transaxle TOYOTA RAV4 2006 Service Repair Manual

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–213
AX
56. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with
ATF, and install it to the transaxle.
57. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Coat a new governor apply gasket No. 1 with ATF,
and install it to the transaxle.
58. INSTALL TRANSMISSION VALVE BODY ASSEMBLY
(a) Make sure that the manual valve lever position,
install the valve body with the 17 bolts to the
transaxle.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
HINT:
Each bolt length is indicated below.
Bolt length:
25 mm (0.984 in.) for bolt A
41 mm (1.614 in.) for bolt B
45 mm (1.771 in.) for bolt C
NOTICE:
• Push the valve body against the accumulator
piston spring and the check ball body to
install it.
• When installing the valve body to the
transaxle case, do not hold the solenoids.
• Tighten the bolts marked by * in the
illustration first temporarily because they are
positioning bolts.
(b) Connect the 5 solenoid connectors.
(c) Install the ATF temperature sensor, clamp and bolt.
Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
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AX–214U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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59. INSTALL VALVE BODY OIL STRAINER ASSEMBLY
(a) Coat a new O-ring with ATF, and install it to the oil
strainer.
(b) Install the oil strainer and 3 bolts to the valve body.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
60. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-
ASSEMBLY
(a) Install the 3 magnets in the oil pan.
(b) Install a new oil pan gasket to the oil pan.
(c) Install the oil pan to the transaxle with the 18 bolts.
Torque: 7.6 N*m (77 kgf*cm, 67 in.*lbf)
NOTICE:
Because the bolts are seal bolts, apply seal
packing to new bolts and tighten them within 10
minutes after application.
61. INSTALL SPEED SENSOR
(a) Coat 2 new O-rings with ATF, and install them to the
2 sensors.
(b) Install the 2 sensors with the 2 bolts to the transaxle.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
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U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–215
AX
62. INSTALL OIL COOLER INLET TUBE UNION
(a) Coat a new O-ring with ATF, and install it to the
union.
(b) Install the union to the transaxle.
Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf)
63. INSTALL OIL COOLER OUTLET TUBE UNION
(a) Coat a new O-ring with ATF, and install it to the
union.
(b) Install the union to the transaxle case.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
64. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Coat 4 new O-rings with ATF, and install them to the
4 plugs.
(b) Install the 4 plugs to the transaxle.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
65. INSTALL BREATHER PLUG HOSE
(a) Install the breather plug hose to the breather plug.
66. INSTALL PARK/NEUTRAL POSITION SWITCH
ASSEMBLY
(a) Install the park/neutral position switch onto the
manual valve lever shaft and temporarily install the
2 adjusting bolts.
(b) Install a new lock plate and the nut.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
(c) Temporarily install the control shaft lever.
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AX–216U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(d) Turn the lever counterclockwise until it stops, and
then turn it clockwise 2 notches.
(e) Remove the control shaft lever.
(f) Align the groove with neutral basic line.
(g) Tighten the 2 bolts.
Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
(h) Using a screwdriver, stake the nut with the lock
plate.
(i) Install the control shaft lever, washer and nut.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
67. INSTALL SPEEDOMETER DRIVEN HOLE COVER
SUB-ASSEMBLY
(a) Coat a new O-ring with ATF and install it to the hole
cover.
(b) Install the hole cover to the transaxle with the bolt.
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U241E AUTOMATIC TRANSAXLE – OIL PUMPAX–221
AX
REASSEMBLY
1. INSTALL FRONT OIL PUMP OIL SEAL
(a) Using SST, install a new oil seal to the pump.
SST 09350-32014 (09351-32140)
HINT:
The seal end should be flush with the outer edge of
the oil pump.
(b) Coat the lip of the oil seal with petroleum jelly.
2. INSTALL FRONT OIL PUMP BODY O-RING
(a) Coat a new O-ring with ATF, and install it to the oil
pump body.
3. INSTALL FRONT OIL PUMP DRIVEN GEAR
(a) Coat the front oil pump driven gear with ATF, and
install it to the oil pump body with the maked side
facing up.
4. INSTALL FRONT OIL PUMP DRIVE GEAR
(a) Coat the front oil pump drive gear with ATF, and
install it to the oil pump body with the maked side
facing up.
5. INSTALL STATOR SHAFT ASSEMBLY
(a) Set stator shaft by aligning each bolt hole.
(b) Using a T30 ''torx'' socket, install the 11 bolts.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
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AX–222U241E AUTOMATIC TRANSAXLE – OIL PUMP
AX
6. INSTALL CLUTCH DRUM OIL SEAL RING
NOTICE:
Do not expand the ring ends excessively.
(a) Install the 2 clutch drum oil seal rings.
7. INSPECT OIL PUMP ASSEMBLY (See page AX-219)
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AX–230U241E AUTOMATIC TRANSAXLE – FORWARD CLUTCH
AX
REASSEMBLY
1. INSTALL INPUT SHAFT OIL SEAL RING
(a) Compress the oil seal ring from both sides to reduce
dimension A.
Dimension A:
5.0 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the
input shaft.
2. INSTALL FORWARD CLUTCH PISTON O-RING
(a) Coat 2 new O-rings with ATF, and install them to the
forward clutch piston.
3. INSTALL FORWARD CLUTCH PISTON SUB-
ASSEMBLY
(a) Install the forward clutch piston to the forward clutch
drum.
4. INSTALL FORWARD CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Place the forward clutch return spring onto the
forward clutch piston.
(b) Place SST on the return spring, and compress the
return spring with a press.
SST 09350-32014 (09351-32070)
(c) Install the snap ring with a snap ring expander. Be
sure the end gap of the snap ring is not aligned with
the spring retainer claw.
NOTICE:
• Stop the press when the spring sheet is
lowered to the place 1 to 2 mm (0.039 to 0.078
in.) from the snap ring groove.
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U241E AUTOMATIC TRANSAXLE – FORWARD CLUTCHAX–231
AX
• This prevents the spring sheet from being
deformed.
• Do not expand the snap ring excessively.
5. INSTALL FORWARD CLUTCH FLANGE HOLE SNAP
RING
(a) Install the 5 plates, 5 discs and flange.
Install order:
P - D - P - D - P - D - P - D - P - D - F
HINT:
P = Plate
D = Disc
F = Flange
(b) Using a screwdriver, install the snap ring.
(c) Check that the end gap of the snap ring is not
aligned with one of the cutouts.
6. INSPECT PACK CLEARANCE OF FORWARD
CLUTCH (See page AX-228)
7. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
(a) Inspect the clutch disc rotation.
(1) After inserting the multiple disc clutch into the
multiple disc clutch hub, rotate the forward
clutch and check that the disc lightly rotates.
NOTICE:
Do not place the forward clutch in a vise.
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U241E AUTOMATIC TRANSAXLE – VALVE BODYAX–253
AX
REASSEMBLY
1. INSTALL MANUAL VALVE
(a) Install the manual valve to the valve body.
2. INSTALL SHIFT SOLENOID VALVE S4
(a) Install the shift solenoid valve S4 to the valve body
with the bolt.
Torque: 11 N*m (112 kgf*cm, 9 ft.*lbf)
3. INSTALL SHIFT SOLENOID VALVE SL2
(a) Install the shift solenoid valve SL2 to the valve body
with the bolt and plate.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
4. INSTALL SHIFT SOLENOID VALVE DSL
(a) Install the shift solenoid valve DSL to the valve body
with the bolt.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
5. INSTALL SHIFT SOLENOID VALVE SL1
(a) Install the shift solenoid valve SL1 to the valve body
with the bolt and plate.
Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
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AX–254U241E AUTOMATIC TRANSAXLE – VALVE BODY
AX
6. INSTALL SHIFT SOLENOID VALVE SLT
(a) Install the shift solenoid valve SLT to the valve body
with the bolt and plate.
Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
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