATIC TRANSAXLE ASSEMBLY
(a) Fix the transaxle.
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C115282E01
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53. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Coat a new oil seal with MP grease.
(b) Install the oil seal to the transaxle case.
SST 09950-60010 (09951-00230), 09950-70010
(09951-07100)
Standard depth:
0 +-0.5 mm (0 +-0.197 in. )
54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY
(a) Install the parking lock rod to the manual valve lever.
55. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
(a) Install a new spacer and manual valve lever shaft to
the transaxle case.
NOTICE:
Do not damage the oil seal when installing the
shaft to the transaxle case.
(b) Using a pin punch and hammer, drive in a new pin.
(c) Turn the spacer and the lever shaft to align the small
hole for locating the staking position in the spacer
with 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.
D026468E01
D026382E02
D003565E01
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56. INSTALL MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using needle-nose pliers, install the retainer spring.
NOTICE:
Hang the spring on the shaft firmly.
57. 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)
HINT:
The bolt length is indicated below.
Bolt length:
25.0 mm (0.984 in.)
NOTICE:
Make sure that the parking rod is placed
between the parking pawl and the guide of the
parking bracket when the parking bracket is
installed.
58. INSTALL MANUAL DETENT SPRING SUB-
ASSEMBLY
(a) Install the manual detent spring and cover with the 2
bolts.
Torque: 20 N*m (205 kgf*cm, 15 ft.*lbf) for bolt A
12 N*m (122 kgf*cm, 9 ft.*lbf) for bolt B
HINT:
• Tighten bolt A first, and then bolt B.
• Each bolt length is indicated below.
Bolt length:
27 mm (1.06 in.) for bolt A
16 mm (0.63 in.) for bolt B
NOTICE:
Make sure to install the manual detent spring
and cover in this order.
59. INSTALL B-3 ACCUMULATOR PISTON
(a) Coat a new O-ring with ATF, and install it to the B-3
accumulator piston.
NOTICE:
Make sure that the O-ring is not twisted and that
it does not protrude abnormally from the
accumulator piston. Apply sufficient ATF before
installing the O-ring. The O-ring must be
installed in the correct position.
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D003561E01
D003560E01
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