TOYOTA RAV4 2006 Service Repair Manual

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–177
AX
46. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Remove the 2 oil seal rings from the transaxle.
47. REMOVE NO. 1 TRANSAXLE CASE PLUG
(a) Remove the 2 plugs from the transaxle rear cover.
(b) Remove the 2 O-rings from the 2 plugs.
48. REMOVE REAR TRANSAXLE COVER SUB-
ASSEMBLY
(a) Remove the 11 bolts.
(b) Tap the circumference of the rear cover with a
plastic-faced hammer to remove the transaxle rear
cover from the transaxle.
(c) Remove the 2 outer rear clutch oil seal rings from
the transaxle rear cover.
(d) Using a T30 ''torx'' socket wrench, remove the 2
screws and transaxle rear cover plate.
D003914E04
C134984
D009943E02
D009184E01
C083140E01

AX–178U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(e) Using SST, remove the needle-roller bearing from
the transaxle rear cover.
SST 09387-00041 (09387-01010, 09387-01030,
09387-01040)
49. 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.
50. REMOVE BRAKE APPLY TUBE
(a) Remove the bolt, clamp and 2 brake apply tubes.
(b) Remove the brake apply tube from the clamp.
51. REMOVE FRONT CLUTCH APPLY TUBE
52. REMOVE NO. 1 GOVERNOR APPLY GASKET
(a) Using a screwdriver, remove the 2 governor apply
gaskets.
D003801E01
D003799E02
D003794E02
D025510E01
D003591E01

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–179
AX
53. REMOVE DIRECT CLUTCH ASSEMBLY
(a) Remove the thrust bearing and direct clutch from
the transaxle.
(b) Remove the bearing race from the direct clutch.
54. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY
(a) Remove the rear planetary sun gear from the
transaxle.
(b) Remove the rear planetary sun gear thrust bearing
from the rear planetary sun gear.
(c) Remove the No. 1 thrust washer and 1-way clutch
thrust bearing from the rear planetary sun gear.
D003586E01
D008053E01
D003587E01
D003791E01
D008054E01

AX–180U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
55. REMOVE 1-WAY CLUTCH ASSEMBLY
(a) Remove the 1-way clutch from the transaxle.
(b) Remove the 1-way clutch inner race from the 1-way
clutch.
56. REMOVE 1-WAY CLUTCH SLEEVE OUTER
57. REMOVE 2ND BRAKE CLUTCH DISC
(a) Using a screwdriver, remove the 2nd brake hole
snap ring.
(b) Remove the flange, 3 discs and 3 plates from the
transaxle.
58. INSPECT 2ND BRAKE CLUTCH DISC (See page AX-
186)
59. REMOVE 2ND BRAKE PISTON ASSEMBLY
(a) Using a screwdriver, pry out the snap ring.
D008055E01
D003909E02
D003589E03
C129388
D008058E03

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–181
AX
(b) Remove the 2nd brake piston from the transaxle.
60. REMOVE 1ST AND REVERSE BRAKE CLUTCH DISC
(a) Remove the flange, 5 discs and 5 plates from the
transaxle.
61. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC
(See page AX-186)
62. REMOVE REAR PLANETARY GEAR ASSEMBLY
(a) Using a screwdriver, pry out the snap ring from the
brake hub.
(b) Remove the rear planetary gear from the transaxle.
(c) Remove the thrust washer from the rear planetary
gear.
D008059E01
D009941E01
D003616E02
D008062E01
D003910E01

AX–182U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(d) Remove the thrust bearing race from the rear
planetary gear.
63. REMOVE INPUT SUN GEAR
(a) Remove the 2 thrust bearings, bearing race and
input sun gear from the transaxle.
64. REMOVE FRONT PLANETARY GEAR ASSEMBLY
(a) Using a chisel and hammer, unstake the lock
washer.
NOTICE:
Push down all 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, remove the front planetary
gear from the counter drive gear.
SST 09950-60010 (09951-00450)
D003593E01
D003873E03
D003595E02
D003596E01
D003597E01

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–183
AX
(d) Remove the front planetary gear from the brake
hub.
65. REMOVE FRONT PLANETARY RING GEAR
(a) Using a screwdriver, pry out the brake hub snap ring
and front planetary ring gear from the brake hub.
66. REMOVE 1ST AND REVERSE BRAKE PISTON
(a) Using SST, a press and ring expander, remove the
snap ring and piston return spring.
SST 09387-00070
NOTICE:
• Stop the press when the spring sheet is
lowered 1 to 2 mm (0.039 to 0.078 in.) from the
snap ring groove, preventing the spring sheet
from deforming.
• Do not expand the snap ring excessively.
(b) Remove the 1st and reverse brake return spring
from the 1st and reverse brake piston.
(c) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the transaxle 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 with your hand using a waste
cloth.
• Make sure not to spatter ATF when applying
compressed air.
D008063E01
D003615E03
D003600E01
D008061E01
D003800E01

AX–184U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(d) Remove the 2 O-rings from the 1st and reverse
brake piston.
67. INSPECT 1ST AND REVERSE BRAKE RETURN
SPRING SUB-ASSEMBLY (See page AX-186)
68. REMOVE COUNTER DRIVE GEAR
(a) Using SST and a press, press out the counter drive
gear from the transaxle.
SST 09950-60010 (09951-00600), 09950-70010
(09951-07100)
(b) As shown in the illustration, tighten the 2 bolts
evenly and make a clearance of approximately. 20.0
mm (0.797 in.) between the counter drive gear and
the inner race.
(c) Using SST, remove the tapered roller bearing.
SST 09950-60010 (09951-00600), 09950-40011
(09951-04010, 09952-04010, 09953-04020,
09954-04010, 09955-04011, 09958-04011)
(d) Using a brass bar and hammer, tap out the 2
counter drive gear bearing outer races from the
transaxle.
D003913E01
D003601E01
D003602E01
D003603E02
D003798E01

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–185
AX
69. REMOVE COUNTER DRIVE GEAR HOLE SNAP RING
(a) Using a screwdriver, pry out the snap ring from the
transaxle.
70. REMOVE NO. 2 BREATHER PLUG
71. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Remove the bolt, the transaxle apply tube clamp
and the differential gear lube apply tube from the
transaxle.
INSPECTION
1. INSPECT AUTOMATIC TRANSAXLE OIL PAN SUB-
ASSEMBLY
(a) Remove the magnets and use them to collect any
steel chips. Examine the clips and particles in the
pan and on the magnet to determine what type of
wear has occurred in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non-magnetic): bush wear
2. INSPECT INPUT SHAFT END PLAY
(a) Fix the transaxle case with the oil pump side facing
up.
(b) Using a dial indicator, measure the input shaft end
play.
Standard end play:
0.26 to 1.25 mm (0.0103 to 0.0492 in.)
D003604E01
D003607E01
AT00103E01
D008046E01

AX–186U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
3. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC
Check to see 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 is peeling off or discolored,
or even if a part of the groove is defaced, replace
all discs.
• Before assembling new discs, soak them in ATF
for at least 15 minutes.
4. INSPECT UNDERDRIVE BRAKE RETURN SPRING
SUB-ASSEMBLY
(a) Using a vernier caliper, measure the free length of
the underdrive brake return spring together with the
spring seat.
Standard free length:
14.04 mm (0.5213 in.)
5. INSPECT 2ND BRAKE CLUTCH DISC
(a) Check to see 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 is peeling off or
discolored, or even if a part of the printed
number is defaced, replace all discs.
• Before assembling new discs, soak them in
ATF for at least 15 minutes.
6. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC
(a) Check to see 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 is peeling off or
discolored, or even if a part of the groove is
defaced, replace all discs.
• Before assembling new discs, soak them in
ATF for at least 15 minutes.
7. INSPECT 1ST AND REVERSE BRAKE RETURN
SPRING SUB-ASSEMBLY
(a) Using a vernier caliper, measure the free length of
the 1st and reverse brake return spring together
with the spring seat.
Standard free length:
15.51 mm (0.6106 in.)
D009196E01
D003806E01
D004083E01
D009189E01
D003811E01