transaxle TOYOTA RAV4 2006 Service Repair Manual

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–219
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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.
SST 09387-00070
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.
(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
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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
D003916E06
D003917E01
C138660E01
D003918E03

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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 of the
direction of the race.
• When installing the thrust bearing and front
sun gears, be careful about the direction of
the parts.
• When installing 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.
D008074E01
C089123E02
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.)
D026591E04

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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 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.)
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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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D008058E03
C092977E04
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(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.)

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(c) Install the rear planetary sun gear to the rear
planetary gear.
NOTICE:
After installing the rear planetary sun gear, make
sure that the B1 discs are engaged.
26. INSTALL 2ND BRAKE CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the
transaxle case.
(c) Temporarily install the snap ring.
27. 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 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
(c) Temporarily remove the snap ring, attach the
selected flange and reinstall the snap ring.
NOTICE:
Secure the snap ring so that the ends are visible
through the groove of the transaxle case.
D026714E05
C136371E01
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.) 8 -
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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 D).
(e) Using a vernier caliper and straightedge, measure
the dimension shown in the illustration.
(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
Standard bearing thickness and diameter
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
Thickness Inside Outside
3.6 mm (0.1417 in.) 56.3 mm (2.217 in.) 75.7 mm (2.980 in.)

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–227
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30. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Install 3 new governor apply gaskets to the
transaxle case.
31. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.
NOTICE:
Make sure to install the clamp to the apply tube
before installing the apply tube to the transaxle
case. This prevents the apply tube from being
deformed or damaged.
(b) Install the clutch apply tube.
(c) Install the brake apply tube to the transaxle case
with a bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
NOTICE:
The tube should be securely inserted until it
reaches the stopper.
32. INSTALL NEEDLE ROLLER BEARING
(a) Using SST and a press, press the needle roller
bearing into the transaxle rear cover.
SST 09950-60010 (09951-00230, 09952-06010)
Standard depth:
20.55 to 21.25 mm (0.8091 to 0.8366 in.)
NOTICE:
• The engraved mark side of the bearing
should face upward.
• Continue pressing until the specified value is
obtained.
(b) Coat a needle roller bearing with ATF.
33. INSTALL REAR CLUTCH OIL SEAL RING OUTER
(a) Coat 3 new rear clutch oil seal rings with ATF, and
install them to the transaxle rear cover.
NOTICE:
The snap ring should be fully engaged in the
groove of the drum.
3.8 mm (0.1496 in.) 56.3 mm (2.217 in.) 75.7 mm (2.980 in.) Thickness Inside Outside
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34. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Coat 4 new O-rings with ATF.
(b) Install the 4 O-rings to the 4 plugs.
(c) Install the 4 plugs to the transaxle rear cover.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
35. INSTALL TRANSAXLE REAR COVER SUB-
ASSEMBLY
(a) Remove any packing material and be careful not to
spill oil on the contact surfaces of the transaxle rear
cover or the transaxle case.
(b) Apply seal packing to the cover.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or Equivalent
NOTICE:
Make sure that the seal packing is applied in a
bead (section diameter:
1.2 mm (0.047 in.)) so
that the entire sealing surface will be evenly
sealed. The seal packing should also protrude
slightly from the flange after the installation of
the cover has been completed.
(c) Apply adhesive to the bolt threads of bolt A.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or Equivalent
(d) Install the 11 bolts.
Torque: 19 N*m (190 kgf*cm, 14 ft.*lbf) for bolt A
25 N*m (250 kgf*cm, 18 ft.*lbf) for other
bolts
36. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs, 4 plates and flange to the
transaxle case.
NOTICE:
Be careful of the order of the discs, plate and
flange.
C138647
C138665E01
C136369E01
D026414E01