transaxle TOYOTA RAV4 2006 Service Repair Manual

AX–150U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE ASSEMBLY
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5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
(a) Install the automatic transaxle with the 5 upper side
mounting bolts to the engine.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) for bolt A
46 N*m (469 kgf*cm, 34 ft.*lbf) for bolt B
(b) Install the 4 lower side mounting bolts.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
(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 5
bolts.
(d) Install the flywheel housing under cover.
6. INSTALL ENGINE MOUNTING BRACKET LH
(a) Install the mounting bracket with the 3 bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
7. INSTALL ENGINE MOUNTING BRACKET FR
(a) Install the mounting bracket with the 4 bolts.
Torque: 64 N*m (657 kgf*cm, 47 ft.*lbf) for 14
mm head bolt
12 N*m (122 kgf*cm, 9 ft.*lbf) for 12 mm
head bolt
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8. INSTALL ENGINE MOUNTING BRACKET RR
(a) Install the mounting bracket with the 3 bolts.
Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf)
9. INSTALL TRANSMISSION OIL COOLER
(a) Install the oil cooler (see page AX-127).
10. CONNECT WIRE HARNESS
(a) Connect the wire harness clamps.
(b) Connect the speed sensor connectors.
(c) Connect the transaxle wire connector.
(d) Connect the park/neutral position switch connector.
11. 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 wire with the nut.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
(c) Connect the starter connector.
(d) Install the terminal nut and cover the nut with the
cap.
Torque: 9.8 N*m (100 kgf*cm, 7 in.*lbf)
12. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Install the engine with transaxle (see page EM-105).
13. ADD AUTOMATIC TRANSAXLE FLUID
Fluid type:
Toyota Genuine ATF WS
14. INSPECT AUTOMATIC TRANSAXLE FLUID
(a) Inspect the automatic transaxle fluid (see page AX-
102).
15. PERFORM RESET MEMORY
(a) Perform the RESET MEMORY procedures (A/T
initialization) (see page AX-18).
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DISASSEMBLY
1. REMOVE SPEEDOMETER DRIVEN HOLE COVER
SUB-ASSEMBLY
(a) Remove the bolt and hole cover from the transaxle.
(b) Remove the O-ring from the hole cover.
2. REMOVE PARK/NEUTRAL POSITION SWITCH
ASSEMBLY
(a) Remove the nut, washer and control shaft lever.
(b) Using a screwdriver, unstake the lock plate and
remove the lock nut and lock plate.
(c) Remove the 2 bolts and pull out the park/neutral
position switch.
3. REMOVE BREATHER PLUG HOSE
(a) Remove the breather plug hose from the breather
plug.
4. REMOVE OIL COOLER OUTLET TUBE UNION
(a) Remove the union.
(b) Remove the O-ring from the union.
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AX–166U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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5. REMOVE OIL COOLER INLET TUBE UNION
(a) Remove the union.
(b) Remove the O-ring from the union.
6. REMOVE SPEED SENSOR
(a) Remove the 2 bolts and 2 speed sensors from the
transaxle.
(b) Remove the 2 O-rings from the sensors.
7. REMOVE NO. 1 TRANSAXLE CASE PLUG
(a) Remove the 4 plugs from the transaxle.
(b) Remove the 4 O-rings from the 4 plugs.
8. FIX AUTOMATIC TRANSAXLE ASSEMBLY
9. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-
ASSEMBLY
(a) Remove the 18 bolts.
(b) Remove the oil pan and 3 magnets.
(c) Remove the gasket from the oil pan.
10. INSPECT AUTOMATIC TRANSAXLE OIL PAN SUB-
ASSEMBLY (See page AX-185)
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11. REMOVE VALVE BODY OIL STRAINER ASSEMBLY
(a) Remove the 3 bolts and oil strainer.
(b) Remove the O-ring from the oil strainer.
12. REMOVE TRANSMISSION WIRE
(a) Remove the 5 connectors from the shift solenoid
valves.
(b) Remove the bolt, clamp and ATF temperature
sensor.
(c) Remove the bolt and transaxle solenoid wire from
the transaxle.
(d) Remove the O-ring from the transaxle solenoid wire.
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AX–168U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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13. REMOVE TRANSMISSION VALVE BODY ASSEMBLY
(a) Support the valve body assembly and remove the
17 bolts and the valve body assembly.
14. REMOVE NO. 1 GOVERNOR APPLY GASKET
(a) Remove the governor apply gasket from the
transaxle.
15. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET
(a) Remove the 2nd brake gasket from the transaxle.
16. REMOVE BRAKE DRUM GASKET
(a) Remove the brake drum gasket from the transaxle.
17. REMOVE CHECK BALL BODY
(a) Remove the check ball body and spring from the
transaxle.
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18. REMOVE C-3 ACCUMULATOR PISTON
(a) Remove the compression spring from the C-3
accumulator piston.
(b) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the oil hole and remove the C-3 accumulator
piston.
NOTICE:
• Applying compressed air may cause the
piston to jump out. When removing the
piston, hold it with your hand using a waste
cloth.
• Make sure not to spatter ATF when applying
compressed air.
(c) Remove the O-ring from the C-3 accumulator
piston.
19. REMOVE C-1 ACCUMULATOR PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the oil hole and remove the C-1 accumulator
piston and compression spring.
NOTICE:
• Applying compressed air may cause the
piston to jump out. When removing the
piston, hold it with your hand using a waste
cloth.
• Make sure not to spatter ATF when applying
compressed air.
(b) Remove the 2 O-rings from the C-1 accumulator
piston.
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AX–170U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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20. REMOVE B-3 ACCUMULATOR PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the oil hole and remove the B-3 accumulator
piston and 2 compression springs.
NOTICE:
• Applying compressed air may cause the
piston to jump out. When removing the
piston, hold it with your hand using a waste
cloth.
• Make sure not to spatter ATF when applying
compressed air.
(b) Remove the O-ring from the B-3 accumulator
piston.
21. REMOVE MANUAL DETENT SPRING SUB-
ASSEMBLY
(a) Remove the 2 bolts, manual detent spring and
cover.
22. REMOVE PARKING LOCK PAWL BRACKET
(a) Remove the 2 bolts and parking lock pawl bracket.
23. REMOVE MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using needle-nose pliers, remove the retainer
spring.
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24. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY
(a) Using a chisel and hammer, unstake and remove
the manual valve lever spacer.
(b) Using a pin punch and hammer, tap out the manual
valve lever shaft spring pin.
HINT:
Slowly drive out the pin so that it will not fall into the
transaxle.
(c) Remove the manual valve lever shaft and manual
valve lever.
25. REMOVE PARKING LOCK ROD SUB-ASSEMBLY
(a) Remove the parking lock rod from the manual valve
lever.
26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Using a screwdriver, pry out the oil seal from the
transaxle.
27. INSPECT INPUT SHAFT END PLAY (See page AX-
185)
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AX–172U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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28. REMOVE NO. 1 TRANSAXLE CASE PLUG
(a) Remove the 2 plugs.
(b) Remove the 2 O-rings from the plug.
29. REMOVE TRANSAXLE HOUSING
(a) Remove the 16 bolts.
(b) Tap on the circumference of the transaxle housing
with a plastic-faced hammer to remove the
transaxle housing from the transaxle.
NOTICE:
Differential may be accidentally removed when
the transaxle housing is removed.
30. REMOVE UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Using SST, remove the cylindrical roller bearing
from the transaxle.
SST 09514-35011
31. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Remove the oil seal ring from the transaxle housing.
32. REMOVE OIL PUMP ASSEMBLY
(a) Remove the 7 bolts and oil pump assembly from the
transaxle.
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