transaxle TOYOTA RAV4 2006 Service Repair Manual

U241E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–257
AX
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the 2 front differential pinions, 2 pinion
thrust washers, 2 front differential side gears and 2
side gear thrust washers from the differential case.
7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Place the transaxle case in a vise.
(b) Using SST, remove the oil seal.
SST 09308-00010
8. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Place the transaxle housing in a vise.
(b) Using SST, remove the oil seal.
SST 09308-00010
INSPECTION
1. INSPECT FRONT 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
C083136E01
D025600E03
D025599E04
C083138E01Thickness Thickness
1.0 mm (0.0394 in.) 1.2 mm (0.0472 in.)
1.1 mm (0.0433 in.) 1.3 mm (0.0512 in.)

AX–258U241E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
AX
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 front differential pinion shaft with ATF, and
install it to the differential case.
3. INSPECT FRONT DIFFERENTIAL SIDE GEAR
BACKLASH (See page AX-257)
4. INSTALL FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch and hammer, tap in the pinion
shaft straight pin.
(b) Using a chisel and hammer, stake the differential
case.
5. INSTALL FRONT DIFFERENTIAL CASE REAR
TAPERED ROLLER BEARING
(a) Using SST and a press, press in the front differential
case tapered roller bearing rear inner race to the
differential case.
SST 09608-06041
C083137E01
C083135E01
C060005E01
C060006E01
D025218E03

U241E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–259
AX
(b) Using SST and a hammer, tap in the case washer
and front differential case tapered roller bearing rear
outer race to the transaxle case.
SST 09950-60020 (09951-00710), 09950-70010
(09951-07100)
6. INSTALL FRONT DIFFERENTIAL CASE FRONT
TAPERED ROLLER BEARING
(a) Using SST and a press, press in the front differential
case tapered roller bearing front inner race to the
differential case.
SST 09608-06041
(b) Using SST and a hammer, tap in the front
differential case tapered roller bearing front outer
race to the transaxle housing.
SST 09950-60020 (09951-00680), 09950-70010
(09951-07100), 09950-60010 (09951-00340)
7. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring
gear to 90 to 110
C (194.0 to 230.0F).
(b) Clean the contact surface of the front differential
case.
(c) Align the matchmarks, and install the front
differential ring gear case quickly.
D025219E02
D025216E01
D025217E01
D025215E03
C083132E02

AX–260U241E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
AX
(d) Tighten the 10 bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
8. INSPECT TAPERED ROLLER BEARING PRELOAD
(a) Install the differential assembly to the transaxle
case.
(b) Install the transaxle housing to the transaxle case.
(c) Install the 16 bolts.
Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) for bolt A
29 N*m (296 kgf*cm, 21 ft.*lbf) for bolt B
and C
HINT:
Each bolt length is indicated below.
Bolt length:
50 mm (1.97 in.) for bolt A and B
42 mm (1.65 in.) for bolt C
(d) Using SST, turn the differential.
SST 09564-32011
(e) Using SST and torque wrench, measure the preload
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) for new
0.10 to 0.35 N*m (1.0 to 3.6 kgf*cm, 0.9
to 3.1 in.*lbf) for used
C083133E01
C083139E01
C050259E01
C083572E01
C083572E01

U241E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–261
AX
Standard adjusting shim thickness
(f) Remove the 16 bolts.
(g) Using a practic-faced hammer, remove the
transaxle housing.
(h) Remove the differential.
Mark Thickness
0 1.90 mm (0.074 in.)
1 1.95 mm (0.077 in.)
2 2.00 mm (0.079 in.)
3 2.05 mm (0.081 in.)
4 2.10 mm (0.083 in.)
5 2.15 mm (0.085 in.)
6 2.20 mm (0.087 in.)
7 2.25 mm (0.089 in.)
8 2.30 mm (0.091 in.)
9 2.35 mm (0.093 in.)
A 2.40 mm (0.094 in.)
B 2.45 mm (0.096 in.)
C 2.50 mm (0.098 in.)
D 2.55 mm (0.100 in.)
E 2.60 mm (0.102 in.)
F 2.65 mm (0.104 in.)
G 2.70 mm (0.106 in.)
H 2.75 mm (0.108 in.)
J 2.80 mm (0.110 in.)
D009182E01
C083139E01

AX–262U241E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
AX
9. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Coat the lip of a new oil seal with a little amount of
MP grease.
(b) Using SST and a hammer, tap in the oil seal.
SST 09350-32014 (09351-32150), 09950-70010
(09951-07150)
10. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Coat the lip of a new oil seal with a little amount of
MP grease.
(b) Using SST and a hammer, tap in the oil seal.
SST 09350-32014 (09351-32150), 09950-70010
(09951-07150)
D025606E01
D025605E01

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)DS–7
DS
REMOVAL
(2005/11-2006/01)
1. REMOVE FRONT WHEEL
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Drain the automatic transaxle fluid for U140F (see
page AX-147).
(b) Drain the automatic transaxle fluid for U241E (see
page AX-146).
3. REMOVE FRONT AXLE HUB NUT (See page AH-6)
4. DISCONNECT FRONT SPEED SENSOR LH
(a) Disconnect the speed sensor (see page BC-191).
5. DISCONNECT FRONT SPEED SENSOR RH
HINT:
Use the same procedures described for the LH side.
6. DISCONNECT FRONT DISC BRAKE CYLINDER
ASSEMBLY LH (See page BR-40)
7. DISCONNECT FRONT DISC BRAKE CALIPER
ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
8. REMOVE FRONT STABILIZER LINK ASSEMBLY LH
(See page SP-30)
9. REMOVE FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
10. DISCONNECT FRONT SUSPENSION LOWER NO. 1
ARM SUB-ASSEMBLY LH (See page AH-7)
11. DISCONNECT FRONT SUSPENSION LOWER NO. 1
ARM SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
12. DISCONNECT STEERING KNUCKLE WITH AXLE
HUB LH
(a) Put matchmarks on the drive shaft and axle hub.
NOTICE:
Do not punch the marks.
(b) Using a plastic-faced hammer, disconnect the
steering knuckle with axle hub.
NOTICE:
Be careful not to damage the boot and speed
sensor rotor.
Do not excessively push out the drive shaft from
the axle assembly.
13. DISCONNECT STEERING KNUCKLE WITH AXLE
HUB RH
HINT:
Use the same procedures described for the LH side.
C129488E01

DS–8DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)
DS
14. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
(See page PS-42)
15. DISCONNECT TIE ROD END SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
16. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
(a) Using SST, remove the front drive shaft.
SST 09520-01010, 09520-24010 (09520-32040)
NOTICE:
• Be careful not to damage the transaxle case
oil seal, inboard joint boot and drive shaft
dust cover.
• Be careful not to drop the drive shaft.
17. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
(a) Remove the 2 bolts and pull out the drive shaft
together with the drive shaft bearing case.
(b) Remove the drive shaft from the transaxle.
NOTICE:
• Be careful not to damage the inboard joint
boot and drive shaft dust cover.
• Be careful not to drop the drive shaft.
18. FIX FRONT AXLE ASSEMBLY
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the
vehicle with the drive shaft removed. Therefore, if it
is absolutely necessary to place the vehicle weight
on the hub bearing, first support it with SST.
SST 09608-16042 (09608-02021, 09608-02041)
C127631E01
C127638
C129482E01

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)DS–9
DS
REMOVAL
(2006/01- )
1. REMOVE FRONT WHEEL
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Drain the automatic transaxle fluid for U140F (see
page AX-147).
(b) Drain the automatic transaxle fluid for U241E (see
page AX-146).
(c) Drain the automatic transaxle fluid for U151E (see
page AX-172).
3. REMOVE FRONT AXLE HUB NUT (See page AH-8)
4. DISCONNECT FRONT SPEED SENSOR LH
(a) Disconnect the speed sensor (see page BC-191).
5. REMOVE FRONT SPEED SENSOR RH
HINT:
Use the same procedures described for the LH side.
6. DISCONNECT FRONT DISC BRAKE CYLINDER
ASSEMBLY LH (See page BR-40)
7. DISCONNECT FRONT DISC BRAKE CYLINDER
ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
8. REMOVE FRONT STABILIZER LINK ASSEMBLY LH
(See page SP-30)
9. REMOVE FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
10. DISCONNECT FRONT SUSPENSION LOWER NO. 1
ARM SUB-ASSEMBLY LH (See page SP-21)
11. DISCONNECT FRONT SUSPENSION LOWER NO. 1
ARM SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
12. DISCONNECT STEERING KNUCKLE WITH AXLE
HUB LH
(a) Put matchmarks on the drive shaft and axle hub.
NOTICE:
Do not punch the marks.
(b) Using a plastic-faced hammer, disconnect the
steering knuckle with axle hub.
NOTICE:
Be careful not to damage the boot and speed
sensor rotor.
Do not excessively push out the drive shaft from
the axle assembly.
C129488E01

DS–10DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 2WD)
DS
13. DISCONNECT STEERING KNUCKLE WITH AXLE
HUB RH
HINT:
Use the same procedures described for the LH side.
14. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
(See page PS-42)
15. DISCONNECT TIE ROD END SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
16. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
(a) Using SST, remove the front drive shaft.
SST 09520-01010, 09520-24010 (09520-32040)
NOTICE:
• Be careful not to damage the transaxle case
oil seal, inboard joint boot and drive shaft
dust cover.
• Be careful not to drop the drive shaft.
17. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
(a) Remove the 2 bolts and pull out the drive shaft
together with the drive shaft bearing case.
(b) Remove the drive shaft from the transaxle.
NOTICE:
• Be careful not to damage the transaxle case
oil seal, inboard joint boot and drive shaft
dust cover.
• Be careful not to drop the drive shaft.
18. FIX FRONT AXLE ASSEMBLY
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the
vehicle with the drive shaft removed. Therefore, if it
is absolutely necessary to place the vehicle weight
on the hub bearing, first support it with SST.
SST 09608-16042 (09608-02021, 09608-02041)
C127631E01
C127638
C129482E01