pan TOYOTA RAV4 2006 Service Manual PDF

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–191
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(c) Using SST and a press, install the counter drive
gear and bearing to the transaxle.
SST 09950-70010 (09951-07150), 09950-60020
(09951-00750)
NOTICE:
Do not apply excessive pressure.
10. INSTALL 1ST AND REVERSE BRAKE PISTON
(a) Coat 2 new O-rings with ATF.
(b) Install the 2 O-ring to the 1st and reverse brake
piston.
(c) Coat the 1st and reverse brake piston with ATF, and
install it to the transaxle.
11. INSTALL 1ST AND REVERSE BRAKE RETURN
SPRING SUB-ASSEMBLY
(a) Using SST, a press and snap ring expander, press
the piston return spring and snap ring to the
transaxle.
SST 09387-00070
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, preventing the
spring sheet from being deform.
• Do not expand the snap ring excessively.
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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 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 case.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
62. 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.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
63. 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)
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6. INSTALL CLUTCH DRUM OIL SEAL RING
(a) Install the 2 clutch drum oil seal rings.
NOTICE:
Do not expand the ring ends excessively.
7. INSPECT OIL PUMP ASSEMBLY (See page AX-218)
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U140F AUTOMATIC TRANSAXLE – DIRECT CLUTCHAX–235
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3. INSPECT DIRECT CLUTCH RETURN SPRING SUB-
ASSEMBLY
(a) Using a vernier caliper, measure the free length of
the spring together with the spring seat.
Standard free length:
22.58 mm (0.8898 in.)
REASSEMBLY
1. INSTALL DIRECT CLUTCH RETURN SPRING SUB-
ASSEMBLY
(a) Coat the direct clutch piston with ATF, and install it
to the direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the
direct clutch piston.
(b) Install the piston return spring to the direct clutch
drum.
(c) Install the clutch balancer to the direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the
direct clutch balancer.
(d) Place SST on the clutch balancer and compress the
piston return spring with a press.
SST 09387-00020
(e) Using a snap ring expander, install the snap ring to
the direct clutch drum.
NOTICE:
• Be sure the end gap of the snap ring is not
aligned with the clutch balancer claw.
• 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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AX–236U140F AUTOMATIC TRANSAXLE – DIRECT CLUTCH
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• This prevents the spring sheet from being
deformed.
• Do not expand the snap ring excessively.
2. INSTALL DIRECT MULTIPLE DISC CLUTCH DISC
(a) Install the 3 plates, 3 discs and flange to the direct
clutch drum.
Install in order:
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.
3. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
(a) Install the direct clutch on the transaxle rear cover.
(b) Using a dial indicator, measure the direct clutch
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Standard pack clearance:
0.515 to 0.825 mm (0.0203 to 0.0324 in.)
If the pack clearance is less than the minimum,
parts may have been assembled incorrectly, so
check and reassemble again.
If the stroke is not as specified, select another
flange.
HINT:
There are 6 flanges in different thickness.
Standard flanges in different thickness
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No. Thickness No. Thickness
1 3.0 mm (.118 in.) 4 3.3 mm (0.130 in.)
2 3.1 mm (0.122 in.) 5 3.4 mm (0.134 in.)
3 3.2 mm (0.126 in.) 6 3.5 mm (0.138 in.)

AX–34U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM
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DIAGNOSIS SYSTEM
1. DESCRIPTION
(a) When troubleshooting On-Board Diagnostic (OBD
II) vehicles, the vehicle must be connected to the
OBD II scan tool (complying with SAE J1987).
Various data output from the vehicle's ECM can
then be read.
(b) OBD II regulations require that the vehicle's on-
board computer illuminates the Malfunction
Indicator Lamp (MIL) on the instrument panel when
the computer detects a malfunction in:
(1) The emission control system/components
(2) The powertrain control components (which affect
vehicle emissions)
(3) The computer
In addition, the applicable Diagnostic Trouble
Codes (DTCs) prescribed by SAE J2012 are
recorded in the ECM memory.
When the malfunction does not reoccur, the MIL
stays illuminated until the ignition switch is
turned OFF, and the MIL turns OFF when the
engine is started. However, the DTCs remain
recorded in the ECM memory.
(c) To check DTCs, connect the intelligent tester to the
Data Link Connector 3 (DLC3) of the vehicle. The
tester displays DTCs, the freeze frame data and a
variety of the engine data.
The DTCs and freeze frame data can be erased
with the tester (see page AX-40).
2. NORMAL MODE AND CHECK MODE
(a) The diagnosis system operates in "normal mode"
during normal vehicle use. In normal mode, "2 trip
detection logic" is used to ensure accurate detection
of malfunctions. "Check mode" is also available to
technicians as an option. In check mode, "1 trip
detection logic" is used for simulating malfunction
symptoms and increasing the system's ability to
detect malfunctions, including intermittent
malfunctions.
3. 2 TRIP DETECTION LOGIC
(a) When a malfunction is first detected, the
malfunction is temporarily stored in the ECM
memory (1st trip). If the same malfunction is
detected during the next drive cycle, the MIL is
illuminated (2nd trip).
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5. REMOVE SPEED SENSOR
(a) Remove the 2 bolts and the 2 speed sensors from
the transaxle.
6. REMOVE SPEEDOMETER DRIVEN HOLE COVER
SUB-ASSEMBLY
(a) Remove the bolt and cover.
(b) Remove the O-ring from the cover.
7. REMOVE NO. 1 TRANSAXLE CASE PLUG
(a) Remove the 4 plugs from the transaxle case.
(b) Remove the 4 O-rings from the 4 plugs.
8. FIX AUTOMATIC TRANSAXLE ASSEMBLY
(a) Fix the transaxle.
9. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-
ASSEMBLY
(a) Remove the 18 bolts, oil pan and gasket.
(b) Remove the 2 magnets from the oil pan.
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U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–191
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10. INSPECT TRANSMISSION OIL CLEANER MAGNET
(a) Remove the magnets and use them to collect any
steel chips. Examine the chips and particles in the
pan and on the magnet to determine what type of
wear has occurred in the transaxle.
Result:
Steel (magnetic):
Wear of the bearing, gear and plate
Brass (non-magnetic):
Wear of the bush
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 7 connectors from the shift solenoid
valves.
(b) Remove the bolt, lock plate and temperature
sensor.
(c) Remove the bolt and transmission wire from the
transaxle case.
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U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–205
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(d) Remove the front planetary gear from the brake
hub.
65. REMOVE FRONT PLANETARY RING GEAR
(a) Using a screwdriver, remove the snap ring and front
planetary ring gear from the brake hub.
66. REMOVE 1ST AND REVERSE BRAKE RETURN
SPRING SUB-ASSEMBLY
(a) Place SST on the return spring, and compress the
return spring with a press.
NOTICE:
Stop the press when the spring seat is lowered 1
to 2 mm (0.039 to 0.078 in.) from the snap ring
groove to prevent the spring seat from being
deformed.
SST 09387-00070
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
Do not expand the snap ring excessively.
67. INSPECT 1ST AND REVERSE BRAKE RETURN
SPRING SUB-ASSEMBLY (See page AX-210)
68. REMOVE 1ST AND REVERSE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the transaxle case to remove the 1st and reverse
brake piston.
NOTICE:
• Applying compressed air may cause the
piston to jump out. When removing the
piston, hold it using a waste cloth.
• Take care not to splash ATF when applying
compressed air.
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(b) Remove the 2 O-rings from the 1st and reverse
brake piston.
69. REMOVE COUNTER DRIVE GEAR
(a) Using SST and a press, remove the counter drive
gear from the transaxle case.
SST 09950-60010 (09951-00590), 09950-70010
(09951-07100)
(b) As shown in the illustration, tighten the 2 bolts
evenly and make a clearance of approximately. 20.0
mm (0.787 in.) between the counter drive gear and
the inner race.
(c) Using SST, remove the tapered roller bearing.
SST 09950-60010 (09951-00590), 09950-00020,
09950-00030, 09950-40011 (09957-04010)
70. REMOVE TRANSFER DRIVEN PINION FRONT
BEARING
(a) Using a snap ring expander, remove the snap ring.
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