transaxle TOYOTA RAV4 2006 Service Repair Manual

AX–38U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
AX
CHECK MODE PROCEDURE
1. DESCRIPTION
(a) Check mode has a higher sensitivity to malfunctions
and can detect malfunctions that normal mode
cannot detect. Check mode can also detect all the
malfunctions that normal mode can detect. In check
mode, DTCs are detected with 1 trip detection logic.
2. CHECK MODE PROCEDURE
(a) Make sure that the following conditions below are
met:
(1) Battery positive voltage 11 V or more
(2) Throttle valve fully closed
(3) Transaxle in the P or N position
(4) A/C OFF
(b) Turn the ignition switch OFF.
(c) Connect the intelligent tester to the CAN VIM. Then
connect the CAN VIM to the DLC3.
(d) Turn the ignition switch ON and turn the tester ON.
(e) Enter the following menus: DIAGNOSIS /
ENHANCED OBD II / CHECK MODE.
(f) Change the ECM to check mode. Make sure the
MIL flashes as shown in the illustration.
NOTICE:
All DTCs and freeze frame data will be erased if:
1) the intelligent tester is used to change the
ECM from normal mode to check mode or vice
versa; or 2) during check mode, the ignition
switch is turned from ON to ACC or OFF.
Before check mode, make notes of the DTCs
and freeze frame data.
(g) Start the engine. The MIL should turn off after the
engine starts.
(h) Perform "MONITOR DRIVE PATTERN" for the ECT
test (see page AX-21).
(Or, simulate the conditions of the malfunction
described by the customer.)
(i) After simulating the malfunction conditions, use the
tester to check the DTC and freeze frame data.
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U151F AUTOMATIC TRANSAXLE – FLOOR SHIFT ASSEMBLYAX–165
AX
ADJUSTMENT
1. INSPECT SHIFT LEVER POSITION
(a) When shifting the lever from P to the R position with
the ignition switch ON and the brake pedal
depressed, make sure that the shift lever moves
smoothly and moves correctly into position.
(b) Start the engine and make sure that the vehicle
moves forward when shifting the lever from N to the
D position and moves rearward when shifting the
lever to the R position.
If the operation cannot be performed as specified,
inspect the park/neutral position switch assembly
and check the shift lever assembly installation
condition.
2. ADJUST SHIFT LEVER POSITION
(a) Shift the shift lever to the N position.
(b) Slide the adjuster case cover in the direction shown
in the illustration and pull out the lock piece.
(c) Gently pull the cable rod toward the rear of the
vehicle by hand to pull the cable taut.
(d) Press the lock piece into the adjuster case and lock
it.
(e) Slide the cover in the direction shown in the
illustration.
NOTICE:
Slide the cover past the protrusion of the lock
piece.
(f) Inspect the operation.
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AX–166U151F AUTOMATIC TRANSAXLE – FLOOR SHIFT ASSEMBLY
AX
REASSEMBLY
1. INSTALL SHIFT LOCK RELEASE BUTTON
(a) Install the spring and button and attach the claws to
the position indicator light housing.
2. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY
3. INSTALL POSITION INDICATOR LIGHT HOUSING
(a) Install the indicator light housing and attach the 2
claws to the shift position indicator housing.
4. INSTALL LOWER POSITION INDICATOR HOUSING
(a) Install the position indicator slide cover with slide
No. 2 cover to the indicator housing.
(b) Install the housing and attach the 4 claws to the
floor shift assembly.
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U151F AUTOMATIC TRANSAXLE – FLOOR SHIFT ASSEMBLYAX–167
AX
INSTALLATION
1. INSTALL FLOOR SHIFT ASSEMBLY
(a) Connect the 2 connectors and attach the clamp.
(b) Install the floor shift with the 4 bolts.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
2. CONNECT TRANSMISSION CONTROL CABLE
ASSEMBLY
(a) Turn the nut of the control cable and push in the
lock.
(b) Install the control cable onto the shift lever retainer.
NOTICE:
• Install the cable with the protruding portion of
the cable outer facing upward.
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AX–168U151F AUTOMATIC TRANSAXLE – FLOOR SHIFT ASSEMBLY
AX
• After installing, check that the lock of the
cable outer is protruding beyond portion A-A,
as shown in the illustration.
(c) Connect the control cable to the shift lever.
NOTICE:
Connect the control cable so that the adjusting
mechanism lock of the control cable is installed
on the driver side of the vehicle.
3. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
4. INSPECT SHIFT LEVER POSITION (See page AX-164)
5. ADJUST SHIFT LEVER POSITION (See page AX-164)
6. INSTALL REAR CONSOLE BOX SUB-ASSEMBLY
(a) Install the rear console box (see page IP-26).
7. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY
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AX–170U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL OIL SEAL
AX
REPLACEMENT
1. REPLACE TRANSAXLE HOUSING OIL SEAL LH
(a) Drain the automatic transaxle fluid.
(1) Remove the drain plug and gasket, and drain
the ATF.
(2) Install a new gasket and drain plug.
Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf)
(b) Remove the front drive shaft LH (see page DS-41).
(c) Remove the transaxle housing oil seal LH.
(1) Using SST, tap out the oil seal.
SST 09308-00010
(d) Install a new transaxle housing oil seal LH.
(1) Coat the lip of a new oil seal with MP grease.
(2) Using SST and a hammer, tap in the oil seal.
SST 09223-15020, 09950-70010 (09951-
07200)
Standard depth:
0 +-0.5 mm (0 +-0.020 in.)
(e) Install the front drive shaft LH (see page DS-66).
(f) Add automatic transaxle fluid.
Fluid type:
Toyota Genuine ATF WS
(g) Inspect the transaxle fluid level (see page AX-126).
2. REPLACE TRANSAXLE HOUSING OIL SEAL RH
(a) Remove the engine assembly with transaxle (see
page EM-21).
(b) Drain the automatic transaxle fluid.
(1) Remove the drain plug and gasket, and drain
the ATF.
(2) Install a new gasket and the drain plug.
Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf)
(c) Remove the 3 bolts and drive shaft bearing bracket.
(d) Remove the 3 bolts and rear engine mounting
bracket.
(e) Remove the transfer assembly (see page TF-59).
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U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL OIL SEALAX–171
AX
(f) Remove the transaxle housing oil seal RH.
(1) Using a screwdriver with vinyl tape wound
around its tip, remove the oil seal.
NOTICE:
Be careful not to damage the housing.
(g) Install a new transaxle housing oil seal RH.
(1) Coat the lip of a new oil seal with MP grease.
(2) Using SST and a hammer, tap in the oil seal.
SST 09649-17010, 09950-70010 (09951-
07200)
Standard depth:
6.0 +-0.5 mm (0.236 +-0.020 in.)
(h) Install the transfer assembly (see page TF-75).
(i) Install the rear engine mounting bracket with the 3
bolts.
Torque: 64 N*m (652 kgf*cm, 47 ft.*lbf)
(j) Install the drive shaft bearing bracket with the 3
bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
(k) Install the engine with transaxle (see page EM-31).
(l) Add automatic transaxle fluid.
Fluid type:
Toyota Genuine ATF WS
(m) Inspect the fluid level (see page AX-126).
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AX–176U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY
AX
INSTALLATION
1. INSPECT TORQUE CONVERTER CLUTCH
ASSEMBLY
(a) Inspect the torque converter clutch (see page AX-
179).
2. INSTALL TORQUE CONVERTER CLUTCH
ASSEMBLY
(a) Install the torque converter clutch to the automatic
transaxle.
(b) Using a vernier caliper, measure dimension A
between the transaxle and end surface of the drive
plate.
(c) Using a vernier caliper and straightedge, measure
dimension B shown in the illustration and check that
B is greater than A.
Standard dimension:
A + 1.0 mm (0.039 in.) or more
3. INSTALL AUTOMATIC TRANSMISSION CASE
PROTECTOR
(a) Install the protector with the 2 bolts.
Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)
4. INSTALL NO. 1 TRANSMISSION CONTROL CABLE
BRACKET
(a) Install the cable bracket with the 2 bolts.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
5. INSTALL TRANSMISSION OIL FILLER TUBE SUB-
ASSEMBLY
(a) Install the filler tube with the bolt.
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
(b) Install the ATF dipstick.
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U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLYAX–177
AX
6. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
(a) Install the automatic transaxle to the engine with the
7 upper side mounting bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
(b) Install the 3 lower side mounting bolts.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) for bolt A
46 N*m (469 kgf*cm, 34 ft.*lbf) for bolt B
(c) Install the 6 torque converter clutch mounting bolts.
Torque: 41 N*m (418 kgf*cm, 30 ft.*lbf)
HINT:
First install the green colored bolt and then the other
5 bolts.
(d) Install the flywheel housing under cover with the 2
bolts.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
7. INSTALL TRANSFER ASSEMBLY
(a) Install the transfer (see page TF-75).
8. INSTALL ENGINE MOUNTING BRACKET LH
(a) Install the mounting bracket with the 4 bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
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AX–178U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY
AX
9. INSTALL FRONT ENGINE MOUNTING BRACKET
(a) Install the mounting bracket with the 4 bolts.
Torque: 64 N*m (657 kgf*cm, 47 ft.*lbf)
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) for filler
tube bolt
10. INSTALL REAR ENGINE MOUNTING BRACKET
(a) Install the mounting bracket with the 3 bolts.
Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf)
11. INSTALL TRANSMISSION OIL COOLER HOSES AND
TUBE
(a) Install the transmission oil cooler hoses and tube
(see page AX-152).
12. CONNECT WIRE HARNESS
(a) Connect the wire harness clamps.
(b) Connect the 2 speed sensor connectors.
(c) Connect the transaxle wire connector.
(d) Connect the park/neutral position switch connector.
13. INSTALL STARTER ASSEMBLY
(a) Install the starter with the 2 bolts.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
(b) Connect the starter connector.
(c) Install the terminal nut and cover the nut with the
cap.
Torque: 9.8 N*m (100 kgf*cm, 88 in.*lbf)
14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the engine with transaxle (see page EM-31).
15. ADD AUTOMATIC TRANSAXLE FLUID
Fluid type:
Toyota Genuine ATF WS
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A126954