TOYOTA RAV4 2006 Service Repair Manual

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–237
AX
(b) Install the accumulator piston to the transaxle case.
(1) Coat the piston with ATF.
(2) Install the 2 springs to the piston, and install the
piston (with springs) to the transaxle case.
NOTICE:
Before installing the springs, check the
identification color of each spring. Standard
accumulator spring
Standard accumulator spring
60. INSTALL REVERSE CLUTCH ACCUMULATOR
PISTON
(a) Coat 2 new O-rings with ATF, and install them to the
reverse 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.
(b) Install the piston to the transaxle case.
(1) Coat the accumulator piston with ATF.
(2) Install the spring to the piston, and install the
piston (with spring) to the transaxle case.
NOTICE:
Before installing the spring, check the
identification color of the spring.
Standard accumulator spring
61. INSTALL C-3 ACCUMULATOR PISTON
(a) Coat a new O-ring with ATF, and install it to the C-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.
D025512E02Spring Free length /
Outer diameterIdentification Color
Inner Inner 62.00 mm (2.4409
in.) /
15.50 mm (0.610 in.)Purple
Outer Outer 74.23 mm (2.9224
in.) /
21.70 mm (0.8543 in.)
D026402E09
C092978E03Free length
Outer diameterIdentification Color
60.96 mm (2.3999 in.) /
14.10 mm (0.5551 in.)Yellow
D003902E02

AX–238U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(b) Install the piston to the transaxle case and coat the
piston with ATF.
(c) Install the spring to the C-3 accumulator piston.
(d) Install the spring to the C-3 accumulator piston.
NOTICE:
Before installing the spring, check the
identification color of the spring.
Standard accumulator spring
62. INSTALL CHECK BALL BODY
(a) Coat the check ball body with ATF.
(b) Install the check ball body and spring.
NOTICE:
Be sure to place the spring in the hole in the
check ball body. Be careful of the direction of
the parts.
63. INSTALL BRAKE DRUM GASKET
(a) Coat a new brake drum gasket with ATF, and install
it to the transaxle case.
NOTICE:
Be sure not to damage the lip of the transaxle
case brake gasket when inserting the gasket to
the case. Apply sufficient ATF to the gasket
before installation. Be careful of the direction of
parts.
64. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with
ATF, and install it to the transaxle case.
NOTICE:
Be sure not to damage the lip of the transaxle
case brake gasket when inserting the gasket to
the case. Apply sufficient ATF to the gasket
before installation. Be careful of the direction of
parts.
C083146E01
D003555E01
Free length
Outer diameterColor
72.20 mm (2.8425 in.) /
19.0 mm (0.748 in.)Colorless
D003554E02
C083129E01
C083128E01

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–239
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65. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Coat a new governor apply gasket with ATF, and
install it to the transaxle case.
NOTICE:
Be sure not to damage the lip of the transaxle
case brake gasket when inserting the gasket to
the case. Apply sufficient ATF to the gasket
before installation. Be careful of the direction of
parts.
66. INSTALL TRANSMISSION WIRE
(a) Coat a new O-ring with ATF, and install it to the
transmission wire.
NOTICE:
Make sure that the O-ring is not twisted,
protruded, or pinched when installing the wire
transmission to the transaxle case. Apply
sufficient ATF to the O-ring before installation.
(b) Install the transmission wire retaining bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
67. CONNECT TRANSMISSION WIRE
(a) Coat the O-ring of the ATF temperature sensor with
AT F.
(b) Apply ATF to the bolt.
(c) Install the ATF temperature sensor with the lock
plate and bolt.
Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
(d) Connect the 7 solenoid valve connectors.
68. INSTALL TRANSMISSION VALVE BODY ASSEMBLY
(a) Apply ATF to the 17 bolts.
(b) While positioning the manual valve lever position,
install the valve body to the transaxle case with the
17 bolts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
25.0 mm (0.984 in.) for bolt A
57.0 mm (2.244 in.) for bolt B
41.0 mm (1.614 in.) for bolt C
C083127E01
D003636E02
D003547E07
C091927E07
C091933E02

AX–240U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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NOTICE:
• Push the valve body against the accumulator
piston spring and the check ball body to
install the valve body.
• When installing the valve body to the
transaxle case, do not hold the solenoids.
• Temporarily tighten the bolts marked with (1)
in the illustration first because they are
positioning bolts.
69. INSTALL VALVE BODY OIL STRAINER ASSEMBLY
(a) Coat a new O-ring with ATF and install it to the oil
strainer.
NOTICE:
Make sure that the O-ring is not twisted or
pinched. Apply sufficient ATF to the O-ring
before installation.
(b) Apply ATF to the 3 bolts.
(c) Install the oil strainer to the valve body with the 3
bolts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
70. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-
ASSEMBLY
(a) Install the 2 magnets to the oil pan.
(b) Install the oil pan and a new oil pan gasket to the
transaxle case with the 18 bolts.
Torque: 7.6 N*m (77 kgf*cm, 67 in.*lbf)
NOTICE:
Completely remove any oil or grease from the
contact surface of the transaxle case and the oil
pan with the gasket before installing the oil pan
to the case.
C091932E02
C091931E02
C086316E03
C091925E01

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–241
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71. 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)
72. INSTALL SPEEDOMETER DRIVEN HOLE COVER
SUB-ASSEMBLY
(a) Coat a new O-ring with ATF, and install it to the
cover.
(b) Install the cover with the bolt.
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
73. INSTALL SPEED SENSOR
(a) Coat 2 new O-rings with ATF and install them to the
2 sensors.
(b) Install the 2 sensors to the transaxle case with the 2
bolts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
74. INSTALL OIL COOLER INLET TUBE ELBOW
(a) Coat a new O-ring with ATF, and install it to the
elbow.
(b) Install the elbow to the transaxle case.
Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf)
75. INSTALL OIL COOLER OUTLET TUBE ELBOW
(a) Coat a new O-ring with ATF, and install it to the
elbow.
(b) Install the elbow to the transaxle case.
Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf)
76. INSTALL BREATHER PLUG HOSE
(a) Install the breather plug hose to the transaxle case
firmly.
C136368
D030672E06
C136372E01
C136373E01

AX–242U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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77. INSTALL PARK/NEUTRAL POSITION SWITCH
ASSEMBLY
(a) Install the switch to the manual valve shaft.
(b) Temporarily install the 2 bolts.
(c) Install a new lock washer 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 and 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)
(i) Using a screwdriver, stake the nut with the lock
washer.
D009639E02
C140282
C140281
D009642E01
D009643E02

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–243
AX
(j) Install the control shaft lever with the washer and
nut.
Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
78. INSTALL SPEEDOMETER DRIVEN HOLE COVER
SUB-ASSEMBLY
(a) Coat a new O-ring with ATF and install it to the
speedometer driven hole cover.
(b) Install the bolt and hole cover to the transaxle.
Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
C140280

AX–248U151E AUTOMATIC TRANSAXLE – OIL PUMP
AX
REASSEMBLY
1. INSTALL FRONT OIL PUMP OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal to
the oil pump body.
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 MP grease.
2. INSTALL FRONT OIL PUMP BODY O-RING
(a) Coat a 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.
• 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 T30 "torx" socket, install the 11 bolts.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
D003654E01
C055817E03
C119012E05
D009206E13
D003651E01

U151E AUTOMATIC TRANSAXLE – OIL PUMPAX–249
AX
6. INSTALL CLUTCH DRUM OIL SEAL RING
(a) Coat 2 new 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 (See page AX-246)
D026627E02

AX–252U151E AUTOMATIC TRANSAXLE – SECOND BRAKE PISTON
AX
REASSEMBLY
1. INSTALL 2ND BRAKE PISTON O-RING
(a) Coat 2 new O-rings with ATF, and install them in the
2nd brake piston.
NOTICE:
Make sure that the O-ring is not twisted or
pinched.
2. INSTALL 2ND BRAKE PISTON
(a) Coat the 2nd brake piston with ATF, and install it to
the 2nd brake cylinder.
NOTICE:
Be careful not to damage the O-ring.
3. INSTALL 2ND BRAKE PISTON RETURN SPRING
SUB-ASSEMBLY
(a) Install the 2nd brake piston return spring.
NOTICE:
After installing the spring, check that all of the
springs fit in the piston correctly.
(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.
(d) 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 a position 1 to 2 mm (0.039 to 0.078 in.) from
the snap ring groove. This prevents the spring
seat from being deformed.
D026706E03
D026775E01
D026704E04
D026703E02