ATF t4 TOYOTA RAV4 2006 Service Repair Manual

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–211
AX
(b) Coat the accumulator B-3 piston and spring with
ATF, and install them to the transaxle.
Standard accumulator spring
51. INSTALL C-1 ACCUMULATOR PISTON
(a) Coat 2 new O-rings with ATF, and install them to the
C-1 accumulator piston.
(b) Coat the accumulator C-1 piston with ATF, and
install it to the transaxle.
Standard accumulator spring
52. INSTALL C-3 ACCUMULATOR PISTON
(a) Coat a new O-ring with ATF, and install it to the C-3
accumulator piston.
(b) Coat the C-3 accumulator piston with ATF, and
install it to the transaxle.
D025512E02
Spring Free length
Outer diameterColor
B-3 Inner 60.24 mm (2.3716 in.)
15.9 mm (0.626)Yellowish green
B-3 Outer 74.61 mm (2.9374 in.)
21.7 mm (0.854 in.)Blue
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D003557E02
Spring Free length
Outer diameterColor
C-1 81.53 mm (3.2098 in.)
18.5 mm (0.728 in.)Pink
D003902E02
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AX–212U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(c) Install the compression spring from the C-3
accumulator piston.
53. INSTALL CHECK BALL BODY
(a) Install the check ball body and spring.
54. INSTALL TRANSMISSION WIRE
(a) Coat a new O-ring with ATF, and install it to the
transaxle solenoid wire.
(b) Install the solenoid wire retaining bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
55. INSTALL BRAKE DRUM GASKET
(a) Coat a new brake drum gasket with ATF, and install
it to the transaxle.
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U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–213
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56. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with
ATF, and install it to the transaxle.
57. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Coat a new governor apply gasket No. 1 with ATF,
and install it to the transaxle.
58. INSTALL TRANSMISSION VALVE BODY ASSEMBLY
(a) Make sure that the manual valve lever position,
install the valve body with the 17 bolts to the
transaxle.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
25 mm (0.984 in.) for bolt A
41 mm (1.614 in.) for bolt B
45 mm (1.771 in.) for bolt C
NOTICE:
• Push the valve body against the accumulator
piston spring and the check ball body to
install it.
• When installing the valve body to the
transaxle case, do not hold the solenoids.
• Tighten the bolts marked by * in the
illustration first temporarily because they are
positioning bolts.
(b) Connect the 5 solenoid connectors.
(c) Install the ATF temperature sensor, clamp and bolt.
Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
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AX–214U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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59. INSTALL VALVE BODY OIL STRAINER ASSEMBLY
(a) Coat a new O-ring with ATF, and install it to the oil
strainer.
(b) Install the oil strainer and 3 bolts to the valve body.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
60. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-
ASSEMBLY
(a) Install the 3 magnets in the oil pan.
(b) Install a new oil pan gasket to the oil pan.
(c) Install the oil pan to the transaxle with the 18 bolts.
Torque: 7.6 N*m (77 kgf*cm, 67 in.*lbf)
NOTICE:
Because the bolts are seal bolts, apply seal
packing to new bolts and tighten them within 10
minutes after application.
61. INSTALL SPEED SENSOR
(a) Coat 2 new O-rings with ATF, and install them to the
2 sensors.
(b) Install the 2 sensors with the 2 bolts to the transaxle.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
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U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–215
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62. INSTALL OIL COOLER INLET TUBE UNION
(a) Coat a new O-ring with ATF, and install it to the
union.
(b) Install the union to the transaxle.
Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf)
63. INSTALL OIL COOLER OUTLET TUBE UNION
(a) Coat a new O-ring with ATF, and install it to the
union.
(b) Install the union to the transaxle case.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
64. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Coat 4 new O-rings with ATF, and install them to the
4 plugs.
(b) Install the 4 plugs to the transaxle.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
65. INSTALL BREATHER PLUG HOSE
(a) Install the breather plug hose to the breather plug.
66. INSTALL PARK/NEUTRAL POSITION SWITCH
ASSEMBLY
(a) Install the park/neutral position switch onto the
manual valve lever shaft and temporarily install the
2 adjusting bolts.
(b) Install a new lock plate and the nut.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
(c) Temporarily install the control shaft lever.
C127450
C127449
C134982
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AX–216U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(d) Turn the lever counterclockwise until it stops, and
then turn it clockwise 2 notches.
(e) Remove the control shaft lever.
(f) Align the groove with neutral basic line.
(g) Tighten the 2 bolts.
Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
(h) Using a screwdriver, stake the nut with the lock
plate.
(i) Install the control shaft lever, washer and nut.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
67. INSTALL SPEEDOMETER DRIVEN HOLE COVER
SUB-ASSEMBLY
(a) Coat a new O-ring with ATF and install it to the hole
cover.
(b) Install the hole cover to the transaxle with the bolt.
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U241E AUTOMATIC TRANSAXLE – OIL PUMPAX–221
AX
REASSEMBLY
1. INSTALL FRONT OIL PUMP OIL SEAL
(a) Using SST, install a new oil seal to the pump.
SST 09350-32014 (09351-32140)
HINT:
The seal end should be flush with the outer edge of
the oil pump.
(b) Coat the lip of the oil seal with petroleum jelly.
2. INSTALL FRONT OIL PUMP BODY O-RING
(a) Coat a new O-ring with ATF, and install it to the oil
pump body.
3. INSTALL FRONT OIL PUMP DRIVEN GEAR
(a) Coat the front oil pump driven gear with ATF, and
install it to the oil pump body with the maked side
facing up.
4. INSTALL FRONT OIL PUMP DRIVE GEAR
(a) Coat the front oil pump drive gear with ATF, and
install it to the oil pump body with the maked side
facing up.
5. INSTALL STATOR SHAFT ASSEMBLY
(a) Set stator shaft by aligning each bolt hole.
(b) Using a T30 ''torx'' socket, install the 11 bolts.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
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C055817E03
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AX–230U241E AUTOMATIC TRANSAXLE – FORWARD CLUTCH
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REASSEMBLY
1. INSTALL INPUT SHAFT OIL SEAL RING
(a) Compress the oil seal ring from both sides to reduce
dimension A.
Dimension A:
5.0 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the
input shaft.
2. INSTALL FORWARD CLUTCH PISTON O-RING
(a) Coat 2 new O-rings with ATF, and install them to the
forward clutch piston.
3. INSTALL FORWARD CLUTCH PISTON SUB-
ASSEMBLY
(a) Install the forward clutch piston to the forward clutch
drum.
4. INSTALL FORWARD CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Place the forward clutch return spring onto the
forward clutch piston.
(b) Place SST on the return spring, and compress the
return spring with a press.
SST 09350-32014 (09351-32070)
(c) Install the snap ring with a snap ring expander. Be
sure the end gap of the snap ring is not aligned with
the spring retainer claw.
NOTICE:
• Stop the press when the spring sheet is
lowered to the place 1 to 2 mm (0.039 to 0.078
in.) from the snap ring groove.
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AX–258U241E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
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REASSEMBLY
1. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Coat the 2 front differential side gears, 2 side gear
thrust washers, 2 front differential pinions and 2
pinion thrust washers with ATF, and install them to
the differential case.
2. INSTALL NO. 1 FRONT DIFFERENTIAL PINION
SHAFT
(a) Coat the front differential pinion shaft with ATF, and
install it to the differential case.
3. INSPECT FRONT DIFFERENTIAL SIDE GEAR
BACKLASH (See page AX-257)
4. INSTALL FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch and hammer, tap in the pinion
shaft straight pin.
(b) Using a chisel and hammer, stake the differential
case.
5. INSTALL FRONT DIFFERENTIAL CASE REAR
TAPERED ROLLER BEARING
(a) Using SST and a press, press in the front differential
case tapered roller bearing rear inner race to the
differential case.
SST 09608-06041
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U241E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–259
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(b) Using SST and a hammer, tap in the case washer
and front differential case tapered roller bearing rear
outer race to the transaxle case.
SST 09950-60020 (09951-00710), 09950-70010
(09951-07100)
6. INSTALL FRONT DIFFERENTIAL CASE FRONT
TAPERED ROLLER BEARING
(a) Using SST and a press, press in the front differential
case tapered roller bearing front inner race to the
differential case.
SST 09608-06041
(b) Using SST and a hammer, tap in the front
differential case tapered roller bearing front outer
race to the transaxle housing.
SST 09950-60020 (09951-00680), 09950-70010
(09951-07100), 09950-60010 (09951-00340)
7. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring
gear to 90 to 110
C (194.0 to 230.0F).
(b) Clean the contact surface of the front differential
case.
(c) Align the matchmarks, and install the front
differential ring gear case quickly.
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