TOYOTA RAV4 2006 Service Repair Manual

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–187
AX
REASSEMBLY
1. BEARING POSITION
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AX–188U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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Standard bearing position
2. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the apply tube and clamp to the transaxle
housing with the bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
NOTICE:
Make sure to insert the pipe to the stopper.
3. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Install a new oil seal ring to the transaxle housing.
4. INSTALL UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Using SST and a press, press in the underdrive
cylindrical roller bearing.
SST 09950-60020 (09951-00810), 09950-70010
(09951-07100)
NOTICE:
Do not apply excessive pressure.
Mark Front Race Diameter
Inside / OutsideThrust Bearing Diameter
Inside / OutsideRear Race Diameter
Inside / Outside
A - 57.2 mm (2.252 in.) / 84.96 mm
(3.3449 in.)56.4 mm (2.220 in.) / 83.0 mm
(3.268 in.)
B - 37.73 mm (1.4854 in.) / 58.0 mm
(2.283 in.)29.9 mm (1.177 in.) / 55.5 mm
(2.185 in.)
C - 33.85 mm (1.3327 in.) / 52.2 mm
(2.055 in.)-
D - 23.5 mm (0.925 in.) / 44.0 mm
(1.732 in.)-
E - 36.3 mm (1.429 in. ) / 52.2 mm
(2.055 in.)34.5 mm (1.358 in.) / 48.5 mm
(1.909 in.)
F - 34.6 mm (1.362 in.) / 52.2 mm
(2.055 in.)-
G 40.3 mm (1.587 in.) / 58.0 mm
(2.283 in.)38.6 mm (1.520 in.) / 60.0 mm
(2.362 in.)38.6 mm (1.520 in.) / 58.0 mm
(2.283 in.)
H - 53.6 mm (2.110 in.) / 69.6 mm
(2.740 in.)-
I - 33.8 mm (1.331 in.) / 48.2 mm
(1.898 in.)30.3 mm (1.193 in.) / 46.0 mm
(1.811 in.)
J - 53.6 mm (2.110 in.) / 70.18 mm
(2.763 in.) or 69.6 mm (2.740 in.)-
D003607E01
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U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–189
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5. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Install 2 new oil seal rings to the transaxle.
6. INSTALL UNDERDRIVE BRAKE PISTON
(a) Wind a vinyl tape around SST at the place 4.0 mm
(0.157 in.) above from the bottom end until the
thickness of the wound tape is about 5.0 mm (0.197
in.)
SST 09950-60010 (09951-00320)
NOTICE:
Clean SST to remove deposited oil before
winding a vinyl tape.
(b) Using SST and a press, press in the needle-roller
bearing to the transaxle until the wound vinyl tape
contacts the transaxle case.
SST 09950-60010 (09951-00320), 09950-70010
(09951-07100)
(c) Coat 2 new O-rings with ATF, and install them to the
underdrive brake piston.
(d) Install the underdrive brake piston to the transaxle.
D003914E04
D003809E03
D003810E01
D003794E02
D003609E01

AX–190U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(e) Using SST, a snap ring expander and press, press
in the piston return spring and snap ring to the
transaxle.
SST 09387-00020
NOTICE:
Do not apply excessive pressure.
7. INSTALL NO. 2 BREATHER PLUG
8. INSTALL COUNTER DRIVE GEAR HOLE SNAP RING
(a) Using a screwdriver, press in the snap ring to the
transaxle.
9. INSTALL COUNTER DRIVE GEAR
(a) Using SST and a press, press in the 2 bearings
outer races to the transaxle.
SST 09950-60020 (09951-00890), 09950-70010
(09951-07150)
(b) Using SST and a press, press in the tapered roller
bearing to the counter drive gear until the bearing
race contacts with the snap ring.
NOTICE:
Do not apply excessive pressure.
SST 09649-17010
D003610E01
D003604E01
D003611E02
D003613E01

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.
D003614E01
D003913E01
D003813E01
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AX–192U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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12. INSTALL FRONT PLANETARY RING GEAR
(a) Using a screwdriver, install the front planetary ring
gear and snap ring to the brake hub.
13. INSTALL FRONT PLANETARY GEAR ASSEMBLY
(a) Install the front planetary gear assembly to the
brake hub.
(b) Using SST and a press, press-fit the front planetary
gear.
SST 09950-60010 (09951-00500), 09950-70010
(09951-07100)
NOTICE:
Do not apply excessive pressure.
(c) Install the washer, as shown in the illustration.
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D008063E01
D003916E04
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U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–193
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(d) Using SST, install the nut.
SST 09387-00030, 09387-00080
Torque: 280 N*m (2,855 kgf*cm, 206 ft.*lbf)
(e) Using SST and a torque wrench, measure the
turning torque of the bearing while rotating SST at
60 rpm. When the measured value is not within the
specified value, gradually tighten the nut until it
reaches the specified value.
SST 09387-00080
Torque: Turning torque at 60 rpm
0.51 to 1.02 N*m (5.1 to 10.0 kgf*cm, 4.4
to 8.7 in.*lbf) for new
0.3 to 0.5 N*m (3.1 to 5.1 kgf*cm, 27 to
4.4 in.*lbf) for used
HINT:
Use a torque wrench with a fulcrum length of 160
mm (6.3 in.).
(f) Using a chisel and hammer, stake the front
planetary gear washer.
14. INSTALL INPUT SUN GEAR
(a) Install the 2 thrust bearings, bearing race and front
planetary sun gear to the front planetary gear.
Standard bearing and race diameter
D003596E01
D003918E01
D008074E02
D003873E03
Item Inside Outside
Bearing 34.6 mm (1.362 in.) 52.2 mm (2.055 in.)
Race 40.3 mm (1.587 in.) 58.0 mm (2.283 in.)
Bearing 38.6 mm (1.52 in.) 60.0 mm (2.362 in.)

AX–194U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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15. INSTALL REAR PLANETARY GEAR ASSEMBLY
(a) Coat the bearing race with ATF, and install it to the
rear planetary gear assembly.
Standard bearing race diameter
(b) Install the No. 2 thrust washer.
(c) Install the rear planetary gear to the rear planetary
ring gear.
(d) Using a screwdriver, install the snap ring.
16. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC
(a) Install the 5 plates and 5 discs.
Install in order:
P - D - P - D - P - D - P - D - P - D
HINT:
P = Plate
D = Disc
D003593E01
Item Inside Outside
Race 38.6 mm (1.520 in.) 58.0 mm (2.83 in.)
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D008062E01
D003616E02
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U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–195
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(b) Using a vernier caliper, measure the distance
between the disc surface and the contact surface of
the 2nd brake cylinder and transaxle (Dimension A).
(c) Select an appropriate flange so that the pack
clearance will meet the specified value.
0.745 to 1.21 mm (0.0293 to 0.0476 in.)
HINT:
Piston stroke = Dimension A - Flange thickness
Standard flange thickness
(d) Install the flange.
17. INSTALL 2ND BRAKE PISTON ASSEMBLY
(a) Install the 2nd brake piston to the transaxle.
(b) Install the snap ring and measure the inside
diameter.
Standard inside diameter:
More than 167 mm (6.57 in.)
NOTICE:
• Because the taper snap ring has the
positioning direction, check it when
installing.
• When the diameter does not satisfy the
specified value, replace the snap ring with a
new one.
18. INSTALL 1-WAY CLUTCH SLEEVE OUTER
(a) Install the 1-way clutch outer sleeve to the 2nd
brake cylinder.
NOTICE:
Check the positioning direction of the outer
sleeve.
D003618E01Mark Thickness Mark Thickness
1 1.8 mm (0.071in.) 5 2.2 mm (0.087 in.)
2 1.9 mm (0.075 in.) 6 2.3 mm (0.091 in.)
3 2.0 mm (0.079 in.) 7 2.4 mm (0.094 in.)
4 2.1 mm (0.083 in.) 8 2.5 mm (0.098 in.)
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AX–196U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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19. INSTALL 1-WAY CLUTCH ASSEMBLY
(a) Install the inner race to the 1-way clutch.
NOTICE:
Check the direction of the inner race.
(b) Check the rotating direction of the 1-way clutch for
the lock or free operation, as shown in illustration.
(c) Install the 1-way clutch and bearing to the 1-way
clutch sleeve outer.
Standard bearing diameter
NOTICE:
Install the thrust bearing properly so that no-
colored race will be visible.
20. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY
(a) Coat the No. 1 thrust washer with petroleum jelly,
and install it onto the rear planetary sun gear.
(b) Coat the bearing with petroleum jelly, and install it
onto the rear planetary sun gear.
Standard bearing diameter
D003909E02
D009638E02
D003588E02
Item Inside Outside
Bearing 53.6 mm (2.110 in.) 69.6 mm (2.740 in.)
D003908E01
D003791E01
Item Inside Outside
Bearing 33.8 mm (1.331 in) 48.2 mm (1.898 in.)