transaxle TOYOTA RAV4 2006 Service Repair Manual

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–13
AX
NG
OK
(a) Refer to the HYDRAULIC TEST (see page AX-16).
NG
OK
(a) Refer to the MANUAL SHIFTING TEST (see page AX-
17).
NG
OK
(a) Refer to the PROBLEM SYMPTOMS TABLE (see page
AX-21).
NG
OK
(a) Refer to the PROBLEM SYMPTOMS TABLE (see page
AX-21).
NEXT
NG
OK
(a) Refer to the DIAGNOSTIC TROUBLE CODE CHART
(see page AX-35).
NEXTGO TO STEP 17
13HYDRAULIC TEST
GO TO STEP 17
14MANUAL SHIFTING TEST
GO TO STEP 16
15PROBLEM SYMPTOMS TABLE CHAPTER 1
GO TO STEP 19
16PROBLEM SYMPTOMS TABLE CHAPTER 2
17PART INSPECTION
GO TO STEP 21
18DTC CHART

AX–14U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
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NEXT
NEXT
NEXT
NEXT
19CIRCUIT INSPECTION
20IDENTIFICATION OF PROBLEM
21REPAIR OR REPLACE
22CONFIRMATION TEST
END

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–15
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ROAD TEST
1. PROBLEM SYMPTOM CONFIRMATION
(a) Based on the result of the customer problem
analysis, try to reproduce the symptoms. If the
problem is that the transaxle does not shift up, shift
down, or the shift point is too high or too low,
conduct the following road test referring to the
automatic shift schedule and simulate the problem
symptoms.
2. ROAD TEST
NOTICE:
Perform the test at the normal operating ATF
temperature of 50 to 80
C (122 to 176F).
(a) D position test
Move the shift lever to D and fully depress the
accelerator pedal. Check the following:
(1) Check up-shift operation.
Check that the 1
2, 2 3 and 3 O/D up-
shifts take place at the shift point shown in the
automatic shift schedule (see page SS-60).
HINT:
O/D Gear Up-shift Prohibition Control
• Engine coolant temperature is 55
C (131F)
or less and vehicle speed is at 70 km/h (43
mph) or less.
• ATF temperature is 5
C (41F) or less.
O/D Gear Lock-up Prohibition Control
• Brake pedal is depressed.
• Accelerator pedal is released.
• Engine coolant temperature is 60
C (140F)
or less.
(2) Check for shift shock and slip.
Check for shock and slip at the 1
2, 2 3 and
3
O/D up-shifts.
(3) Check for abnormal noise and vibration.
Check for abnormal noise and vibration when
up-shifting from 1
2, 2 3 and 3 O/D while
driving with the shift lever on D, and check while
driving in the lock-up condition.
HINT:
The check for the cause of abnormal noise and
vibration must be done thoroughly as it could
also be due to loss of balance in the differential,
torque converter clutch, etc.
(4) Check kick-down operation.
While driving the vehicle in the 2nd, 3rd and O/D
gears with the shift lever on D, check that the
possible kick-down vehicle speed limits for 2

1, 3
2 and O/D 3 kick-downs conform to
those indicated in the automatic shift schedule
(see page SS-60).
(5) Check for abnormal shock and slip at kick-down.

AX–16U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
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(6) Check the lock-up mechanism.
• Drive the vehicl e in the O/D gear with the shift
lever on D. Maintain a steady speed (lock-up
ON).
• Lightly depress the accelerator pedal and
check that the engine speed does not change
abruptly.
HINT:
• There is no lock-up function in the 1st and
2nd gear.
• If there is a sudden increase in engine speed,
there is no lock-up.
(b) 3 position test
Move the shift lever to 3 and fully depress the
accelerator pedal. Check the following:
(1) Check up-shift operation.
Check that the 1
2 and 2 3 up-shifts take
place and that the shift point conforms to the
automatic shift schedule (see page SS-60).
(2) Check engine braking.
While driving the vehicle in the 3rd gear with the
shift lever on 3, release the accelerator pedal
and check the engine braking effect.
(3) Check for abnormal noises during acceleration
and deceleration, and for shock at up-shift and
down-shift.
(c) 2 position test
Move the shift lever to 2 and fully depress the
accelerator pedal. Check the following:
(1) Check up-shift operation.
Check that the 1
2 up-shift takes place and
that the shift point conforms to the automatic
shift schedule (see page SS-60).
HINT:
There is no O/D up-shift and lock-up when the
shift lever is on 2.
(2) Check engine braking.
While driving the vehicle in the 2nd gear with the
shift lever on 2, release the accelerator pedal
and check the engine braking effect.
(3) Check for abnormal noises during acceleration
and deceleration, and for shock at up-shift and
down-shift.
(d) L position test
Move the shift lever to L and fully depress the
accelerator pedal. Check the following:
(1) Check that there is no up-shift.
While driving the vehicle with the shift lever on L,
check that there is no up-shift to 2nd gear.
HINT:
There is no lock-up in L.

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–17
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(2) Check engine braking.
While driving the vehicle with the shift lever on L,
release the accelerator pedal and check the
engine braking effect.
(3) Check for abnormal noises during acceleration
and deceleration.
(e) R position test
Move the shift lever to R and lightly depress the
accelerator pedal. Check that the vehicle moves
backward without any abnormal noise or vibration.
CAUTION:
Before conducting this test, ensure that no
people or obstacles are in the test area.
(f) P position test
Stop the vehicle on an incline (more than 5
). Then
move the shift lever to P and release the parking
brake. Check that the parking lock pawl holds the
vehicle in place.

AX–18U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
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MECHANICAL SYSTEM TESTS
1. STALL SPEED TEST
HINT:
This test is to check the overall performance of the
engine and transaxle.
NOTICE:
• Do not perform the stall speed test longer than 5
seconds.
• To ensure safety, perform this test in an open and
level area that provides good traction.
• The stall speed test should always be performed
with at least 2 people. One person should observe
the condition of the wheels and wheel chocks
while the other is performing the test.
(a) Connect the intelligent tester to the CAN VIM. Then
connect the CAN VIM to the DLC3.
(b) Run the vehicle until the transmission fluid
temperature has reached 50 to 80
C (122 to 176F).
(c) Allow the engine to idle with the air conditioning
OFF.
(d) Chock all 4 wheels.
(e) Set the parking brake and keep the brake pedal
depressed firmly with your left foot.
(f) Move the shift lever to the D position.
(g) Depress the accelerator pedal as much as possible
with your right foot.
(h) Read the engine rpm (stall speed) and release the
accelerator pedal immediately.
Standard value:
2,150 to 2,450 rpm
Evaluation:
NOTICE:
Perform the test at the normal operating ATF
temperature of 50 to 80
C (122 to 176F).
2. SHIFT TIME LAG TEST
HINT:
This test is to check the condition of the direct clutch,
forward clutch, 1st brake and reverse brake.
(a) Connect the intelligent tester to the CAN VIM. Then
connect the CAN VIM to the DLC3.
(b) Run the vehicle until the transmission fluid
temperature has reached 50 to 80
C (122 to 176F).
(c) Allow the engine to idle with the air conditioning
OFF.
Test Result Possible Cause
Stall speed is lower than standard value • Stator one-way clutch is not operating properly
• Torque converter is faulty (stall speed is less than standard value
by 600 rpm or more)
• Engine power may be insufficient
Stall speed is higher than standard value • Line pressure is low
• C1 clutch slipping
• F3 one-way clutch is not operating properly
• F4 one-way clutch is not operating properly

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–19
AX
(d) Set the parking brake and keep the brake pedal
depressed firmly.
(e) Check the D range time lag.
(1) Move the shift lever to N and wait for 1 minute.
(2) Move the shift lever to D and measure the time
until the shock is felt.
(3) Repeat the 2 procedures above 3 times, and
calculate the average time of the 3 tests.
(f) Check the R range time lag.
(1) Move the shift lever to N and wait for 1 minute.
(2) Move the shift lever to R and measure the time
until the shock is felt.
(3) Repeat the 2 procedures above 3 times, and
calculate the average time of the 3 tests.
Standard value:
D range time lag is less than 1.2 seconds
R range time lag is less than 1.5 seconds
Evaluation:
HYDRAULIC TEST
1. MEASURE LINE PRESSURE
NOTICE:
• Perform the test at the normal operating ATF
temperature: 50 to 80
C (122 to 176F).
• The line pressure test should always be
performed with at least 2 people. One person
should observe the condition of the wheels or
wheel chocks while the other is performing the
test.
• Be careful to prevent SST's hose from interfering
with the exhaust pipe.
• This test must be performed after checking and
adjusting the engine.
• Perform the test with the A/C OFF.
• When conducting the stall test, do not continue
for more than 10 seconds.
(a) Warm up the ATF.
(b) Remove the test plug on the transaxle case center
right side and connect SST.
SST 09992-00095 (09992-00231, 09992-00271)
(c) Fully apply the parking brake and chock the 4
wheels.
(d) Start the engine and check the idling speed.
(e) Keep your left foot firmly on the brake pedal and
move the shift lever to D.
(f) Measure the line pressure when the engine is idling.
Test Result Possible Cause
D range time lag exceeds standard value • Line pressure is low
• C1 clutch is worn
• F3 one-way clutch is not operating properly
• F4 one-way clutch is not operating properly
R range time lag exceeds standard value • Line pressure is low
• C3 clutch is worn
• B4 brake is worn
• F1 one-way clutch is not operating properly
D025472E01

AX–20U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
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(g) Depress the accelerator pedal as much as possible
with your right foot. Quickly read the highest line
pressure reading when the engine speed reaches
stall speed.
(h) Perform the measure line pressure test again with
the shift lever on R.
Specified line pressure:
Evaluation:
Condition Shift Lever on D Shift Lever on R
Idling 372 to 412 kPa
(3.8 to 4.2 kgf/cm
2, 54 to 60 psi)672 to 742 kPa
(6.9 to 7.6 kgf/cm2, 97 to 108 psi)
Stall 931 to 1,031 kPa
(9.5 to 10.5 kgf/cm
2, 135 to 150 psi)1,768 to 1,968 kPa
(18.0 to 20.0 kgf/cm2, 256 to 285 psi)
Problem Possible Cause
Measured values at all positions are higher than specified • Shift solenoid valve SLT defective
• Regulator valve defective
Measured values at all positions are lower than specified • Shift solenoid valve SLT defective
• Regulator valve defective
• Oil pump defective
• U/D (underdrive) direct clutch defective
Pressure is low when shift lever is on D only • D position circuit fluid leak
• Forward clutch defective
Pressure is low when shift lever is on R only • R position circuit fluid leak
• Direct clutch defective
• 1st and reverse brake defective

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEMAX–21
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MANUAL SHIFTING TEST
1. MANUAL SHIFTING TEST
HINT:
• Through this test, it can be determined whether the
trouble occurs in the electrical circuit or if it is a
mechanical problem in the transaxle.
• If any abnormalities are found in the following test, the
problem is in the transaxle itself.
(a) Disconnect the connector of the transmission wire.
HINT:
It is possible to deactivate the electrical shift control
by disconnecting the transmission wire. The gear
positions can then be changed mechanically with
the shift lever.
(b) Drive with the transmission wire disconnected.
Move the shift lever to each position to check
whether the gear position changes as shown in the
table below.
(c) Connect the connector of the transmission wire.
(d) Clear the DTC (see page AX-29).
C127583
Shift Lever Position Gear Position
D3rd
23rd
L3rd
RR
PP

AX–22U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
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INITIALIZATION
1. RESET MEMORY
NOTICE:
• Perform the RESET MEMORY procedures (A/T
initialization) when replacing the automatic
transaxle assembly, engine assembly or ECM.
• RESET MEMORY can be performed only with the
intelligent tester.
HINT:
The ECM memorizes the vehicle conditions when the
ECT controls the automatic transaxle assembly and
engine assembly. Therefore, when the automatic
transaxle assembly, engine assembly, or ECM has been
replaced, it is necessary to reset the memory so that the
ECM can memorize the new information.
The reset procedures are as follows.
(a) Turn the ignition switch OFF.
(b) Connect the intelligent tester to the CAN VIM. Then
connect the CAN VIM to the DLC3.
(c) Turn the ignition switch ON and turn the tester ON.
(d) Enter the following menus: DIAGNOSIS /
ENHANCED OBD II.
(e) Perform the reset memory procedures from the
Engine menu.
CAUTION:
After performing the RESET MEMORY
procedures, be sure to perform the ROAD TEST
(see page AX-12) as described earlier.
HINT:
The ECM learns through the ROAD TEST.