Hub TOYOTA RAV4 2006 Service User Guide

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
AX
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

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–197
AX
34. REMOVE OVERDRIVE BRAKE GASKET
(a) Remove the 2 overdrive brake gaskets from the
transaxle case.
35. REMOVE FORWARD CLUTCH ASSEMBLY
(a) Remove the forward clutch from the transaxle case.
(b) Remove the thrust needle roller bearing from the
forward clutch.
36. REMOVE MULTIPLE DISC CLUTCH HUB
(a) Remove the thrust needle roller bearing, multiple
disc clutch hub, thrust needle roller bearing and No.
1 thrust bearing race from the transaxle case.
37. INSPECT MULTIPLE DISC CLUTCH HUB (See page
AX-209)
38. REMOVE UNDERDRIVE PLANETARY GEAR
ASSEMBLY
(a) Remove the bolt and pawl shaft clamp.
D003573E01
D003574E03
D003906E02
D026787E07
D003576E03

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–201
AX
49. REMOVE BRAKE APPLY TUBE
(a) Remove the bolt, clamp and brake apply tube.
(b) Remove the clutch apply tube.
(c) Remove the brake apply tube from the clamp.
NOTICE:
Do not bend the tubes.
50. REMOVE DIRECT CLUTCH ASSEMBLY
(a) Remove the thrust bearing and the direct clutch
from the transaxle case.
51. REMOVE OVERDRIVE DIRECT CLUTCH HUB SUB-
ASSEMBLY
(a) Remove the thrust bearing race, thrust bearing and
overdrive direct clutch hub from the planetary gear.
52. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-
ASSEMBLY (See page AX-209)
53. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY
(a) Remove the rear planetary sun gear from the
transaxle case.
(b) Remove the thrust needle roller bearing and thrust
bearing race from the rear planetary sun gear.
D026391E05
D026403E06
D026392E09
D026714E05
D026404E07

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–205
AX
(d) Remove the front planetary gear from the brake
hub.
65. REMOVE FRONT PLANETARY RING GEAR
(a) Using a screwdriver, remove the snap ring and front
planetary ring gear from the brake hub.
66. REMOVE 1ST AND REVERSE BRAKE RETURN
SPRING SUB-ASSEMBLY
(a) Place SST on the return spring, and compress the
return spring with a press.
NOTICE:
Stop the press when the spring seat is lowered 1
to 2 mm (0.039 to 0.078 in.) from the snap ring
groove to prevent the spring seat from being
deformed.
SST 09387-00070
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
Do not expand the snap ring excessively.
67. INSPECT 1ST AND REVERSE BRAKE RETURN
SPRING SUB-ASSEMBLY (See page AX-210)
68. REMOVE 1ST AND REVERSE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the transaxle case 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 using a waste cloth.
• Take care not to splash ATF when applying
compressed air.
D026763E03
D003615E05
D003600E01
D026405E04

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–209
AX
80. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Remove the bolt, transaxle apply tube clamp and
differential gear lube apply tube from the transaxle
housing.
NOTICE:
Do not bend the tubes.
INSPECTION
1. INSPECT MULTIPLE DISC CLUTCH HUB
(a) Using a caliper gauge, measure the inside diameter
of the forward clutch hub bushing.
Standard inside diameter:
23.03 to 23.05 mm (0.9067 to 0.9075 in.)
Maximum inside diameter:
23.09 mm (0.9091 in.)
NOTICE:
Check the contact surface of the bushing in the
direct clutch shaft. If any scratch or
discoloration is found, replace the direct clutch
sub-assembly with a new one.
If the inside diameter is greater than the maximum,
replace the forward clutch hub with a new one.
2. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC
(a) Check if the sliding surfaces of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
• If the lining of the disc comes off or is
discolored, or if a part of the groove is worn,
replace all the discs.
• Before installing new discs, immerse them in
ATF for at least 15 minutes.
3. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-
ASSEMBLY
(a) Using a caliper gauge, measure the inside diameter
of the forward clutch hub bushing.
Standard inside diameter:
23.025 to 23.046 mm (0.9065 to 0.9073 in.)
Maximum inside diameter:
23.09 mm (0.9091 in.)
NOTICE:
Check the contact surface of the bushing in the
direct clutch shaft. If any scratch or
discoloration is found, replace the direct clutch
sub-assembly with a new one.
If the inside diameter is greater than the maximum,
replace the forward clutch hub with a new one.
D026400E06
D003829E03
D009196E01
D003829E03

AX–218U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(c) Coat the 1st and reverse brake piston with ATF, and
install it to the transaxle case.
NOTICE:
Be careful not to damage the O-ring.
14. INSTALL 1ST AND REVERSE BRAKE RETURN
SPRING SUB-ASSEMBLY
(a) Place SST on the return spring and compress the
return spring with a press.
NOTICE:
• Stop the press when the spring seat is
lowered 1 to 2 mm (0.039 to 0.078 in.) from the
snap ring groove to prevent the spring seat
from being deformed.
• After installing the return spring, check that
all the return spring's springs fit in the piston
correctly.
SST 09387-00070
(b) Using a snap ring expander, press in the snap ring
to the transaxle case.
NOTICE:
• The snap ring must be fully engaged in the
groove of the transaxle case.
• Fix the snap ring to the inside of the claw of
the spring seat firmly.
15. INSTALL FRONT PLANETARY RING GEAR
(a) Using a screwdriver, install the front planetary ring
gear and snap ring to the brake hub.
NOTICE:
Confirm that the snap ring is engaged in the
groove of the brake hub correctly.
16. INSTALL FRONT PLANETARY GEAR ASSEMBLY
(a) Install the front planetary gear to the brake hub.
D026593E03
D003600E01
D003615E03
D026763E03

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–221
AX
(b) Using a screwdriver, install the snap ring.
NOTICE:
Confirm that the snap ring is fixed in the groove
of the 1st and reverse brake hub correctly.
19. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC
(a) Coat the 6 discs with the ATF.
(b) Install the 6 plates and 6 discs.
NOTICE:
Make sure that the plates and discs are installed
as shown in the illustration.
20. INSPECT PACK CLEARANCE OF FIRST AND
REVERSE BRAKE
(a) Using a vernier caliper, measure the distance
between the disc surface and the contact surface of
the 2nd brake cylinder and transaxle case
(Dimension A).
(b) Select an appropriate flange so that the pack
clearance will meet the specified value.
Standard pack clearance:
1.16 to 1.35 mm (0.0457 to 0.0531 in.)
HINT:
Piston stroke = Dimension A - Flange thickness
Standard flange thickness
(c) Install the flange.
D003616E02
C136370E01
D026452E01
Mark Thickness Mark Thickness
1 1.8 mm (0.071 in.) 5 2.2 mm (0.087 in.)
2 1.9 mm (0.075 in.) 6 2.3 mm (0.091 in.)
3 2.0 mm (0.079 in.) 7 2.4 mm (0.094 in.)
4 2.1 mm (0.083 in.) 8 2.5 mm (0.098 in.)
D003815E01

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–225
AX
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 C).
(e) Using a vernier caliper and straightedge, measure
the dimension shown in the illustration (Dimension
D).
(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
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

AX–230U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(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:
• Fully engage all the discs of underdrive
clutch and hub splines of the underdrive
planetary gear and install them securely.
• Check the position and number of the
grooves on each end face of the differential
drive pinion gear.
(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