TOYOTA RAV4 2006 Service Repair Manual

AX–12U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
NEXT
(a) Refer to the ROAD TEST (see page AX-13).
Result
B
A
(a) Refer to the ELECTRONIC CIRCUIT INSPECTION
PROCEDURE (see page IN-37).
NEXT
(a) Refer to the DTC CHECK / CLEAR (see page AX-33).
Result
B
A
(a) Refer to the AUTOMATIC TRANSMISSION FLUID (see
page AX-126).
(b) Refer to the PARK/NEUTRAL POSITION SWITCH (see
page AX-132).
(c) Refer to the FLOOR SHIFT ASSEMBLY (see page AX-
162).
NG
OK
(a) Refer to the MECHANICAL SYSTEM TESTS (see page
AX-16).
8PROBLEM SYMPTOM CONFIRMATION
Result Proceed to
Symptom does not occur A
Symptom occurs B
GO TO STEP 10
9SYMPTOM SIMULATION
10DTC CHECK*
Result Proceed to
DTC is not output A
DTC is output B
GO TO STEP 18
11BASIC INSPECTION
GO TO STEP 21
12MECHANICAL SYSTEM TESTS

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–13
AX
NG
OK
(a) Refer to the HYDRAULIC TEST (see page AX-18).
NG
OK
(a) Refer to the MANUAL SHIFTING TEST (see page AX-
19).
NG
OK
(a) Refer to the PROBLEM SYMPTOMS TABLE (see page
AX-23).
NG
OK
(a) Refer to the PROBLEM SYMPTOMS TABLE (see page
AX-23).
NEXT
NG
OK
(a) Refer to the DIAGNOSTIC TROUBLE CODE CHART
(see page AX-40).
NEXTGO TO STEP 17
13HYDRAULIC TEST
GO TO STEP 17
14MANUAL SHIFTING TEST
GO TO STEP 16
15PROBLEM SYMPTOMS TABLE CHAPTER 1
GO TO STEP 19
16PROBLEM SYMPTOMS TABLE CHAPTER 2
17PART INSPECTION
GO TO STEP 21
18DTC CHART

AX–14U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
NEXT
NEXT
NEXT
NEXT
19CIRCUIT INSPECTION
20IDENTIFICATION OF PROBLEM
21REPAIR OR REPLACE
22CONFIRMATION TEST
END

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–15
AX
ROAD TEST
1. PROBLEM SYMPTOM CONFIRMATION
(a) Based on the result of the customer problem
analysis, try to reproduce the symptoms. If the
problem is that the transaxle does not shift up, shift
down, or the shift point is too high or too low,
conduct the following road test referring to the
automatic shift schedule and simulate the problem
symptoms.
2. ROAD TEST
NOTICE:
Perform the test at the normal operating ATF
temperature of 50 to 80
C (122 to 176F).
(a) D position test:
Move the shift lever to D and fully depress the
accelerator pedal. Check the following:
(1) Check up-shift operation.
Check that the 1
2, 2 3, 3 4 and 4 5th
up-shifts take place at the shift point shown in
the automatic shift schedule (see page SS-49).
HINT:
5th Gear Up-shift Prohibition Control
• Engine coolant temperature is 55
C (131F)
or less and vehicle speed is at 80 km/h (50
mph) or less.
• ATF temperature is -2
C (28F) or less.
4th Gear Up-shift Prohibition Control
• Engine coolant temperature is 47
C (117F)
or less and vehicle speed is at 55 km/h (34
mph) or less.
5th and 4th Gear Lock-up Prohibition Control
• Brake pedal is depressed.
• Accelerator pedal is released.
• Engine coolant temperature is 60
C (140F)
or less.
(2) Check for shift shock and slip.
Check for shock and slip at the 1
2, 2 3, 3
4 and 4 5th up-shifts.
(3) Check for abnormal noise and vibration.
Check for abnormal noise and vibration when
up-shifting from 1
2, 2 3, 3 4 and 4
5th while driving with the shift lever on D, and
check while driving in the lock-up condition.
HINT:
The check for the cause of abnormal noise and
vibration must be done thoroughly as it could
also be due to loss of balance in the differential,
torque converter clutch, etc.

AX–16U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
(4) Check kick-down operation.
While driving the vehicle in the 2nd, 3rd, 4th and
5th gears with the shift lever on D, check that the
possible kick-down vehicle speed limits for 2

1, 3
2, 4 3 and 5 4 kick-downs conform
to those indicated in the automatic shift schedule
(see page SS-49).
(5) Check for abnormal shock and slip at kick-down.
(6) Check the lock-up mechanism.
• Drive the vehicle in the 5th gear with the shift
lever on D. Maintain a steady speed (lock-up
ON).
• Lightly depress the accelerator pedal and
check that the engine speed does not change
abruptly.
HINT:
• There is no lock-up in the 1st, 2nd and 3rd
gear.
• 4th lock-up operates while uphill-downhill
control is active with the shift lever on D.
• If there is a sudden increase in engine speed,
there is no lock-up.
(b) 4 (O/D OFF) position test:
Move the shift lever to 4 and fully depress the
accelerator pedal. Check the following:
(1) Check up-shift operation.
Check that the 1
2, 2 3 and 3 4 up-shifts
take place and that the shift point conforms to
the automatic shift schedule (see page SS-49).
HINT:
There is no 5th up-shift in the 4 position.
(2) Check engine braking.
While driving the vehicle in the 4th gear with the
shift lever on 4, release the accelerator pedal
and check the engine braking effect.
(3) Check for abnormal noise during acceleration
and deceleration, and for shock at up-shift and
down-shift.
(c) 3 position test:
Move the shift lever to 3 and fully depress the
accelerator pedal. Check the following:
(1) Check up-shift operation.
Check that the 1
2 and 2 3 up-shifts take
place and that the shift point conforms to the
automatic shift schedule (see page SS-49).
HINT:
There is no 3rd up-shift and lock-up in the 3
position.
(2) Check engine braking.
While driving the vehicle in the 3rd gear with the
shift lever on 3, release the accelerator pedal
and check the engine braking effect.

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–17
AX
(3) Check for abnormal noise during acceleration
and deceleration, and for shock at up-shift and
down-shift.
(d) 2 position test:
Move the shift lever to 2 and fully depress the
accelerator pedal. Check the following:
(1) Check up-shift operation.
Check that the 1
2 up-shifts take place and
that the shift point conforms to the automatic
shift schedule (see page SS-49).
HINT:
There is no 3rd up-shift and lock-up when the
shift lever is on 2.
(2) Check engine braking.
While driving the vehicle in the 2nd gear with the
shift lever on 2, release the accelerator pedal
and check the engine braking effect.
(3) Check for abnormal noise during acceleration
and deceleration, and for shock at up-shift and
down-shift.
(e) L position test:
Move the shift lever to L and fully depress the
accelerator pedal. Check the following:
(1) Check no up-shift.
While driving the vehicle with the shift lever on L,
check that there is no up-shift to 2nd gear.
HINT:
There is no lock-up in L.
(2) Check engine braking.
While driving the vehicle with the shift lever on L,
release the accelerator pedal and check the
engine braking effect.
(3) Check for abnormal noises during acceleration
and deceleration.
(f) R position test:
Move the shift lever to R and lightly depress the
accelerator pedal. Check that the vehicle moves
backward without any abnormal noise or vibration.
CAUTION:
Before conducting this test, ensure that no
people or obstacles are in the test area.
(g) P position test:
Stop the vehicle on an incline (more than 5
). Then
move the shift lever to P and release the parking
brake. Check that the parking lock pawl holds the
vehicle in place.
(h) Uphill/downhill control function test:
(1) Check that the gear does not up-shift to the 4th
or 5th gear while the vehicle is driving uphill.
(2) Check that the gear automatically down-shifts
from 5
4 or from 4 3 when the brake is
applied while the vehicle is driving downhill.

AX–18U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
MECHANICAL SYSTEM TESTS
1. STALL SPEED TEST
HINT:
This test is to check the overall performance of the
engine and transaxle.
NOTICE:
• Do not perform the stall speed test longer than 10
seconds.
• To ensure safety, perform this test in an open and
level area that provides good traction.
• The stall speed test should always be performed
with at least 2 people. One person should observe
the condition of the wheels and wheel chocks
while the other is performing the test.
(a) Connect the intelligent tester to the CAN VIM. Then
connect the CAN VIM to the DLC3.
(b) Run the vehicle until the transmission fluid
temperature has reached 50 to 80
C (122 to 176F).
(c) Allow the engine to idle with the air conditioning
OFF.
(d) Chock all 4 wheels.
(e) Set the parking brake and keep the brake pedal
depressed firmly with your left foot.
(f) Move the shift lever to the D position.
(g) Depress the accelerator pedal as much as possible
with your right foot.
(h) Read the engine rpm (stall speed) and release the
accelerator pedal immediately.
Standard value:
2,450 to 2,750 rpm
Evaluation:
NOTICE:
Perform the test at the normal operating ATF
temperature of 50 to 80
C (122 to 176F).
2. SHIFT TIME LAG TEST
HINT:
This test is to check the condition of the direct clutch,
forward clutch, 1st brake and reverse brake.
(a) Connect the intelligent tester to the CAN VIM. Then
connect the CAN VIM to the DLC3.
(b) Run the vehicle until the transmission fluid
temperature has reached 50 to 80
C (122 to 176F).
Test Result Possible Cause
Stall speed is lower than standard value • Engine power output may be insufficient
• Stator one-way clutch not operating properly
HINT:
If the value is less than the specified value by 600 rpm or more, the
torque converter could be faulty.
Stall speed is higher than standard value • Line pressure is too low
• Forward clutch slipping
• U/D (underdrive) brake slipping
• U/D (underdrive) one-way clutch is not operating properly
• No. 1 one-way clutch not operating properly
• Improper fluid level

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–19
AX
(c) Allow the engine to idle with the air conditioning
OFF.
(d) Set the parking brake and keep the brake pedal
depressed firmly.
(e) Check the D range time lag.
(1) Move the shift lever to N and wait for 1 minute.
(2) Move the shift lever to D and measure the time
until the shock is felt.
(3) Repeat the 2 procedures above 3 times, and
calculate the average time of the 3 tests.
(f) Check the R range time lag.
(1) Move the shift lever to N and wait for 1 minute.
(2) Move the shift lever to R and measure the time
until the shock is felt.
(3) Repeat the 2 procedures above 3 times, and
calculate the average time of the 3 tests.
Standard value:
D range time lag is less than 1.2 seconds
R range time lag is less than 1.5 seconds
Evaluation:
Test Result Possible Cause
D range time lag exceeds standard value • Line pressure is too low
• Forward clutch worn
• No. 1 one-way clutch is not operating properly
• U/D (underdrive) one-way clutch is not operating
• U/D (underdrive) brake worn
R range time lag exceeds standard value • Line pressure is too low
• Reverse clutch worn
• 1st and reverse brake worn
• U/D (underdrive) brake worn

AX–20U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
HYDRAULIC TEST
1. PERFORM HYDRAULIC TEST
(a) Measure the line pressure.
NOTICE:
• Perform the test at the normal operating ATF
temperature: 50 to 80
C (122 to 176F).
• The line pressure test should always be
performed with at least 2 people. One person
should observe the condition of the wheels or
wheel chocks while the other is performing
the test.
• Be careful to prevent SST's hose from
interfering with the exhaust pipe.
• This test must be performed after checking
and adjusting the engine.
• Perform the test with the A/C OFF.
• When conducting the stall test, do not
continue for more than 10 seconds.
(1) Warm up the ATF (Automatic Transmission
Fluid).
(2) Lift the vehicle up.
(3) Remove the engine under cover.
(4) Connect the intelligent tester to the DLC3.
(5) Remove the test plug A on the transaxle case
front left side and install SST.
SST 09992-00095 (09992-00231, 09992-
00271)
NOTICE:
There is a difference between the installation
point of the D position and R position.
(6) Start the engine.
(7) Using intelligent tester, shift to D position and
hold 3rd gear by active test, and measure the
line pressure in idling.
Specified line pressure:
(8) Turn the ignition switch off.
(9) Disconnect the connector of the transmission
wire.
HINT:
Disconnect the connector only when performing
the position stall test.
(10)Start the engine.
(11)Firmly depress the brake pedal, shift to the D
position, depress the accelerator pedal all the
way down and check the line pressure while the
stall test is performed.
Specified line pressure:
C136760E02
Condition
D position kPa (kgf/cm2, psi)
Idling 372 to 412 kPa
(3.8 to 4.2 kgf/cm
2, 54 to 60 psi)
Condition
D position kPa (kgf/cm
2, psi)
Stall test 931 to 1,031 kPa
(9.5 to 10.5 kgf/cm
2, 135 to 150 psi)

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–21
AX
(12)Turn the ignition switch off.
(13)Remove SST, and install the test plug A.
(14)Remove the test plug B, install SST and start
the engine.
SST 09992-00095 (09992-00231, 09992-
00271)
(15)Connect the transmission wire connector,
depress the brake pedal firmly, shift to the R
position and check the line pressure while the
engine is idling and during the stall test.
Specified line pressure:
(16)Remove SST, and install the test plug B.
(17)Clear the DTC.
Evaluation:
Condition
R position kPa (kgf/cm2, psi)
Idling 672 to 742 kPa
(6.9 to 7.6 kgf/cm
2, 97 to 108 psi)
Stall test 1,768 to 1,968 kPa
(18.0 to 20.0 kgf/cm
2, 256 to 285 psi)
Problem Possible cause
Measured values at all positions are higher than specified • Shift solenoid valve SLT defective
• Regulator valve defective
Measured values at all positions are lower than specified • Shift solenoid valve SLT defective
• Regulator valve defective
• Oil pump defective
• U/D (underdrive) direct clutch defective
Pressure is low when shift lever is on D only • D position circuit fluid leak
• Forward clutch defective
Pressure is low when shift lever is on R only • R position circuit fluid leak
• Reverse clutch defective
• 1st and reverse brake defective