transaxle TOYOTA RAV4 2006 Service Repair Manual

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REASSEMBLY
1. BEARING POSITION
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Standard bearing position
2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the differential gear lube apply tube and
transaxle apply tube clamp to the transaxle housing
with the bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
NOTICE:
Make sure to insert the pipe to the stopper.
3. 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)
Mark Front Race Diameter
Inside / OutsideThrust Bearing Diameter
Inside / OutsideRear Race Diameter
Inside / Outside
A - 57.2 mm (2.252 in.) / 84.96 mm
(3.3449 in.)56.4 mm (2.220 in.) / 83.0 mm
(3.268 in.)
B - 37.73 mm (1.4854 in.) / 58.0 mm
(2.283 in.)-
C - 33.85 mm (1.3327 in.) / 52.2 mm
(2.055 in.)-
D 24.94 mm (0.982 in.) 23.5 mm (0.925 in.) / 44.0mm
(1.732 in.)-
E - 36.3 mm (1.429 in.) / 51.93 mm
(2.0445 in.)34.5 mm (1.358 in.) / 48.35 mm
(1.904 in.)
F 34.35 mm (1.3524 in.) / 56.57
mm (2.2272 in.)32.45 mm (1.2776 in.) / 56.48
mm (2.2236 in.)-
G 40.15 mm (1.5807 in.) / 59.25
mm (2.3327 in.)38.65 mm (1.5217 in.) / 59.79
mm (2.3539 in.)38.65 mm (1.5217 in.) / 59.25
mm (2.3327 in.)
H - 53.6 mm (2.110 in.) / 69.6 mm
(2.740 in.)-
I 33.02 mm (1.3000 in.) / 45.8 mm
(1.803 in.)31.85 mm (1.2539 in.) / 57.3 mm
(2.256 in.)-
J - 24.79 mm (0.9760 in.) / 39.5 mm
(1.555 in.)23.6 mm (0.929 in.) / 37.95 mm
(1.4941 in.)
K - 56.3 mm (2.216 in.) / 75.96 mm
(2.9905 in.)-
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4. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Coat a new oil seal ring with ATF and install it to the
transaxle housing.
5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Coat the underdrive cylindrical roller bearing with
AT F.
(b) Using SST and a press, press in the underdrive
cylindrical roller bearing.
SST 09950-60020 (09951-00810), 09950-70010
(09951-07100)
NOTICE:
Do not apply excessive pressure to the bearing.
6. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Coat 2 new oil seal rings with ATF, and install them
to the transaxle rear cover.
NOTICE:
• Do not expand the end gap of the oil seal ring
too much.
• Fix the hooks firmly. Confirm that the oil seal
ring rotates freely in its groove.
7. INSTALL NEEDLE ROLLER BEARING
(a) Wrap vinyl tape around SST 4.0 mm (0.157 in.) from
the bottom of SST until the thickness of the tape is
about 5.0 mm (0.197 in.).
SST 09950-60010 (09951-00320), 09950-70010
(09951-07100)
NOTICE:
Clean SST to remove deposited oil before
wrapping vinyl tape.
(b) Coat the needle roller bearing with ATF.
(c) Using SST and a press, press in the needle-roller
bearing to the transaxle case.
SST 09950-60010 (09951-00320), 09950-70010
(09951-07100)
NOTICE:
When the wrapped vinyl tape contacts the
transaxle case, stop press-fitting.
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8. INSTALL UNDERDRIVE BRAKE PISTON
(a) Coat 2 new O-rings with ATF, and install them to the
underdrive brake piston.
NOTICE:
• Make sure that the O-rings are not twisted or
pinched when they are installed.
• Apply sufficient ATF to the O-ring before
installing.
(b) Coat the underdrive brake piston with ATF.
(c) Install the underdrive brake piston to the transaxle
case.
NOTICE:
Be careful not to damage the O-ring.
9. INSTALL UNDERDRIVE 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 to a position 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 09387-00020
(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.
10. INSTALL NO. 2 BREATHER PLUG
11. INSTALL COUNTER DRIVE GEAR BEARING
(a) Coat the counter drive gear bearing with ATF.
(b) Using SST and a press, press in the bearing outer
race.
SST 09950-60020 (09951-01030), 09950-70010
(09951-07150), 09649-17010
NOTICE:
• Do not apply excessive pressure to the
bearing.
• Press-fit the bearing outer race until it
contacts the transaxle case.
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(c) Using a snap ring expander, install the snap ring.
NOTICE:
The white mark side of the snap ring should face
upward.
12. INSTALL COUNTER DRIVE GEAR
(a) Coat the counter drive gear with ATF.
(b) Using SST and a press, press in the tapered roller
bearing to the counter drive gear.
SST 09950-70010 (09951-07150), 09649-17010
NOTICE:
Do not apply excessive pressure to the bearing.
(c) Using SST and a press, press in the counter drive
gear and bearing to the transaxle case.
SST 09950-70010 (09951-07150), 09223-15030,
09527-17011, 09950-60020 (09951-00750)
NOTICE:
Do not apply excessive pressure to the counter
drive gear.
13. INSTALL 1ST AND REVERSE BRAKE PISTON
(a) Coat 2 new O-rings with ATF.
(b) Install the 2 O-rings to the 1st and reverse brake
piston.
NOTICE:
• Make sure that the O-rings are not twisted or
pinched when they are installed.
• Apply sufficient ATF to the O-ring prior to
assembling.
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(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.
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(b) Using SST and a press, press-fit the front planetary
gear.
SST 09950-60010 (09951-00500), 09950-70010
(09951-07100)
NOTICE:
• Do not apply excessive pressure to the
planetary gear.
• Press the inner race of the LH tapered roller
bearing, counter gear and front planetary
gear to the position where no preload should
be applied to one pair of tapered roller
bearings (left and right).
(c) Install a new washer as shown in the illustration.
(d) Using SST, install the nut.
SST 09387-00030, 09387-00080
Torque: 280 N*m (3,355 kgf*cm, 207 ft.*lbf)
NOTICE:
Assemble the washer after pressing each part,
then tighten the nut to the standard torque.
(e) Using SST and a torque wrench, measure the
turning torque of the bearing while rotating SST at
60 rpm. When the measured value is not as
specified, gradually tighten the nut until it reaches
the specified value.
SST 09387-00080
Standard turning torque at 60 rpm:
0.51 to 1.02 N*m (5.1 to 10.0 kgf*cm, 4.4 to 8.7
in.*lbf) for new bearing
0.26 to 0.51 N*m (2.7 to 5.2 kgf*cm, 2.3 to 4.5
in.*lbf) for used bearing
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(f) Tighten the nut gradually until the specified turning
torque of the tapered roller bearing is measured.
Torque: 350 N*m (3,569 kgf*cm, 258 ft.*lbf)
(g) Using a chisel and hammer, stake the front lock
washer.
17. INSTALL INPUT SUN GEAR
(a) Coat the 2 thrust bearings with ATF.
(b) Install the 2 thrust bearings, bearing race and input
sun gear to the front planetary gear.
NOTICE:
• Install the bearing race on the side of the
front planetary carrier. Be careful about the
direction of the race.
• When installing the thrust bearing and front
sun gears, be careful about the direction of
the parts.
• When install the bearing race on the side of
the front sun gear, be careful of the direction
of the race.
• Install the thrust bearing and the race after
holding the parts on the input sun gear by
applying grease. Make sure that the
assembling order is correct.
Standard thrust bearing and bearing race
diameter
18. INSTALL REAR PLANETARY GEAR ASSEMBLY
(a) Install the rear planetary gear to the rear planetary
ring gear.
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Item Inside Outside
Thrust Bearing, A 32.5 mm (1.28 in.) 56.5 mm (2.224 in.)
Thrust Bearing, C 38.6 mm (1.520 in.) 59.7 mm (2.35 in.)
Bearing Race, B 40.2 mm (1.583 in.) 59.3 mm (2.335 in.)
Bearing Race, D 38.6 mm (1.520 in.) 59.3 mm (2.335 in.)
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(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.
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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.)
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21. INSTALL SECOND BRAKE PISTON ASSEMBLY
(a) Install the second brake piston to the transaxle
case.
(b) Install the snap ring and measure the inside
diameter.
Inside diameter:
Greater than 167 mm (6.57 in.)
NOTICE:
• Make sure that the taper snap ring is installed
in the correct direction.
• When the diameter does not meet the
specified value, replace the snap ring with a
new one.
• After installing the snap ring, confirm that
there is no clearance between the 2nd brake
cylinder and the fitting surface of the cylinder
in the transaxle case.
22. INSTALL 1-WAY CLUTCH SLEEVE OUTER
(a) Install the 1-way clutch sleeve outer to the 2nd
brake cylinder.
NOTICE:
Make sure that the outer sleeve is installed in
the correct direction.
23. INSTALL 1-WAY CLUTCH ASSEMBLY
(a) Install the 1-way clutch inner race to the 1-way
clutch.
NOTICE:
• Make sure that the inner race is installed in
the correct direction.
• Confirm that the discrimination mark is
visible.
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