TOYOTA RAV4 2006 Service Repair Manual

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–203
AX
(c) Remove the planetary carrier thrust washer from the
rear planetary sun gear.
54. REMOVE 1-WAY CLUTCH ASSEMBLY
(a) Remove the 1-way clutch and thrust needle roller
bearing from the transaxle case.
(b) Remove the 1-way clutch inner race from the 1-way
clutch.
55. REMOVE 1-WAY CLUTCH SLEEVE OUTER
(a) Remove the 1-way clutch sleeve outer from the
transaxle case.
56. REMOVE NO. 1 PLANETARY CARRIER THRUST
WASHER
(a) Remove the planetary carrier thrust washer from the
planetary gear.
D026393E05
D026598E06
D003909E02
D003589E03
D026394E07

AX–204U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
57. REMOVE 2ND BRAKE CLUTCH DISC
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 4 discs and 4 plates from the
transaxle case.
58. INSPECT 2ND BRAKE CLUTCH DISC (See page AX-
211)
59. REMOVE 2ND BRAKE PISTON ASSEMBLY
(a) Using a screwdriver, remove the snap ring.
(b) Remove the 2nd brake piston from the transaxle
case.
60. REMOVE REAR PLANETARY GEAR ASSEMBLY
(a) Using a screwdriver, remove the snap ring.
(b) Remove the rear planetary gear from the transaxle
case.
D026395E03
D008058E03
D026396E06
D003616E02
D026591E04

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–205
AX
61. REMOVE INPUT SUN GEAR
(a) Remove the 2 thrust needle roller bearings, thrust
bearing race and the input sun gear from the
transaxle case.
62. REMOVE 1ST AND REVERSE BRAKE CLUTCH DISC
(a) Remove the flange, 6 discs and 6 plates from the
transaxle case.
63. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC
(See page AX-211)
64. REMOVE FRONT PLANETARY GEAR ASSEMBLY
(a) Using a chisel and hammer, unstake the lock
washer.
NOTICE:
Push down all the claws of the washer.
Otherwise SST cannot be fully pressed against
the nut, and cannot loosen the nut.
(b) Using SST, remove the nut.
SST 09387-00030, 09387-00080
(c) Using SST and a press, press out the front
planetary gear from the counter drive gear.
SST 09950-60010 (09951-00450), 09950-70010
(09951-07100)
D003873E03
D026397E01
D003595E02
D003596E01
D026398E01

AX–206U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(d) Remove the front planetary gear from the brake
hub.
65. REMOVE FRONT PLANETARY RING GEAR
(a) Using a screwdriver, remove the snap ring and front
planetary ring gear from the brake hub.
66. REMOVE 1ST AND REVERSE BRAKE RETURN
SPRING SUB-ASSEMBLY
(a) Place SST on the return spring, and compress the
return spring with a press.
NOTICE:
Stop the press when the spring seat is lowered 1
to 2 mm (0.039 to 0.078 in.) from the snap ring
groove, to prevent the spring seat from being
deformed.
SST 09387-00070
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
Do not expand the snap ring excessively.
67. INSPECT 1ST AND REVERSE BRAKE RETURN
SPRING SUB-ASSEMBLY (See page AX-211)
68. REMOVE 1ST AND REVERSE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the transaxle case to remove the 1st and reverse
brake 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.
D026763E03
D003615E05
D003600E01
D026405E04

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–207
AX
(b) Remove the 2 O-rings from the 1st and reverse
brake piston.
69. REMOVE COUNTER DRIVE GEAR
(a) Using SST and a press, remove the counter drive
gear from the transaxle case.
SST 09950-60010 (09951-00590), 09950-70010
(09951-07100)
(b) As shown in the illustration, tighten the 2 bolts
evenly and make a clearance of approximately. 20.0
mm (0.787 in.) between the counter drive gear and
the inner race.
(c) Using SST, remove the tapered roller bearing.
SST 09950-60010 (09951-00590), 09950-00020,
09950-00030, 09950-40011 (09957-04010)
70. REMOVE TRANSFER DRIVEN PINION FRONT
BEARING
(a) Using a snap ring expander, remove the snap ring.
D026713E04
C089120E01
D003602E01
D003603E01
D026467E02

AX–208U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(b) Using SST and a press, press out the bearing outer
race.
SST 09950-60020 (09951-00910)
71. REMOVE NO. 2 BREATHER PLUG
72. REMOVE UNDERDRIVE BRAKE RETURN SPRING
SUB-ASSEMBLY
(a) Place SST on the return spring, and compress the
return spring with a press.
NOTICE:
Stop the press when the spring seat is lowered 1
to 2 mm (0.039 to 0.078 in.) from the snap ring
groove to prevent the spring seat from being
deformed.
SST 09387-00020
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
Do not expand the snap ring excessively.
73. INSPECT UNDERDRIVE BRAKE RETURN SPRING
SUB-ASSEMBLY (See page AX-211)
74. REMOVE UNDERDRIVE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the transaxle case to remove the underdrive
brake piston.
(b) Remove the 2 O-rings from the underdrive brake
piston.
C089121E01
D026407E02
D026406E03
D003794E02

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–209
AX
75. REMOVE NEEDLE ROLLER BEARING
(a) Using SST, remove the needle roller bearing from
the transaxle case.
SST 09387-00041 (09387-01010, 09387-01030,
09387-01040)
76. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Remove the 2 oil seal rings from the transaxle case.
77. REMOVE NO. 1 TRANSAXLE CASE PLUG
(a) Remove the 2 transaxle case plugs.
(b) Remove the 2 O-rings from the 2 plugs.
78. REMOVE UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Using SST, remove the underdrive cylindrical roller
bearing from the transaxle case.
SST 09514-35011
79. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Remove the oil seal ring from the transaxle housing.
D003605E01
D003914E04
D026383E01
D003606E01
D003915E09

AX–210U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
80. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Remove the bolt, transaxle apply tube clamp and
differential gear lube apply tube from the transaxle
housing.
NOTICE:
Do not bend the tubes.
INSPECTION
1. INSPECT MULTIPLE DISC CLUTCH HUB
(a) Using a caliper gauge, measure the inside diameter
of the forward clutch hub bushing.
Standard inside diameter:
23.03 to 23.05 mm (0.9067 to 0.9075 in.)
Maximum inside diameter:
23.09 mm (0.9091 in.)
NOTICE:
Check the contact surface of the bushing in the
direct clutch shaft. If any scratch or
discoloration is found, replace the direct clutch
sub-assembly with a new one.
If the inside diameter is greater than the maximum,
replace the forward clutch hub with a new one.
2. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC
(a) Check if the sliding surfaces of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
• If the lining of the disc comes off or is
discolored, or if a part of the groove is worn,
replace the all discs.
• Before installing new discs, immerse them in
ATF for at least 15 minutes.
3. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-
ASSEMBLY
(a) Using a caliper gauge, measure the inside diameter
of the forward clutch hub bushing.
Standard inside diameter:
23.025 to 23.046 mm (0.9065 to 0.9073 in.)
Maximum inside diameter:
23.09 mm (0.9091 in.)
NOTICE:
Check the contact surface of the bushing in the
direct clutch shaft. If any scratch or
discoloration is found, replace the direct clutch
sub-assembly with a new one.
If the inside diameter is greater than the maximum,
replace the forward clutch hub with a new one.
D026400E06
D003829E03
D009196E01
D003829E03

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–211
AX
4. INSPECT 2ND BRAKE CLUTCH DISC
(a) Check if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
• If the lining of the disc comes off or is
discolored, or if a part of the groove is worn,
replace all the discs.
• Before installing new discs, immerse them in
ATF for at least 15 minutes.
5. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC
(a) Check if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
• If the lining of the disc comes off or is
discolored, or if a part of the groove is worn,
replace all the discs.
• Before installing new discs, immerse them in
ATF for at least 15 minutes.
6. INSPECT 1ST AND REVERSE BRAKE RETURN
SPRING SUB-ASSEMBLY
(a) Using a vernier caliper, measure the free length of
the spring together with the spring seat.
Standard free length:
17.61 mm (0.6933 in.)
If the result is not as specified, replace the spring.
7. INSPECT UNDERDRIVE BRAKE RETURN SPRING
SUB-ASSEMBLY
(a) Using a vernier caliper, measure the free length of
the spring together with the spring seat.
Standard free length:
13.24 mm (0.5213 in.)
If the result is not as specified, replace the spring.
8. INSPECT PACK CLEARANCE OF 1ST AND
REVERSE BRAKE
(a) Using a vernier caliper, measure the distance
between the disc surface and the contact surface of
the 2nd brake cylinder and transaxle case
(Dimension A).
(b) Select an appropriate flange so that the pack
clearance will meet the specified value.
Standard pack clearance:
1.16 to 1.35 mm (0.0457 to 0.0531 in.)
D026717E01
D009189E01
D030852E09
D030852E09
D026452E01

AX–212U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
HINT:
Piston stroke = Dimension A - Flange thickness
Standard flange thickness
9. INSPECT PACK CLEARANCE OF 2ND BRAKE
(a) Using a vernier caliper, measure the distance
between the disc surface and snap ring surface
(Dimension B).
(b) Select an appropriate flange so that the pack
clearance will meet the specified value.
Standard pack clearance:
0.62 to 0.91 mm (0.0244 to 0.0358 in.)
HINT:
Piston stroke = Dimension B - Flange thickness -
Snap ring thickness 1.6 mm (0.063 in.)
Standard flange thickness
10. 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
11. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the underdrive clutch assembly 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.
Mark Thickness Mark Thickness
1 1.8 mm (0.071 in.) 5 2.2 mm (0.087 in.)
2 1.9 mm (0.075 in.) 6 2.3 mm (0.091 in.)
3 2.0 mm (0.079 in.) 7 2.4 mm (0.094 in.)
4 2.1 mm (0.083 in.) 8 2.5 mm (0.098 in.)
D026453E01
Mark Thickness Mark Thickness
1 3.0 mm (0.118 in.) 5 3.4 mm (0.134 in.)
2 3.1 mm (0.122 in.) 6 3.5 mm (0.138 in.)
3 3.2 mm (0.126 in.) 7 3.6 mm (0.142 in.)
4 3.3 mm (0.130 in.) - -
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