clock TOYOTA RAV4 2006 Service Owner's Manual

AX–242U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
77. INSTALL PARK/NEUTRAL POSITION SWITCH
ASSEMBLY
(a) Install the switch to the manual valve shaft.
(b) Temporarily install the 2 bolts.
(c) Install a new lock washer and tighten the manual
valve shaft nut.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
(d) Temporarily install the control shaft lever.
(e) Turn the lever counterclockwise until it stops, and
then turn it clockwise 2 notches.
(f) Remove the control shaft lever.
(g) Align the groove and neutral basic line.
(h) Hold the switch in this position and tighten the 2
bolts.
Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
(i) Using a screwdriver, stake the nut with the lock
washer.
D009639E02
C140282
C140281
D009642E01
D009643E02

AX–212U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
HINT:
Piston stroke = Dimension A - Flange thickness
Standard flange thickness
9. INSPECT PACK CLEARANCE OF 2ND BRAKE
(a) Using a vernier caliper, measure the distance
between the disc surface and snap ring surface
(Dimension B).
(b) Select an appropriate flange so that the pack
clearance will meet the specified value.
Standard pack clearance:
0.62 to 0.91 mm (0.0244 to 0.0358 in.)
HINT:
Piston stroke = Dimension B - Flange thickness -
Snap ring thickness 1.6 mm (0.063 in.)
Standard flange thickness
10. INSPECT PACK CLEARANCE OF UNDERDRIVE
BRAKE
(a) Using a dial indicator, measure the underdrive brake
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Standard pack clearance:
1.81 to 2.20 mm (0.0713 to 0.0866 in.)
HINT:
Select an appropriate flange from the table below so
that it will meet the specified value.
Standard flange thickness
11. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the underdrive clutch assembly to the 1-way
clutch.
(b) Check that the underdrive 1-way clutch locks when
turned clockwise and rotates freely when turned
counterclockwise as shown in the illustration.
If the result is not as specified, replace the
underdrive 1-way clutch.
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.)
D026453E01
Mark Thickness Mark Thickness
1 3.0 mm (0.118 in.) 5 3.4 mm (0.134 in.)
2 3.1 mm (0.122 in.) 6 3.5 mm (0.138 in.)
3 3.2 mm (0.126 in.) 7 3.6 mm (0.142 in.)
4 3.3 mm (0.130 in.) - -
D008082E01
Mark Thickness Mark Thickness
1 3.0 mm (0.118 in.) 4 3.1 mm (0.122 in.)
2 3.2 mm (0.126 in.) 5 3.3 mm (0.130 in.)
3 3.4 mm (0.134 in.) - -
D003925E01

AX–224U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(b) Check that the 1-way clutch locks when turned
clockwise and rotates freely when turned
counterclockwise as shown in the illustration..
HINT:
If the result is not as specified, replace the 1-way
clutch.
(c) Install the 1-way clutch and thrust needle roller
bearing to the 1-way clutch sleeve outer.
Standard bearing diameter
NOTICE:
Install the thrust bearing properly so that the
non-colored race will be visible.
24. INSTALL NO. 1 PLANETARY CARRIER THRUST
WA S HE R
(a) Coat the planetary carrier thrust washer with yellow
petrolatum, and install the washer onto the
planetary sun gear.
NOTICE:
After installing the washer, confirm that the
projection of the washer is fixed firmly in the
hole of the planetary sun gear.
25. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY
(a) Coat the planetary carrier thrust washer with yellow
petrolatum, and install the washer onto the rear
planetary sun gear.
(b) Coat the bearing with yellow petrolatum, and install
the bearing onto the rear planetary sun gear.
Standard bearing diameter
D009638E03
D003588E02
Item Inside Outside
Bearing 53.6 mm (2.110 in.) 69.4 mm (2.732 in.)
D026394E07
D026393E05
D026404E07
Item Inside Outside
Race 33.0 mm (1.299 in.) 45.4 mm (1.787 in.)
Bearing 31.85 mm (1.254 in.) 45.2 mm (1.78 in.)

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–229
AX
(c) Using a screwdriver, install the snap ring.
NOTICE:
The snap ring should be fully engaged in the
groove of the drum.
37. INSPECT PACK CLEARANCE OF UNDERDRIVE
BRAKE
(a) Using a dial indicator, measure the underdrive brake
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Standard pack clearance:
1.81 to 2.20 mm (0.0713 to 0.0866 in.)
HINT:
Select an appropriate flange from the table below so
that it will meet the specified value.
Standard flange thickness
(b) Temporarily remove the snap ring, attach the
selected flange and reinstall the snap ring.
(c) Reinstall the snap ring.
38. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the underdrive clutch to the 1-way clutch.
(b) Check that the underdrive 1-way clutch locks when
turned clockwise and rotates freely when turned
counterclockwise as shown in the illustration.
If the result is not as specified, replace the
underdrive 1-way clutch.
39. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the outer race retainer to the 1-way clutch.
NOTICE:
Fix the outer race retainer to the external tooth
of the 1-way clutch firmly.
D026466E01
D008082E01
Mark Thickness Mark Thickness
1 3.0 mm (0.118 in.) 4 3.1 mm (0.122 in.)
2 3.2 mm (0.126 in.) 5 3.3 mm (0.130 in.)
3 3.4 mm (0.134 in.) - -
D003925E01
D003907E02

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–243
AX
77. INSTALL PARK/NEUTRAL POSITION SWITCH
ASSEMBLY
(a) Install the switch to the manual valve shaft.
(b) Temporarily install the 2 bolts.
(c) Install a new lock washer and tighten the manual
valve shaft nut.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
(d) Temporarily install the control shaft lever.
(e) Turn the lever counterclockwise until it stops, and
then turn it clockwise 2 notches.
(f) Remove the control shaft lever.
(g) Align the groove and neutral basic line.
(h) Hold the switch in this position and tighten the 2
bolts.
Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
(i) Using a screwdriver, stake the nut with the lock
washer.
D009639E02
C140282
C140281
D009642E01
D009643E02

AX–216U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(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.
D008094E01
D009642E01
D008033E01
D008032E01

BR–12BRAKE – BRAKE PEDAL
BR
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
(a) Remove the instrument panel (see page IP-4).
3. DISCONNECT CONNECTORS
(a) Disconnect the stop light switch connector.
(b) w/
296 disc brake:
Disconnect the brake pedal load sensing switch
connector.
4. REMOVE STOP LIGHT SWITCH ASSEMBLY
(a) Turn the switch counterclockwise and remove it.
5. REMOVE PUSH ROD PIN
(a) Remove the clip from the push rod pin.
(b) Remove the push rod pin from the push rod clevis.
6. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY
(a) Remove the bolt from the support.
(b) Remove the 4 nuts and support.
C129086E01
C126454

BR–14BRAKE – BRAKE PEDAL
BR
(6) Insert the switch into the adjuster until the
switch body touches the pedal.
NOTICE:
Do not depress the pedal.
(7) Turn the switch a quarter turn clockwise.
Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or
less
NOTICE:
Do not depress the pedal.
(8) Connect the connector to the switch.
(9) Check the switch clearance.
Standard stop light switch clearance:
1.5 to 2.5 mm (0.059 to 0.098 in.)
2. CHECK BRAKE PEDAL FREE PLAY
(a) Stop the engine. Depress the pedal several times
until there is no vacuum in the booster. Then
release the pedal.
(b) Depress the pedal until resistance is felt.
(c) Check the pedal's free play by measuring the
distance between the position in the previous step
and the pedal's released position.
Standard pedal free play:
1.0 to 6.0 mm (0.039 to 0.236 in.)
If the free play is not as specified, check the switch
clearance in the next step.
If the free play is as specified, proceed to the
"CHECK BRAKE PEDAL RESERVE DISTANCE"
procedure.
(d) Check the switch clearance.
Standard stop light switch clearance:
1.5 to 2.5 mm (0.059 to 0.098 in.)
If the clearance is not as specified, reinstall the
switch and recheck the pedal's free play.
If the clearance is as specified, troubleshoot the
brake system and proceed to the "CHECK BRAKE
PEDAL RESERVE DISTANCE" procedure.
C 111 3 0 1 E 0 3
C 111 3 0 2 E 0 1
C 111 3 0 6 E 0 1

BR–16BRAKE – BRAKE PEDAL
BR
(7) Turn the switch a quarter turn clockwise.
Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or
less
NOTICE:
Do not depress the pedal.
(8) Connect the connector to the switch.
(9) Check the switch clearance.
Standard stop light switch clearance:
1.5 to 2.5 mm (0.059 to 0.098 in.)
2. CHECK BRAKE PEDAL FREE PLAY
(a) Stop the engine. Depress the pedal several times
until there is no vacuum in the booster. Then
release the pedal.
(b) Depress the pedal until resistance is felt.
(c) Check the pedal's free play by measuring the
distance between the position in the previous step
and the pedal's released position.
Standard pedal free play:
1.0 to 6.0 mm (0.039 to 0.236 in.)
If the free play is not as specified, check the switch
clearance in the next step.
If the free play is as specified, proceed to the
"CHECK BRAKE PEDAL RESERVE DISTANCE"
procedure.
(d) Check the switch clearance.
Standard stop light switch clearance:
1.5 to 2.5 mm (0.059 to 0.098 in.)
If the clearance is not as specified, reinstall the
switch and recheck the pedal's free play.
If the clearance is as specified, troubleshoot the
brake system and proceed to the "CHECK BRAKE
PEDAL RESERVE DISTANCE" procedure.
3. CHECK BRAKE PEDAL RESERVE DISTANCE
(a) Release the parking brake lever. Start the engine.
(b) Depress the pedal and check the pedal reserve
distance.
(1) Depress the pedal with a force of 490 N (50 kgf,
11 0 l b f ) .
(2) Measure the distance between the pedal and
dash panel shown in the illustration.
Standard pedal reserve distance
If the distance is not as specified, troubleshoot
the brake system.
C 111 3 0 2 E 0 1
C 111 3 0 6 E 0 1
C 111 3 3 9 E 0 1Engine Specified Condition
2AZ-FE (w/o 3rd seat) More than 95 mm (3.74 in.)
2AZ-FE (w/ 3rd seat) More than 120 mm (4.72 in.)
2GR-FE More than 120 mm (4.72 in.)

BR–18BRAKE – BRAKE PEDAL
BR
(b) Install the push rod pin to the push rod clevis.
NOTICE:
The push rod pin must be installed as shown in
the illustration.
(c) Install the clip to the push rod pin.
NOTICE:
The clip must be installed as shown in the
illustration.
3. INSTALL STOP LIGHT SWITCH ASSEMBLY
(a) Insert the switch into the adjuster until the switch
body touches the pedal.
NOTICE:
Do not depress the pedal.
(b) Turn the switch a quarter turn clockwise.
Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less
NOTICE:
Do not depress the pedal.
(c) Check the switch clearance.
Standard stop light switch clearance:
1.5 to 2.5 mm (0.059 to 0.098 in.)
4. CONNECT CONNECTORS
(a) w/
296 disc brake:
Connect the brake pedal load sensing switch
connector.
(b) Connect the stop light switch connector.
5. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See
page BR-13)
6. CHECK BRAKE PEDAL FREE PLAY (See page BR-
14)
7. CHECK BRAKE PEDAL RESERVE DISTANCE (See
page BR-14)
8. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
(a) Install the instrument panel (see page IP-9).
9. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
C 111 3 0 1 E 0 3
C 111 3 0 2 E 0 1