TOYOTA SIENNA 2007 Service Repair Manual

AX–218U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(e) Using vernier calipers and a straightedge, measure
the dimension shown in the illustration.
(f) Calculate the end play value using the following
formula. Select a thrust bearing which satisfies the
end play value and install the selected bearing.
End play:
0.244 to 0.901 mm (0.0096 to 0.0355 in.)
NOTICE:
Make sure that the no-colored race side is facing
the direct clutch assembly.
HINT:
End play = Dimension D - Dimension C
Bearing thickness and diameter : mm (in.)
30. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Install 3 new governor apply gaskets No.1 to the
transaxle case.
31. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.
NOTICE:
Make sure to install the clamp to the apply tube
before installing the apply tube to the transaxle
case. This prevents the apply tube from being
deformed or damaged.
(b) Install the clutch apply tube.
(c) Install the brake apply tube and a bolt to the
transaxle case.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
NOTICE:
The tube should be securely inserted until it
reaches the stopper.
D026470E01
Thickness Inside Outside
3.6 (0.1417) 56.3 (2.217) 75.7 (2.980)
3.8 (0.1496) 56.3 (2.217) 75.7 (2.980)
D026390
D003923
D026391E03

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–219
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32. INSTALL NEEDLE ROLLER BEARING
(a) Using SST and a press, press the needle roller
bearing into the transaxle rear cover.
SST 09950-60010 (09951-00230, 09952-06010)
Press fit depth:
20.55 to 21.25 mm (0.8091 to 0.8366 in.)
NOTICE:
• The engraved mark side of the bearing
should face upward.
• Repeat the press fit until the specified value
is obtained.
(b) Coat a needle roller bearing with ATF.
33. INSTALL REAR CLUTCH OIL SEAL RING OUTER
(a) Coat 3 new rear clutch oil seal rings with ATF, install
them to the transaxle rear cover.
NOTICE:
The snap ring should be fully engaged in the
groove of the drum.
34. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Coat 4 new O-rings with ATF.
(b) Install the 4 O-rings to the 4 transaxle case No.1
plugs.
(c) Install the 4 transaxle case No.1 plugs to the
transaxle rear cover.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
35. INSTALL TRANSAXLE REAR COVER SUB-
ASSEMBLY
(a) Remove any packing material and be careful not to
spill oil on the contact surfaces of the transaxle rear
cover or the transaxle case.
(b) Apply FIPG to the cover.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or
equivalent.
NOTICE:
Make sure that the FIPG is applied in a bead
(section diameter:
1.2) so that the entire
sealing surface will be evenly sealed. The FIPG
should also protrude slightly from the flange
after the assembly of the parts has been
completed.
D026766E01
D026389E01
D026388
D026454E01

AX–220U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(c) Apply liquid sealer to the "A" bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent.
(d) Install the 11 bolts.
Torque: Bolt A
19 N*m (190 kgf*cm, 14 ft.*lbf)
Other bolts:
25 N*m (250 kgf*cm, 18 ft.*lbf)
36. INSTALL UNDERDRIVE CLUTCH DISC NO.2
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs, 4 plates and flange to the
transaxle case.
NOTICE:
Be careful about the order of discs, plate and
flange assembly.
(c) Using a screwdriver, install the snap ring.
NOTICE:
The snap ring should be fully engaged in the
groove of the drum.
37. INSPECT PACK CLEARANCE OF UNDERDRIVE
BRAKE
(a) Using a dial indicator, measure the underdrive brake
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:
1.81 to 2.20 mm (0.0713 to 0.0866 in.)
HINT:
Select an appropriate flange from the table below so
that it will meet the specified value.
Flange thickness: mm (in.)
(b) Temporarily remove the snap ring and attach it to
the flange.
(c) Reinstall the snap ring.
D026387E03
D026414E01
D026466E01
D008082
Mark Thickness Mark Thickness
1 3.0 (0.118) 4 3.1 (0.122)
2 3.2 (0.126) 5 3.3 (0.130)
3 3.4 (0.134) - -

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–221
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38. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the underdrive clutch assembly to the 1-way
clutch.
(b) Rotate the underdrive clutch assembly to check the
rotating direction for the lock or free operation.
39. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the outer race retainer to the 1-way clutch.
NOTICE:
Fix the outer race retainer to the external tooth
of the 1-way clutch firmly.
(b) Install the 1-way clutch to the transaxle case.
NOTICE:
Make sure that the mark on the 1-way clutch
outer race is visible.
(c) Using a screwdriver, install the snap ring to the
transaxle case.
NOTICE:
The snap ring should be fixed fully engaged in
the groove of the transaxle case.
40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
(a) Coat the bearing and bearing race with petroleum
jelly, install them onto the underdrive clutch.
Bearing and bearing race diameter: mm (in.)
D003925E01
D003907E01
D003627E02
D003581E01
D003580
Inside Outside
Bearing 37.73 (1.4854) 58.0 (2.2835)
Race 29.9 (1.1772) 55.5 (2.185)

AX–222U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(b) Install the underdrive clutch assembly to the
transaxle case.
NOTICE:
Do not damage the oil seal when installing the
underdrive clutch drum sub-assembly.
41. INSTALL PARKING LOCK PAWL
(a) Install the pawl pin and spring to the parking lock
pawl.
(b) Temporarily install the parking lock pawl, shaft and
spring to the transaxle case, as shown in the
illustration.
42. INSTALL UNDERDRIVE PLANETARY GEAR
ASSEMBLY
(a) Install the underdrive planetary gear assembly to
the transaxle case.
NOTICE:
Fully engage all the discs of underdrive clutch
and hub splines of the underdrive planetary gear
assembly and install them securely.
(b) Install the parking lock pawl shaft.
D009691E01
D026386
D003579E03
D009693

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–223
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(c) Install the pawl shaft clamp with the bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
(d) Using a straightedge and vernier calipers as shown
in the illustration, measure the gap between the top
of the differential drive pinion in the underdrive
planetary gear and the contact surface of the
transaxle case and housing (Dimension E).
NOTICE:
Record dimension E for the following process.
(e) As shown in the illustration, measure the 2 places of
the transaxle housing, and calculate dimension F
using the formula below.
NOTICE:
Recoad dimension F for the following process.
HINT:
Dimension F = Dimension (1) - Dimension (2)
43. INSTALL MULTIPLE DISC CLUTCH HUB
(a) Install the thrust bearing race No.1 to the transaxle
case while checking its direction.
Bearing race diameter: mm (in.)
(b) Coat the thrust needle roller bearing and race with
yellow petrolatum, install them onto the multiple disc
clutch hub.
Thrust bearing and race diameter: mm (in.)
(c) Coat the needle roller bearing with ATF.
D003576E02
D003875E01
D025511E01
D008087E02
Inside Outside
Bearing race 39.5 (1.555) 45.8 (1.803)
D026710E02
Inside Outside
Thrust Bearing 36.4 (1.433) 52.2 (2.055)

AX–224U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(d) Install the needle roller bearing to the multiple clutch
hub.
Bearing diameter: mm (in.)
(e) Install the multiple clutch hub to the transaxle case.
44. INSTALL FORWARD CLUTCH ASSEMBLY
(a) Coat the thrust needle roller bearing with ATF.
(b) Install the thrust needle roller bearing to the forward
clutch.
Thrust bearing diameter: mm (in.)
NOTICE:
Install the thrust bearing properly so that the no-
colored race or blue ink jet race will be visible.
(c) Install the forward clutch to the forward clutch
assembly.
NOTICE:
• Align the splines of all discs in the forward
clutch with those of multiple clutch hub to
install them securely.
• Be careful not to damage the bushing inside
of the forward clutch hub during installation.
45. INSTALL OVERDRIVE BRAKE GASKET
(a) Install 2 new overdrive brake gaskets.
46. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a) Install the differential gear assembly to the transaxle
case.
D026711E02
Inside Outside
Bearing 23.6 (0.929) 44 (1.732)
D003820E01
Inside Outside
Thrust Bearing 33.58 (1.3220) 51.9 (2.043)
D003574E02
D003573
D026450E04

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47. INSTALL THRUST BEARING UNDERDRIVE RACE
NO.2
(a) Install the thrust bearing underdrive race No.2 to the
underdrive planetary gear assembly.
48. INSTALL THRUST NEEDLE ROLLER BEARING
(a) Coat the thrust needle roller bearing with ATF.
(b) Calculate the end play value using the following
formula and values of Dimension E and F that are
measured when installing the cylindrical roller
bearing and underdrive planetary gear. Select an
appropriate underdrive planetary gear thrust
bearing race No.2 which satisfies the specified end
play value, and install the selected bearing race.
End play:
0.498 to 0.993 mm (0.01961 to 0.03909 in.)
HINT:
End play = Dimension F - Dimension E - thrust
bearing thickness 2.5 mm (0.0984 in.) - underdrive
thrust bearing race No.2 thickness.
Race thickness: mm (in.)
Bearing and bearing race diameter: mm (in.)
49. INSTALL OIL PUMP ASSEMBLY
(a) Install the oil pump to the transaxle case with the 7
bolts.
Torque: 22 N*m (226 kgf*cm, 16 ft.*lbf)
D025506E03
D025505E02
F - E Thickness
Less than 7.72 (0.3039) 3.5 (0.138)
7.72 (0.3039) 3.8 (0.150)
Inside Outside
Bearing 57.2 (2.252) 84.96 (3.345)
Bearing race 56.4 (2.22) 83 (3.268)
D003569E03

AX–226U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(b) Coat the O-ring of oil pump with ATF.
NOTICE:
Confirm that the input shaft rotates smoothly
with the manual operation after installing the oil
pump.
50. INSTALL TRANSAXLE HOUSING
(a) Remove any packing material and be careful not to
spill oil on the contact surface of the transaxle case
or transaxle housing.
(b) Apply FIPG to the transaxle case.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or
equivalent
(c) Install the transaxle housing and 16 bolts to the
transaxle case.
To r q u e : B o l t A
22 N*m (225 kgf*cm, 16 ft.*lbf)
Bolt B
29 N*m (300 kgf*cm, 22 ft.*lbf)
Bolt C
29 N*m (295 kgf*cm, 21 ft.*lbf)
Bolt D
22 N*m (226 kgf*cm, 16 ft.*lbf)
HINT:
Apply seal packing or equivalent to bolts A and D.
Seal packing:
THREE BOND 2403 or equivalent
Bolt length
Bolt A:
50 mm (1.969 in.)
Bolt B:
50 mm (1.969 in.)
Bolt C:
42 mm (1.654 in.)
Bolt D:
72 mm (2.835 in.)
NOTICE:
Tighten the bolts within 10 minutes of sealant
application.
D003629E02
D003630E02
D003568E01

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–227
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51. INSPECT INPUT SHAFT END PLAY
(a) Using a dial indicator, measure the input shaft end
play.
End play:
0.262 to 1.249 mm (0.0100 to 0.0494 in.)
52. FIX AUTOMATIC TRANSAXLE ASSEMBLY
(a) Fix the transaxle assembly.
53. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Coat a new oil seal with MP grease.
(b) Install the oil seal to the transaxle case.
SST 09950-60010 (09951-00230), 09950-70010
(09951-07100)
Oil seal installation depth:
0 +- 0.5 mm (0 +- 0.197 in. )
54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY
(a) Install the parking lock rod to the manual valve lever.
55. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
(a) Install a new spacer and manual valve lever shaft to
the transaxle case.
NOTICE:
Do not damage the oil seal when installing the
shaft to the transaxle case.
D008091E01
D003631
D026468E01
D026382E01
D003565E01