transaxle TOYOTA RAV4 2006 Service Repair Manual

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–193
AX
18. REMOVE C-3 ACCUMULATOR PISTON
(a) Remove the spring from the C-3 accumulator
piston.
(b) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the oil hole and remove the C-3 accumulator
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.
(c) Remove the O-ring from the C-3 accumulator
piston.
19. REMOVE REVERSE CLUTCH ACCUMULATOR
PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the oil hole and remove the reverse accumulator
piston and spring.
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.
(b) Remove the 2 O-rings from the reverse clutch
accumulator piston.
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AX–194U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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20. REMOVE B-3 ACCUMULATOR PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the oil hole and remove the B-3 accumulator
piston and 2 springs.
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.
(b) Remove the O-ring from the B-3 accumulator
piston.
21. REMOVE MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using needle-nose pliers, remove the manual valve
lever shaft retainer spring.
22. REMOVE MANUAL DETENT SPRING SUB-
ASSEMBLY
(a) Remove the 2 bolts, manual detent spring and
cover.
23. REMOVE PARKING LOCK PAWL BRACKET
(a) Remove the 2 bolts and parking lock pawl bracket.
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U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–195
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24. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY
(a) Using a chisel and hammer, cut off and remove the
spacer.
(b) Using a pin punch (
35 mm) and hammer, drive out
the pin.
HINT:
Slowly drive out the pin so that it does not fall into
the transaxle case.
(c) Remove the manual valve lever shaft and manual
valve lever.
25. REMOVE PARKING LOCK ROD SUB-ASSEMBLY
(a) Remove the parking lock rod from the manual valve
lever.
26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Using a screwdriver, pry out the oil seal from the
transaxle case.
NOTICE:
Do not apply excessive force when removing
the oil seal.
27. FIX AUTOMATIC TRANSAXLE ASSEMBLY
(a) Fix the transaxle case in place with the oil pump
side facing up.
28. INSPECT INPUT SHAFT ENDPLAY (See page AX-212)
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AX–196U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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29. REMOVE TRANSAXLE HOUSING
(a) Remove the 16 bolts.
(b) Tap on the circumference of the transaxle housing
with a plastic-faced hammer to remove the
transaxle housing from the transaxle case.
NOTICE:
The differential may be accidentally removed
when the transaxle housing is removed.
30. REMOVE OIL PUMP ASSEMBLY
(a) Remove the 7 bolts and oil pump from the transaxle
case.
31. REMOVE THRUST NEEDLE ROLLER BEARING
(a) Remove the thrust needle roller bearing from the
underdrive planetary gear.
32. REMOVE NO. 2 THRUST BEARING UNDERDRIVE
RACE
(a) Remove the thrust bearing race from the underdrive
planetary gear.
33. REMOVE DIFFERENTIAL GEAR ASSEMBLY
(a) Remove the differential gear from the transaxle
case.
C115282
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U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–197
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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.
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AX–198U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(b) Remove the parking lock pawl shaft.
(c) Push the parking lock pawl.
HINT:
Failure to do so will cause interference when the
underdrive planetary gear is removed.
(d) Remove the underdrive planetary gear from the
transaxle case.
NOTICE:
Make sure that the underdrive planetary gear
dose not fall out.
39. REMOVE PARKING LOCK PAWL
(a) Remove the spring, pawl pin and parking lock pawl.
40. REMOVE UNDERDRIVE CLUTCH ASSEMBLY
(a) Remove the underdrive clutch, thrust bearing and
bearing race from the transaxle case.
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U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–199
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41. REMOVE UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Using a screwdriver, remove the snap ring from the
transaxle case.
NOTICE:
Do not apply excessive force when removing
the snap ring.
(b) Remove the underdrive 1-way clutch from the
transaxle case.
(c) Remove the outer race retainer from the 1-way
clutch.
42. REMOVE NO. 2 UNDERDRIVE CLUTCH DISC
(a) Using a screwdriver, remove the snap ring.
NOTICE:
Do not apply excessive force when removing
the snap ring.
(b) Remove the flange, 4 discs and 4 plates from the
transaxle case.
43. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC (See
page AX-209)
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AX–200U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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44. REMOVE TRANSAXLE REAR COVER SUB-
ASSEMBLY
(a) Remove the 11 bolts.
(b) Tap on the circumference of the rear cover with a
plastic hammer to remove the transaxle rear cover
from the transaxle case.
45. REMOVE NO. 1 TRANSAXLE CASE PLUG
(a) Remove the 4 plugs from the transaxle rear cover.
(b) Remove the 4 O-rings from the 4 plugs.
46. REMOVE REAR CLUTCH OIL SEAL RING OUTER
(a) Remove the 3 rear clutch oil seal rings from the
transaxle rear cover.
47. REMOVE NEEDLE ROLLER BEARING
(a) Using SST, remove the bearing from the transaxle
rear cover.
SST 09387-00041 (09387-01021, 09387-01030,
09387-01040)
48. REMOVE NO. 1 GOVERNOR APPLY GASKET
(a) Using a screwdriver, remove the 3 apply gaskets.
C136369
C138647
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U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–201
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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.
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AX–202U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(c) Remove the planetary carrier thrust washer from the
rear planetary sun gear.
54. REMOVE 1-WAY CLUTCH ASSEMBLY
(a) Remove the 1-way clutch and thrust needle roller
bearing from the transaxle case.
(b) Remove the 1-way clutch inner race from the 1-way
clutch.
55. REMOVE 1-WAY CLUTCH SLEEVE OUTER
(a) Remove the 1-way clutch sleeve outer from the
transaxle case.
56. REMOVE NO. 1 PLANETARY CARRIER THRUST
WA S HE R
(a) Remove the planetary carrier thrust washer from the
planetary gear.
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