TOYOTA SIENNA 2007 Service Repair Manual

U151E AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCHAX–261
AX
DISASSEMBLY
1. INSPECT UNDERDRIVE PACK CLEARANCE
HINT:
(See page AX-262)
2. REMOVE UNDERDRIVE CLUTCH FLANGE NO.2
HOLE SNAP RING
(a) Using a screwdriver, remove the underdrive clutch
flange No.2 snap ring.
3. REMOVE UNDERDRIVE CLUTCH DISC NO.1
(a) Remove the flange, 4 discs and 4 plates from the
underdrive clutch drum.
4. REMOVE UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Place SST on the clutch balancer and compress the
spring with a press.
SST 09350-32014
(b) Using a snap ring expander, remove the snap ring.
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.
(c) Remove the clutch balancer from the underdrive
clutch drum.
D003701E01
D026430E01
D003703E01
C056359E01

AX–262U151E AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCH
AX
(d) Remove the return spring from the underdrive clutch
drum.
5. REMOVE UNDERDRIVE CLUTCH PISTON SET
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b) Holding the underdrive clutch piston by hand, apply
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
transaxle case to remove the underdrive clutch
piston.
6. REMOVE UNDERDRIVE CLUTCH DRUM O-RING
(a) Using a screwdriver, remove the O-ring from the
underdrive clutch drum.
INSPECTION
1. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal rings.
(b) Install a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch pack clearance while
applying and releasing compressed air (392 kPa,
4.0 kgf/cm
2, 57 psi).
Pack clearance:
1.51 to 1.71 mm (0.0594 to 0.0673 in.)
If the pack clearance is not as specified, inspect the
discs, plates and flange.
HINT:
There are 5 flanges in different thickness.
Flange thickness: mm (in.)
C056360E02
D003705
D026465E02
D026429E01
Mark Thickness Mark Thickness
1 3.0 (0.118) 4 3.6 (0.122)
2 3.2 (0.126) 5 3.8 (0.130)
3 3.4 (0.134) - -

U151E AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCHAX–263
AX
2. INSPECT UNDERDRIVE CLUTCH DISC NO.1
(a) Check if the sliding surface of the disc, plate and
flange are worn or burnt. If necessary, replace them.
HINT:
• If the lining of the disc comes off or discolors, or if
a part of the groove is worn, replace all discs.
• Before installing new discs, immerse them in ATF
for at least 15 minutes.
3. INSPECT UNDERDRIVE CLUTCH DRUM SUB-
ASSEMBLY
(a) Using a dial indicator, measure the inside diameter
of the underdrive clutch drum bushing.
Standard drum bushing:
37.06 to 37.08 mm (1.4591 to 1.4598 in.)
Maximum drum bushing:
37.13 mm (1.4618 in.)
If the inside diameter is greater than the maximum,
replace the underdrive clutch drum.
4. INSPECT UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Using a vernier calipers, measure the free length of
the spring together with the spring seat.
Standard free length:
17.14 mm (0.6752 in.)
REASSEMBLY
1. INSTALL UNDERDRIVE CLUTCH DRUM O-RING
(a) Coat a new O-ring with ATF, and install it to the
underdrive clutch drum.
NOTICE:
Make sure that the O-ring is not twisted or
pinched.
2. INSTALL UNDERDRIVE CLUTCH PISTON SET
(a) Coat the underdrive clutch piston with ATF, and
install it to the underdrive clutch piston drum.
NOTICE:
• Be careful not to damage the O-ring.
• Be careful not to damage the lip of the piston.
D004077
D008129E01
D003824
D026465E01
D003860

AX–264U151E AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCH
AX
3. INSTALL UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Install the return spring to the underdrive clutch
drum.
NOTICE:
Installing the spring sub-assembly, check that
all of the springs are fit in the piston correctly.
(b) Coat the clutch balancer with ATF.
(c) Install the clutch balancer to the underdrive clutch
drum.
NOTICE:
Be careful not to damage the lip of the clutch
balancer.
(d) Place SST on the clutch balancer and compress the
piston return spring with a press.
SST 09350-32014 (09351-32070)
(e) Using a snap ring expander, install the snap ring to
the underdrive 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.
(g) Set the end gap of the snap ring in the underdrive
clutch drum as shown in the illustration.
NOTICE:
The end gap of the snap ring should not align
with any of the stoppers.
C056360E02
C056359E01
D003703E01
D025592E01

U151E AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCHAX–265
AX
4. INSTALL UNDERDRIVE CLUTCH DISC NO.1
(a) Coat the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the
underdrive clutch drum.
NOTICE:
Make sure that the plates, discs, and flange are
installed as shown in the illustration.
5. INSTALL 1ST & REVERSE BRAKE RETURN SPRING
SHAFT SNAP RING
(a) Using a screwdriver, install the underdrive clutch
flange No.2 hole snap ring.
(b) Check that the end gap of 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. INSPECT UNDERDRIVE PACK CLEARANCE
HINT:
(See page AX-262)
D026431E01
D003701

AX–266U151E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
AX
TRANSMISSION
U151E AUTOMATIC TRANSAXLE
DIFFERENTIAL CASE
COMPONENTS
C114871E03

U151E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–267
AX
DISASSEMBLY
1. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place matchmarks on the front differential ring gear
and differential case.
(b) Remove the 14 bolts.
(c) Using a plastic hammer, tap on the front differential
ring gear to remove it from the case.
2. REMOVE FRONT DIFFERENTIAL CASE FRONT
TAPERED ROLLER BEARING
(a) Using SST, remove the front differential case front
differential tapered roller bearing from the
differential case.
SST 09950-00020, 09950-00030, 09950-60010
(09951-00490), 09950-40011 (09957-04010)
(b) Using SST, remove the front differential case front
tapered roller bearing outer race.
SST 09308-00010
D026445E03
D026446E01
C050237E01
D025595E01
D025596E02

AX–268U151E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
AX
3. REMOVE FRONT DIFFERENTIAL CASE REAR
TAPERED ROLLER BEARING
(a) Using SST, remove the front differential case rear
tapered roller bearing from the differential case.
SST 09950-00020, 09950-00030, 09950-60010
(09951-00490), 09950-40011 (09957-
04010), 09308-00010
(b) Using SST, remove the front differential case rear
tapered roller bearing outer race.
SST 09308-00010
4. REMOVE FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch and hammer, install the straight
pin.
NOTICE:
Before removing the straight pin, unstake it with
a pin punch.
5. REMOVE FRONT DIFFERENTIAL PINION SHAFT
NO.1
(a) Remove the front differential pinion shaft No.1 from
the differential case.
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.
D025597E03
D025598E01
C050240
C050241E01
C050242E01

U151E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–269
AX
7. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, remove the oil seal.
SST 09950-70010 (09951-07100), 09215-00013
(09215-00471)
8. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100), 09608-10010
INSPECTION
1. INSPECT BACKLASH
(a) Using a dial indicator, inspect the backlash of the
side gear.
Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)
Thrust washer thickness
REASSEMBLY
1. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Apply ATF to the 2 front differential side gears, 2
side gear thrust washers, 2 front differential pinions
and 2 pinion thrust washers and install them to the
differential case.
D025599E01
D025600E01
C050252
Mark Thickness
- 1.625 mm (0.0640 in.)
- 1.725 mm (0.0679 in.)
- 1.825 mm (0.0719 in.)
C050242E01

AX–270U151E AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
AX
2. INSTALL FRONT DIFFERENTIAL PINION SHAFT
NO.1
(a) Coat the front differential pinion shaft No.1 with ATF,
and install it to the differential case.
3. INSPECT BACKLASH
HINT:
(See page AX-269)
4. INSTALL FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch and a hammer, install the pinion
shaft straight pin.
(b) Using a chisel and a hammer, stake the differential
case.
NOTICE:
Stake the differential case after adjusting the
backlash.
5. INSTALL FRONT DIFFERENTIAL CASE FRONT
TAPERED ROLLER BEARING
(a) Using SST and a press, install the front differential
case front tapered roller bearing to the differential
case.
SST 09316-12010, 09550-60010 (09951-00490),
09950-70010 (09951-07100)
NOTICE:
Do not damage the bearing cage when installing
the bearing inner race.
(b) Using SST and a hammer, install the front
differential case tapered roller bearing front outer
race to the transaxle housing.
SST 09550-60010 (09951-00490), 09950-60020
(09951-00910)
C050241E01
C050253
C050254
D026447E01
C083736