TOYOTA RAV4 2006 Service Repair Manual

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–197
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Standard flange thickness
(e) Temporarily remove the snap ring, attach the
selected flange and restore the snap ring.
NOTICE:
Secure the snap ring so that its gap is visible
through the groove of the transaxle case.
17. INSTALL DIRECT CLUTCH
(a) Install the bearing race to the direct clutch.
Standard bearing diameter
(b) Install the direct clutch and thrust needle roller
bearing to the rear planetary sun gear.
NOTICE:
The disc in the direct clutch should completely
align with the hub attached outside the rear
planetary sun gear. Otherwise, the rear cover
cannot be installed.
(c) Clean the connector part of the transaxle case and
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 B).
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
D003802E01
Item Inside Outside
Bearing race 30.3 mm (1.193 in.) 46.0 mm (1.811 in.)
D003586E01
D003624E01

AX–198U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(e) Measure the 2 places of the rear cover as shown in
the illustration and calculate a dimension C using
the following formula.
HINT:
Dimension C = Dimension (1) - Dimension (2)
(f) Calculate the end play value using the following
formula. Select a thrust bearing which satisfies the
end play value and install it.
End play:
0.198 to 0.936 mm (0.00800 to 0.03685 in.)
NOTICE:
Make sure that the colored race side is facing
the direct clutch assembly.
HINT:
End play = Dimension C - Dimension B
Standard bearing thickness and diameter
18. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Install 2 new apply gaskets to the transaxle.
19. INSTALL FRONT CLUTCH APPLY TUBE
(a) Install the clamp to the front clutch apply tube.
NOTICE:
Make sure to install the clamp to the apply pipe
before installing the apply pipe to the transaxle
case. This prevents the apply pipe from being
deformed or damaged.
20. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.
NOTICE:
Make sure to install the clamp to the apply pipe
before installing the apply pipe to the transaxle
case. This prevents the apply pipe from being
deformed or damaged.
D003922E01
Thickness Inside Outside
3.58 mm (0.1409 in.) 53.6 mm (2.110 in.) 69.6 mm (2.740 in.)
3.88 mm (0.1528 in.) 53.6 mm (2.110 in.) 70.18 mm (2.763 in.)
D003591E01
D003923E01
D003923E01

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–199
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(b) Install the 2 apply tubes to the transaxle with the
bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
NOTICE:
Each pipe should be securely inserted until it
reaches the stopper.
21. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Install 2 new O-rings to the 2 plugs.
(b) Install the 2 plugs to the transaxle rear cover.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
22. INSTALL TRANSAXLE REAR COVER SUB-
ASSEMBLY
(a) Using SST and a press, press in the bearing.
SST 09950-60010 (09951-00230, 09951-00350)
Standard depth:
12.05 to 12.75 mm (0.4744 to 0.5020 in.)
NOTICE:
• Face the inscribed mark side of the bearing
race up.
• Repeat the press-fit until the specified value
is obtained.
(b) Apply adhesive to the 2 screws.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or Equivalent
(c) Using a T30 ''torx'' socket, install the transaxle rear
cover plate with the 2 screws.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
D025510E01
C134984
D009193E01
C083140E01

AX–200U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(d) Coat 2 new oil seal rings with ATF, and install them
to the transaxle rear cover.
(e) Remove any packing material and be careful not to
get oil on the contacting surfaces of the transaxle
rear cover or the transaxle.
(f) Apply seal packing to the cover.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or Equivalent
(g) Coat the needle roller bearing with ATF.
(h) Apply adhesive to the threads of the bolts labeled A.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or Equivalent
(i) Install the 11 bolts.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A
25 N*m (255 kgf*cm, 18 ft.*lbf) for other
bolt
23. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Install 2 new oil seals to the transaxle.
24. INSTALL UNDERDRIVE BRAKE PISTON
(a) Wind a vinyl tape around SST at the 4.0 mm (0.157
in.) above from the bottom end until the thickness of
the wound tape is about 5.0 mm (0.197 in.).
SST 09550-60010 (09951-00320)
NOTICE:
Clean SST to remove deposited oil before
winding a vinyl tape.
D009194E01
D009946E02
D009943E01
D003914E04
D003809E01

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–201
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(b) Using SST and a press, press in the needle-roller
bearing to the transaxle until the wound vinyl tape
contacts the transaxle case.
SST 09550-60010 (09951-00320), 09950-70010
(09951-07100), 09387-00020
(c) Coat 2 new O-rings with ATF, and install them to the
underdrive brake piston.
(d) Install the underdrive brake piston to the transaxle.
25. INSTALL UNDERDRIVE BRAKE RETURN SPRING
SUB-ASSEMBLY
(a) Install the underdrive brake return spring to the
underdrive brake piston.
(b) Using SST, a snap ring expander and press, press
the return spring and install the snap ring to the
transaxle.
SST 09387-00020
NOTICE:
Do not apply excessive pressure.
D003810E01
D003794E02
D003609E01
D008071E01
D003610E01

AX–202U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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26. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC
(a) Install the 3 discs and 3 plates to the transaxle.
Install in order:
P - D - P - D - P - D
HINT:
D = Disc
P = Plate
(b) Using a screwdriver, install the snap ring.
(c) Using a dial indicator, measure the underdrive brake
piston stroke while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Standard piston stroke:
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
(d) Temporarily remove the snap ring and attach the
flange. Restore the snap ring.
27. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the outer race retainer to the 1-way clutch.
C129391E01
D008050E01
D008082E01Mark Thickness Mark Thickness
1 3.0 mm (0.118 in.) 3 3.4 mm (0.134 in.)
2 3.2 mm (0.126 in.) - -
D003907E02

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–203
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(b) Install the underdrive clutch assembly to the 1-way
clutch. Rotate the underdrive clutch to check the
rotating direction for the lock or free operation.
(c) Install the 1-way clutch to the transaxle.
NOTICE:
Make sure that the mark on the 1-way clutch
outer race is visible.
(d) Using a screwdriver, install the snap ring to the
transaxle.
28. INSTALL UNDERDRIVE CLUTCH
(a) Coat the bearing and bearing race with petroleum
jelly, and install them onto the underdrive clutch.
Standard race diameter
(b) Install the underdrive clutch assembly to the
transaxle.
29. INSTALL UNDERDRIVE PLANETARY GEAR
ASSEMBLY
(a) Install the parking lock pawl pin and torsion spring to
the parking lock pawl.
D003925E02
C050158E01
D003581E02
D003580E02
Item Inside Outside
Bearing 37.73 mm (1.4854 in.) 58.0 mm (2.283 in.)
Race 29.9 mm (1.177 in.) 55.5 mm (2.185 in.)
D009691E02

AX–204U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(b) Temporarily install the parking lock pawl, shaft and
spring to the transaxle case as shown in the
illustration.
(c) Install the underdrive planetary gear assembly to
the transaxle.
NOTICE:
Engage all the discs of the underdrive clutch
and hub splines of the underdrive planetary gear
assembly firmly and assemble them securely.
(d) Install the parking lock pawl shaft.
(e) Install the pawl shaft clamp with the bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
(f) 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 contact surface of the transaxle
and housing (Dimension D).
NOTICE:
Note down the dimension D as it is necessary
for the following process.
D009692E01
D003579E04
D009693E01
D003576E03
D003875E02

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–205
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(g) As shown in the illustration, measure the 2 places of
the transaxle housing. Calculate the dimension E
using the formula.
NOTICE:
Note down the dimension E as it is necessary
for the following process.
HINT:
Dimension E = Dimension (1) - Dimension (2)
30. INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB
(See page AX-187)
31. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Install the bearing race to the transaxle while
checking its direction.
Standard bearing diameter
(b) Coat the thrust needle roller bearing and race with
petroleum jelly, and install them onto the multiple
disc clutch hub.
Standard thrust bearing and race diameter
(c) Install the input shaft thrust bearing to the multiple
clutch hub.
Standard bearing diameter
(d) Install the forward clutch hub to the transaxle.
32. INSTALL FORWARD CLUTCH ASSEMBLY
(a) Install the input shaft thrust bearing to the forward
clutch.
Standard bearing diameter
NOTICE:
Install the thrust bearing properly so that the
race "B" will be visible.
D025511E01
D008087E03
Item Inside Outside
Bearing race 34.5 mm (1.358 in.) 48.5 mm (1.909 in.)
D003628E01
Item Inside Outside
Bearing 36.3 mm (1.429 in.) 52.25 mm (2.055 in.)
D003929E01
Item Inside Outside
Bearing 23.5 mm (0.925 in.) 44.0 mm (1.732 in.)
D011358E01
Item Inside Outside
Bearing 33.85 mm (1.3327 in.) 52.2 mm (2.055 in.)

AX–206U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(b) Install the forward clutch to the multiple clutch hub.
NOTICE:
Align the splines of all discs in the forward
clutch with those of multiple clutch hub to
assemble them securely.
33. INSTALL OVERDRIVE BRAKE GASKET
(a) Install 2 new overdrive brake gaskets to the
transaxle.
34. INSTALL FRONT DIFFERENTIAL ASSEMBLY
(a) Install the differential assembly to the transaxle.
35. INSTALL NO. 2 THRUST BEARING UNDERDRIVE
RACE
(a) Install the thrust bearing race to the underdrive
planetary gear.
36. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Calculate the end play value using the following
formula and value of Dimensions D and E that were
measured when installing the cylindrical roller
bearing and underdrive planetary gear. Select an
appropriate underdrive planetary gear thrust
bearing race No. 2 which satisfies the specified end
play value, and install it.
Standard end play:
0.498 to 0.993 mm (0.0194 to 0.0390 in.)
D003574E03
D003573E01
C050035E01
D025506E04
D025505E03