TOYOTA SIENNA 2007 Service Repair Manual

U151E AUTOMATIC TRANSAXLE – DIRECT CLUTCHAX–251
AX
7. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
AND OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch &
overdrive clutch pack clearance while applying and
releasing compressed air (392 kPa, 4.0 kgf/cm
2, 57
psi).
Clearance:
0.61 to 0.83 mm (0.02401 to 0.03268 in.)
If the pack clearance is less than the minimum,
parts may have been assembled incorrectly, so
check and reassemble again. If the clearance is not
as specified, select another flange.
HINT:
There are 7different thicknesses of flanges
available.
Flange thickness: mm (in.)
(b) Check that the disc rotates when rotating the disc
after inserting the rear planetary sun gear.
NOTICE:
Do not place the rear planetary sun gear in a
vise.
REASSEMBLY
1. INSTALL OVERDRIVE DIRECT CLUTCH O-RING
(a) Coat an O-ring with ATF, and install it to the direct
clutch drum.
NOTICE:
Make sure that the O-ring is not twisted or
pinched when it is installed.
2. INSTALL OVERDRIVE DIRECT CLUTCH DRUM SUB-
ASSEMBLY
(a) Coat the direct clutch drum with ATF, and install it to
the intermediate shaft.
NOTICE:
• Be careful not to damage the O-ring.
• Be careful not to damage the lip of the direct
clutch drum.
No. Thickness No. Thickness
0 2.5 (0.098) 4 2.9 (0.114)
1 2.6 (0.102) 5 3.0 (0.118)
2 2.7 (0.106) 6 3.1 (0.122)
3 2.8 (0.110) - -
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AX–252U151E AUTOMATIC TRANSAXLE – DIRECT CLUTCH
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3. INSTALL OVERDRIVE DIRECT CLUTCH PISTON
(a) Coat the overdrive direct clutch piston with ATF, and
install it to the direct clutch drum.
4. INSTALL OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Install the overdrive clutch return spring to the direct
clutch drum.
NOTICE:
Installing the spring sub-assembly, check that
all of the springs are fit in piston correctly.
(b) Coat the clutch balancer with ATF.
(c) Install the clutch balancer to the direct clutch drum.
NOTICE:
• Be careful not to damage the lip of the direct
clutch balancer.
• Make sure that the lip of the seal is not
pinched and that it has no other defects.
• Apply sufficient ATF to the sealing lip before
installing the clutch balancer.
(d) Place SST on the clutch balancer and compress the
overdrive clutch return spring with a press.
SST 09387-00020
(e) Using a snap ring expander, install the snap ring to
the direct clutch drum.
(f) Be sure that the end gap of the snap ring is not
aligned with the spring retainer claw.
NOTICE:
• Stop the press when the spring seat is
lowered to the place 1 to 2 mm (0.039 to 0.078
in.) from the snap ring groove.
• This prevents the spring seat from being
deformed.
• Do not expand the snap ring excessively.
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U151E AUTOMATIC TRANSAXLE – DIRECT CLUTCHAX–253
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(g) Set the end gap of the snap ring in the piston shown
in the illustration.
NOTICE:
The end gap of the snap ring should not align
with any of the stoppers.
5. INSTALL OVERDRIVE DIRECT CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the
intermediate shaft.
NOTICE:
Make sure that the plates, discs, and flange are
installed as shown in the illustration.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not
aligned with one of the cutouts.
NOTICE:
The snap ring should be fully engaged in the
groove of the drum.
6. INSTALL DIRECT MULTIPLE DISC CLUTCH DISC
(a) Coat the 3 disc with ATF.
(b) Install the cushion plate, 3 plates, 3 disc and flange
to the intermediate shaft.
NOTICE:
• Install the cushion plate with the mark on the
white surface facing to plate.
• Be careful about the order of discs, plate and
flange assembly.
(c) Using a screwdriver, install the snap ling.
(d) Check that the end gap of the snap ling is not
aligned with one of the cutouts.
NOTICE:
The slap ring should be fixed certainly in the
groove of the drum.
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D026417E01
D026421E01
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AX–254U151E AUTOMATIC TRANSAXLE – UNDERDRIVE PLANETARY GEAR
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TRANSMISSION
U151E AUTOMATIC TRANSAXLE
UNDERDRIVE PLANETARY GEAR
COMPONENTS
C114868E03

U151E AUTOMATIC TRANSAXLE – UNDERDRIVE PLANETARY GEARAX–255
AX
DISASSEMBLY
1. INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
HINT:
(See page AX-256)
2. REMOVE FRONT PLANETARY GEAR NUT
(a) Using SST, loosen the staked part of the lock nut.
SST 09930-00010 (09931-00010, 09931-00020),
09387-00050
(b) Place the underdrive planetary gear in a soft jaw
vise.
NOTICE:
Be careful not to damage the differential drive
pinion.
(c) Using a socket wrench, remove the lock nut.
3. REMOVE CYLINDRICAL ROLLER BEARING RACE
INNER
(a) Using SST, remove the cylindrical roller bearing
race inner.
SST 09950-00020, 09950-00030, 09950-60010
(09951-00320, 09957-04010)
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AX–256U151E AUTOMATIC TRANSAXLE – UNDERDRIVE PLANETARY GEAR
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4. REMOVE UNDERDRIVE PLANETARY GEAR
ASSEMBLY
(a) Using SST and a press, remove the differential drive
pinion, parking lock gear, counter driven gear with
underdrive planetary ring gear and radial ball
bearing front.
SST 09950-60010 (09951-00320), 09387-00050,
09950-00020, 09950-00030, 09950-40011
(09957-04010)
(b) Place the underdrive planetary gear in a soft jaw
vise.
(c) Using SST, remove the radial ball bearing rear from
the underdrive planetary gear.
SST 09950-60010 (09951-00320), 09950-00030,
09950-40011 (09957-04010)
5. REMOVE UNDERDRIVE PLANETARY RING GEAR
(a) Using a snap ring pliers, remove the snap ring.
(b) Remove the underdrive planetary ring gear from the
counter driven gear.
INSPECTION
1. INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a) Using SST, fix the underdrive planetary gear
assembly.
SST 09387-00050
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U151E AUTOMATIC TRANSAXLE – UNDERDRIVE PLANETARY GEARAX–257
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(b) Using SST and a torque wrench, measure the
turning torque of the underdrive planetary gear
assembly while rotating the torque wrench at 60
rpm.
SST 09387-00050
Turning torque at 60 rpm.:
0.50 to 1.42 N*m (5.1 to 14.5 kgf*cm, 4.4 to 12.6
in.*lbf)
HINT:
Use a torque wrench with a fulcrum length of 160
mm (6.3 in.).
REASSEMBLY
1. INSTALL UNDERDRIVE PLANETARY RING GEAR
(a) Install a new snap ring to the outer race of the radial
ball bearing rear.
HINT:
When replacing the bearing, also replace the
counter driven gear with a new one.
(b) Using a piston ring compressor, squeeze the snap
ring.
(c) Using SST and a press, press in the outer race of
the radial ball bearing rear.
SST 09950-60020 (09951-00890), 09950-70010
(09951-07100)
NOTICE:
Be sure not to damage the snap ring during
outer race installation.
(d) Install the underdrive planetary ring gear to the
counter driven gear.
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AX–258U151E AUTOMATIC TRANSAXLE – UNDERDRIVE PLANETARY GEAR
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(e) Using a snap ring pliers, install the snap ring.
2. INSTALL UNDERDRIVE PLANETARY GEAR
ASSEMBLY
(a) Using SST and a press, press the radial ball bearing
rear in the underdrive planetary gear.
SST 09502-12010, 09950-60010 (09951-00260),
09950-70010 (09951-07100)
NOTICE:
Press the bearing until it becomes flat at the
bottom.
(b) Install the counter driven gear with planetary ring
gear to the underdrive planetary gear.
(c) Using SST and a press, press in the radial ball
bearing front.
SST 09502-12010, 09950-60010 (09951-00260),
09950-70010 (09951-07100)
NOTICE:
Press the counter driven gear while rotating it.
(d) Using SST and a press, press in the parking lock
gear.
SST 09502-12010, 09950-60010 (09951-00260),
09950-70010 (09951-07100)
NOTICE:
Press the counter driven gear while rotating it.
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U151E AUTOMATIC TRANSAXLE – UNDERDRIVE PLANETARY GEARAX–259
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3. INSTALL DIFFERENTIAL DRIVE PINION
(a) Using SST and a press, press the differential drive
pinion.
SST 09726-40010, 09950-60010 (09951-00260),
09950-70010 (09951-07100)
NOTICE:
Press the counter driven gear while rotating it.
4. INSTALL CYLINDRICAL ROLLER BEARING RACE
INNER
(a) Using SST and a press, press the cylindrical roller
bearing race inner.
SST 09506-35010, 09950-60010 (09951-00260),
09950-70010 (09951-07100)
NOTICE:
Press the counter driven gear while rotating it.
5. INSTALL FRONT PLANETARY GEAR NUT
(a) Place the underdrive planetary gear in a soft jaw
vise.
NOTICE:
Be careful not to damage the differential drive
pinion.
(b) Using a socket wrench, install a new lock nut.
Torque: 280 N*m (2,885 kgf*cm, 207 ft.*lbf)
HINT:
Use a torque wrench with a fulcrum length of 750
mm (29.53 in.).
(c) Using a pin punch and hammer, stake the lock nut.
CAUTION:
Be sure that there are no cracks on the nut.
6. INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
HINT:
(See page AX-256)
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AX–260U151E AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCH
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TRANSMISSION
U151E AUTOMATIC TRANSAXLE
UNDERDRIVE CLUTCH
COMPONENTS
C114869E04