transaxle TOYOTA RAV4 2006 Service Repair Manual

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–203
AX
(c) Install the underdrive planetary gear to the
transaxle.
NOTICE:
Engage all the discs of underdrive clutch and
the hub splines of the underdrive planetary gear
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 calipers 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:
Make a note of dimension D as it is necessary
for the following process.
(g) As shown in the illustration, measure the 2 places of
the transaxle housing. Calculate the dimension E
using the formula.
NOTICE:
Make a note of dimension E as it is necessary
for the following process.
HINT:
Dimension E = Dimension (1) - Dimension (2)
D003579E04
D009693E01
D003576E03
D003875E01
D025511E01

AX–204U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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33. INSTALL MULTIPLE DISC CLUTCH HUB
(a) Install the bearing race to the transaxle while
checking its direction.
Standard bearing race diameter
(b) Coat the thrust bearing and race with petroleum
jelly, and install them onto the multiple disc clutch
hub.
Standard thrust bearing and race diameter
(c) Install the bearing to the multiple clutch hub.
Standard bearing diameter
(d) Install the forward clutch hub to the transaxle.
34. INSTALL FORWARD CLUTCH ASSEMBLY
(a) Install the thrust bearing to the forward clutch.
Standard bearing diameter
NOTICE:
Install the thrust bearing properly so that the
race "B" will be visible.
(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.
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.) 52.2 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.)
D003574E03

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–205
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35. INSTALL OVERDRIVE BRAKE GASKET
(a) Install 2 new overdrive brake gaskets.
36. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear to the transaxle.
37. INSTALL NO. 2 THRUST BEARING UNDERDRIVE
RACE
(a) Install the thrust bearing race to the underdrive
planetary gear.
38. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Calculate the end play value using the following
formula and values of Dimensions D and E that
were measured when installing 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 instal it.
End play:
0.498 to 0.993 mm (0.0196 to 0.0390 in.)
HINT:
End play = Dimension E - Dimension D - thrust
bearing thickness 3.28mm (0.1291 in.) - underdrive
thrust bearing race thickness.
Standard race thickness
D003573E01
D003577E01
D025506E04
D025505E03
E - D Thickness
Less than 7.64 mm (0.3008 in.) 3.5 mm (0.138 in.)
7.64 mm (0.3008 in.) 3.8 m (0.150 in.)

AX–206U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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Standard bearing and bearing race diameter
39. INSTALL OIL PUMP ASSEMBLY
(a) Install the oil pump to the transaxle with the 7 bolts.
Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
(b) Coat the O-ring of the oil pump with ATF.
40. INSTALL TRANSAXLE HOUSING
(a) Remove any packing material and be careful not to
get oil on the contacting surface of the transaxle
housing.
(b) Apply FIPG to the transaxle.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or Equivalent
(c) Install the transaxle housing to the transaxle with
the 16 bolts.
Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) for bolt A
29 N*m (296 kgf*cm, 21 ft.*lbf) for bolt B
and C
HINT:
Each bolt length is indicated below.
Bolt length:
50 mm (1.969 in.) for bolt A
50 mm (1.969 in.) for bolt B
42 mm (1.654 in.) for bolt C
NOTICE:
Because the bolt labeled A are seal bolts, apply
seal packing to new bolts and tighten them
within 10 minutes after application.
Seal packing:
Toyota Genuine Seal Packing 1281,
Item Inside Outside
Bearing 57.2 mm (2.252 in.) 84.96 mm (3.3449 in.)
Bearing race 56.4 mm (2.220 in.) 83.0mm (3.268 in.)
D003569E08
D003629E03
D003630E07
C126600

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–207
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Three Bond 1281 or Equivalent
41. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Install 2 new O-rings to the 2 plugs.
(b) Install the 2 plugs to the transaxle housing.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
42. INSPECT INPUT SHAFT END PLAY (See page AX-
184)
43. FIX AUTOMATIC TRANSAXLE ASSEMBLY
44. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Coat a new oil seal with ATF.
(b) Install the oil seal to the transaxle.
45. INSTALL PARKING LOCK ROD SUB-ASSEMBLY
(a) Install the parking lock rod to the manual valve lever.
C134983
D003631E01
D003632E01
D003905E01

AX–208U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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46. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
(a) Install a new spacer and manual valve lever shaft to
the transaxle.
(b) Using a pin punch and hammer, tap in a new pin.
(c) Turn the spacer and lever shaft to align the small
hole for locating the staking position mark on the
lever shaft.
(d) Using a pin punch, stake the spacer through the
small hole.
(e) Check that the spacer does not turn.
47. INSTALL MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using needle-nose pliers, install the retainer spring.
48. INSTALL PARKING LOCK PAWL BRACKET
(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 N*m (205 kgf*cm, 15 ft.*lbf)
Bolt length:
25 mm (0.984 in.)
D003565E02
D003564E01
D003930E01
D003559E01
D003561E02

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49. INSTALL MANUAL DETENT SPRING SUB-
ASSEMBLY
(a) Install the manual detent spring with the 2 bolts.
NOTICE:
Make sure to install the manual detent spring
and cover in this order.
Torque: 20 N*m (204 kgf*cm, 16 ft.*lbf) for bolt A
12 N*m (122 kgf*cm, 9 ft.*lbf) for bolt B
HINT:
Each bolt length is indicated below.
27 mm (1.063 in.) for bolt A
16 mm (0.630 in.) for bolt B
50. INSTALL B-3 ACCUMULATOR PISTON
(a) Coat a new O-ring with ATF, and install it to the B-3
accumulator piston.
(b) Coat the piston with ATF, install it 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.
D003560E01
D003904E05
D025512E02
Spring Free length
Outer diameterColor
B-3 Inner 60.24 mm (2.3716 in.)
15.9 (0.626 in.)Yellowish green
B-3 Outer 74.61 mm (2.9374 in.)
21.7 mm (0.854 in.)Blue
D003903E01

A X –210U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(b) Coat the 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 piston with ATF, install it to the transaxle
case.
Standard accumulator spring
(c) Install the spring from the C-3 accumulator piston.
53. INSTALL CHECK BALL BODY
(a) Install the check ball body and spring.
D003557E01
Spring Free length
Outer diameterColor
C-1 81.53 mm (3.2098 in.)
18.5 mm (0.728 in.)Pink
D003902E02
C083146E01
Spring Free length
Outer diameterColor
C - 3 90.49 mm (3.5626 in.)
19.2 mm (0.756 in.)White
D003555E01
D003554E02

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–211
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54. INSTALL BRAKE DRUM GASKET
(a) Coat a new brake drum gasket with ATF, and install
it to the transaxle.
55. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with
ATF, and install it to the transaxle.
56. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Coat a new governor apply gasket No. 1 with ATF,
and install it to the transaxle.
57. 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)
C083129E01
C083128E01
C083127E01
D003636E05
D003547E07

AX–212U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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58. INSTALL TRANSMISSION VALVE BODY ASSEMBLY
(a) Align the groove of the manual valve with the pin of
lever.
(b) Install the 17 bolts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
NOTICE:
• Push the valve body against the accumulator
piston spring and the check ball body to
install it.
• Tighten the bolts marked by * in the
illustration first temporarily because they are
positioning bolts.
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
(c) Connect the 5 solenoid connectors.
(d) Coat the O-ring of the temperature sensor with ATF.
(e) Install the ATF temperature sensor with the lock
plate and bolt.
Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
59. INSTALL VALVE BODY OIL STRAINER ASSEMBLY
(a) Coat a new O-ring with ATF.
(b) Install the O-ring to the oil strainer.
(c) Install the oil strainer with the 3 bolts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
D003553E10
C130917E01
D009180E01
D009179E01