TOYOTA RAV4 2006 Service Repair Manual

AX–162U151F AUTOMATIC TRANSAXLE – FLOOR SHIFT ASSEMBLY
AX
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 SHIFT LEVER KNOB SUB-ASSEMBLY
3. REMOVE REAR CONSOLE BOX SUB-ASSEMBLY
(a) Remove the console box (see page IP-20).
4. DISCONNECT TRANSMISSION CONTROL CABLE
ASSEMBLY
(a) Disconnect the control cable from the shift lever.
(b) Turn the nut and disconnect the control cable from
the shift lever retainer.
5. REMOVE FLOOR SHIFT ASSEMBLY
(a) Remove the 4 bolts and floor shift.
C130920
C127813E01
C127815

U151F AUTOMATIC TRANSAXLE – FLOOR SHIFT ASSEMBLYAX–163
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(b) Disconnect the 2 connectors and detach the clamp.
DISASSEMBLY
1. REMOVE LOWER POSITION INDICATOR HOUSING
(a) Detach the 4 claws and remove the housing.
(b) Remove the position indicator slide cover with slide
No. 2 cover.
2. REMOVE POSITION INDICATOR LIGHT HOUSING
(a) Detach the 2 claws and remove the indicator light
housing from the floor shift position indicator
housing.
3. REMOVE INDICATOR LIGHT WIRE SUB-ASSEMBLY
C127814
C127818
C127816

AX–164U151F AUTOMATIC TRANSAXLE – FLOOR SHIFT ASSEMBLY
AX
4. REMOVE SHIFT LOCK RELEASE BUTTON
(a) Detach the 2 claws and remove the button and
spring from the position indicator light housing.
C127817

AX–288U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
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7. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, tap out the oil seal.
SST 09950-70010 (09951-07100), 09215-00013
(09215-00471)
8. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, tap out the oil seal.
SST 09950-70010 (09951-07100), 09608-10010
INSPECTION
1. INSPECT DIFFERENTIAL SIDE GEAR BACKLASH
(a) Using a dial indicator, measure the backlash of the
side gear.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0070 in.)
Standard thrust washer thickness:
1.625 mm (0.0640 in.)
1.725 mm (0.0679 in.)
1.825 mm (0.0719 in.)
REASSEMBLY
1. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Coat the 2 front differential side gears, 2 side gear
thrust washers, 2 front differential pinions and 2
pinion thrust washers with ATF and install them to
the differential case.
2. INSTALL NO. 1 FRONT DIFFERENTIAL PINION
SHAFT
(a) Coat the No. 1 front differential pinion shaft with
ATF, and install it to the differential case.
D025599E01
D025600E01
C050252E01
C050242E02
C050241E03

U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–289
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3. INSTALL FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch and a hammer, tap in the pinion
shaft straight pin.
(b) Using a chisel and a hammer, stake the differential
case.
NOTICE:
Stake it after adjusting the backlash.
4. INSTALL FRONT DIFFERENTIAL CASE REAR
TAPERED ROLLER BEARING
(a) Using SST and a press, press in the front differential
case rear tapered roller bearing to the differential
case.
SST 09550-60010, 09950-60020 (09951-00680),
09950-70010 (09951-07100)
NOTICE:
• When replacing the bearing, be sure to
replace it together with the outer race.
• When replacing a bearing of the differential
case, replace both the front and rear bearings
together.
(b) Using SST and a hammer, tap in the front
differential case rear tapered roller bearing outer
race to the transaxle housing.
SST 09550-60010, 09950-60020 (09951-00680),
09950-70010 (09951-07100, 09951-00890)
NOTICE:
When replacing the bearing, be sure to replace it
together with the outer race.
C127426
C127427
C083734E02
C083736E03

AX–290U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
AX
5. INSTALL FRONT DIFFERENTIAL CASE FRONT
TAPERED ROLLER BEARING
(a) U si ng SST and a pres s, pr es s in the f ron t di fferent ial
case front tapered roller bearing to the differential
case.
SST 09550-60010, 09950-60020 (09951-00680),
09950-70010 (09951-07100, 09951-00890)
NOTICE:
• When replacing the bearing, be sure to
replace it together with the outer race.
• When replacing a bearing of the differential
case, replace both the front and rear bearings
together.
(b) Using SST and a hammer, tap in the front
differential case front tapered roller bearing outer
race to the transaxle housing.
SST 09550-60010, 09950-60020 (09951-00680),
09950-70010 (09951-07100, 09951-00890)
NOTICE:
• When replacing the bearing, be sure to
replace it together with the outer race.
• Clearance is not allowed between the bearing
and transaxle housing.
6. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD
(a) Install the differential assembly to the transaxle
case.
(b) Clean the matching surfaces of the transaxle case
and transaxle housing.
(c) Install the transaxle housing to the transaxle case
and tighten them with the 16 bolts.
Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) for bolt A
29 N*m (295 kgf*cm, 21 ft.*lbf) for bolt B
29 N*m (295 kgf*cm, 21 ft.*lbf) for bolt C
22 N*m (224 kgf*cm, 16 ft.*lbf) for bolt D
HINT:
• Each bolt length is indicated below.
Bolt length:
50 mm (1.97 in.) for bolt A
50 mm (1.97 in.) for bolt B
42 mm (1.65 in.) for bolt C
72 mm (2.84 in.) for bolt D
• Usually, bolt A is a non-reusable bolt. In this
case, however, it can be used after cleaning it.
C127428E01
D025603E01
C127429
D003568E04

U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–291
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(d) Using SST, turn the differential assembly right and
left 2 or 3 times to allow the bearing to settle.
SST 09564-32011
(e) Using SST and a torque wrench, measure the
turning torque of the differential.
SST 09564-32011
Torque: Standard turning torque at 60 rpm
0.20 to 0.69 N*m (2.0 to 7.0 kgf*cm, 1.8
to 6.1 in.*lbf)
HINT:
If the turning torque is not within the specified value,
refer to the table below and select a thrust washer
so that the turning torque is within the specified
value.
Flange thickness
D025604E03
Mark Thickness Mark Thickness
0 2.00 mm (0.0787
in.)J 2.025 mm
(0.07972 in.)
1 2.05 mm (0.0807
in.)K 2.075 mm
(0.08169 in.)
2 2.10 mm (0.0827
in.)L 2.125 mm
(0.08366 in.)
3 2.15 mm (0.0846
in.)M 2.175 mm
(0.08563 in.)
4 2.20 mm (0.0866
in.)N 2.225 mm
(0.08760 in.)
5 2.25 mm (0.0886
in.)P 2.275 mm
(0.08957 in.)
6 2.30 mm (0.0906
in.)Q 2.325 mm
(0.09154 in.)
7 2.35 mm (0.0925
in.)R 2.375 mm
(0.09350 in.)
8 2.40 mm (0.0945
in.)S 2.425 mm
(0.09547 in.)
9 2.45 mm (0.0965
in.)T 2.475 mm
(0.09744 in.)
A 2.50 mm (0.0984
in.)U 2.525 mm
(0.09941 in.)
B 2.55 mm (0.1004
in.)V 2.575 mm
(0.10138 in.)
C 2.60 mm (0.1024
in.)W 2.625 mm
(0.10335 in.)
D 2.65 mm (1.1043
in.)X 2.675 mm
(0.10531 in.)
E 2.70 mm (0.1063
in.)Y 2.725 mm
(0.10728 in.)
F 2.75 mm (0.1083
in.)AA 2.775 mm
(0.10925 in.)
G 2.80 mm (0.1102
in.)AB 2.825 mm
(0.11122 in.)
H 2.85 mm (0.1122
in.)--

AX–292U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
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(f) Remove the 16 bolts and the transaxle housing.
(g) Remove the differential assembly.
7. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and a heater, heat the front differential
ring gear to 90 to 110
C (194.0 to 230.0F).
NOTICE:
Do not overheat the ring gear to 110
C (230.0F)
or more.
(b) Clean the contract surface of the front differential
case.
(c) Align the matchmarks, and install the front
differential ring gear case quickly.
NOTICE:
• Check the position and number of the
grooves on each end face of the differential
ring gear.
• Do not install the bolts while the ring gear is
hot.
(d) Tighten the 14 bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
NOTICE:
Tighten the bolts a little at a time in diagonal
order.
C050259E02
C127429
D025215E03
C140285E01
C127422

U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–293
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8. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Coat the lip of a new oil seal with a small amount of
MP grease.
(b) Using SST and a hammer, tap in the oil seal.
SST 09223-15020, 09950-70010 (09951-07100)
9. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Coat the lip of a new oil seal with a small amount of
MP grease.
(b) Using SST and a hammer, tap in the oil seal.
SST 09710-30050, 09950-70010 (09951-07100)
C083738E02
D025606E01

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–3
AX
DEFINITION OF TERMS
Te r m D e f i n i t i o n
Monitor description Description of what the ECM monitors and how it detects malfunctions (monitoring purpose and its details).
Related DTCs Diagnostic code.
Typical enabling conditionPreconditions that allow the ECM to detect malfunctions.
With all preconditions satisfied, the ECM sets the DTC when the monitored value(s) exceeds the
malfunction threshold(s).
Sequence of operationThe priority order that is applied to monitoring, if multiple sensors and components are used to detect the
malfunction.
While another sensor is being monitored, the next sensor or component will not be monitored.
Required sensor/Components The sensors and components that are used by the ECM to detect malfunctions.
Frequency of operationThe number of times that the ECM checks for malfunctions per driving cycle.
"Once per driving cycle" means that the ECM detects malfunction only 1 time during a single driving cycle.
"Continuous" means that the ECM detects a malfunction every time the enabling condition is met.
DurationThe minimum time that the ECM must sense a continuous deviation in the monitored value(s) before
setting a DTC. This timing begins after the "typical enabling conditions" are met.
Malfunction thresholds Beyond this value, the ECM will conclude that there is a malfunction and set a DTC.
MIL operationMIL illumination timing after a defect is detected.
"Immediate" means that the ECM illuminates the MIL the instant the ECM determines that there is a
malfunction.
"2 driving cycle" means that the ECM illuminates the MIL if the same malfunction is detected again in the
2nd driving cycle.
Component operating rangeNormal operation range of sensors and solenoids under normal driving conditions.
Use these ranges as a reference.
They cannot be used to judge if a sensor or solenoid is defective or not.