TOYOTA RAV4 2006 Service Repair Manual

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–223
AX
21. INSTALL SECOND BRAKE PISTON ASSEMBLY
(a) Install the second brake piston to the transaxle
case.
(b) Install the snap ring and measure the inside
diameter.
Inside diameter:
Greater than 167 mm (6.57 in.)
NOTICE:
• Make sure that the taper snap ring is installed
in the correct direction.
• When the diameter does not meet the
specified value, replace the snap ring with a
new one.
• After installing the snap ring, confirm that
there is no clearance between the 2nd brake
cylinder and the fitting surface of the cylinder
in the transaxle case.
22. INSTALL 1-WAY CLUTCH SLEEVE OUTER
(a) Install the 1-way clutch sleeve outer to the 2nd
brake cylinder.
NOTICE:
Make sure that the outer sleeve is installed in
the correct direction.
23. INSTALL 1-WAY CLUTCH ASSEMBLY
(a) Install the 1-way clutch inner race to the 1-way
clutch.
NOTICE:
• Make sure that the inner race is installed in
the correct direction.
• Confirm that the discrimination mark is
visible.
D026396E06
D008058E03
C092977E04
D003909E02

AX–224U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(b) Check that the 1-way clutch locks when turned
clockwise and rotates freely when turned
counterclockwise as shown in the illustration..
HINT:
If the result is not as specified, replace the 1-way
clutch.
(c) Install the 1-way clutch and thrust needle roller
bearing to the 1-way clutch sleeve outer.
Standard bearing diameter
NOTICE:
Install the thrust bearing properly so that the
non-colored race will be visible.
24. INSTALL NO. 1 PLANETARY CARRIER THRUST
WA S HE R
(a) Coat the planetary carrier thrust washer with yellow
petrolatum, and install the washer onto the
planetary sun gear.
NOTICE:
After installing the washer, confirm that the
projection of the washer is fixed firmly in the
hole of the planetary sun gear.
25. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY
(a) Coat the planetary carrier thrust washer with yellow
petrolatum, and install the washer onto the rear
planetary sun gear.
(b) Coat the bearing with yellow petrolatum, and install
the bearing onto the rear planetary sun gear.
Standard bearing diameter
D009638E03
D003588E02
Item Inside Outside
Bearing 53.6 mm (2.110 in.) 69.4 mm (2.732 in.)
D026394E07
D026393E05
D026404E07
Item Inside Outside
Race 33.0 mm (1.299 in.) 45.4 mm (1.787 in.)
Bearing 31.85 mm (1.254 in.) 45.2 mm (1.78 in.)

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–225
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(c) Install the rear planetary sun gear to the rear
planetary gear.
NOTICE:
After installing the rear planetary sun gear, make
sure that the B1 discs are engaged.
26. INSTALL 2ND BRAKE CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the
transaxle case.
(c) Temporarily install the snap ring.
27. 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 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
(c) Temporarily remove the snap ring, attach the
selected flange and reinstall the snap ring.
NOTICE:
Secure the snap ring so that the ends are visible
through the groove of the transaxle case.
D026714E05
C136371E01
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.) 8 -
D003623E02

AX–226U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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28. INSTALL OVERDRIVE DIRECT CLUTCH HUB SUB-
ASSEMBLY
(a) Install the direct clutch hub to the planetary gear.
NOTICE:
Be careful not to damage the bushing inside the
overdrive clutch hub during installation.
(b) Coat the thrust bearing with ATF.
(c) Install the bearing race and the thrust bearing to the
direct clutch hub.
NOTICE:
Be careful not to drop the bearing when it is
installed.
Standard bearing and race diameter
29. INSTALL DIRECT CLUTCH ASSEMBLY
(a) Coat the thrust bearing with ATF.
(b) Install the direct clutch and thrust bearing to the rear
planetary sun gear.
NOTICE:
The disc in the direct clutch should completely
match with the hub attached outside the rear
planetary sun gear. Otherwise, the rear cover
cannot be installed.
(c) Clean the connecting part of the transaxle case and
the rear cover.
(d) As shown in the illustration, place a straightedge on
the direct clutch drum and measure the distance
between the transaxle case and the straightedge
using a vernier caliper (Dimension D).
(e) Using a vernier caliper and straightedge, measure
the dimension shown in the illustration.
(f) Calculate the end play value using the following
formula. Select a thrust bearing which satisfies the
end play value and install the selected bearing.
Standard end play:
0.244 to 0.901 mm (0.0096 to 0.0355 in.)
NOTICE:
Make sure that the non-collared race side is
facing the direct clutch.
HINT:
End play = Dimension D - Dimension C
Standard bearing thickness and diameter
D026392E09
Item Inside Outside
Bearing 24.7 mm (0.972 in.) 39.5 mm (1.555 in.)
Race 23.6 mm (0.929 in.) 38.0 mm (1.496 in.)
D026403E06
D026469E02
D026470E01
Thickness Inside Outside
3.6 mm (0.1417 in.) 56.3 mm (2.217 in.) 75.7 mm (2.980 in.)

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–227
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30. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Install 3 new governor apply gaskets to the
transaxle case.
31. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.
NOTICE:
Make sure to install the clamp to the apply tube
before installing the apply tube to the transaxle
case. This prevents the apply tube from being
deformed or damaged.
(b) Install the clutch apply tube.
(c) Install the brake apply tube to the transaxle case
with a bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
NOTICE:
The tube should be securely inserted until it
reaches the stopper.
32. INSTALL NEEDLE ROLLER BEARING
(a) Using SST and a press, press the needle roller
bearing into the transaxle rear cover.
SST 09950-60010 (09951-00230, 09952-06010)
Standard depth:
20.55 to 21.25 mm (0.8091 to 0.8366 in.)
NOTICE:
• The engraved mark side of the bearing
should face upward.
• Continue pressing until the specified value is
obtained.
(b) Coat a needle roller bearing with ATF.
33. INSTALL REAR CLUTCH OIL SEAL RING OUTER
(a) Coat 3 new rear clutch oil seal rings with ATF, and
install them to the transaxle rear cover.
NOTICE:
The snap ring should be fully engaged in the
groove of the drum.
3.8 mm (0.1496 in.) 56.3 mm (2.217 in.) 75.7 mm (2.980 in.) Thickness Inside Outside
D026390E01
D026391E05
D026766E01
D026389E03

AX–228U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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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 seal packing 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 bolt threads of bolt A.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or Equivalent
(d) Install the 11 bolts.
Torque: 19 N*m (190 kgf*cm, 14 ft.*lbf) for bolt A
25 N*m (250 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.
C138647
C138665E01
C136369E01
D026414E01

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–229
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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
D003907E02

AX–230U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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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.)
D009691E03

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–231
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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:
• Check the position and number of the
grooves on each end face of the differential
drive pinion gear.
• Fully engage all the discs of underdrive
clutch and hub splines of the underdrive
planetary gear and install them securely.
(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
D003576E03
D003875E01

AX–232U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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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.)