TOYOTA SIENNA 2007 Service Repair Manual

AX–228U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(b) Using a pin punch and hammer, drive in a new pin.
(c) Turn the spacer and the lever shaft to align the small
hole for locating the staking position in the spacer
with the staking position mark on the lever shaft.
(d) Using a pin punch, stake the spacer through the
small hole.
(e) Check that the spacer does not turn.
56. INSTALL MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using needle-nose pliers, install the retainer spring.
NOTICE:
Hang the spring on the shaft firmly.
57. INSTALL PARKING LOCK PAWL BRACKET
(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 N*m (205 kgf*cm, 15 ft.*lbf)
Bolt length:
25 mm (0.984 in.)
NOTICE:
Make sure that the parking rod is placed
between the parking pawl and the guide of the
parking bracket when the parking bracket is
installed.
58. INSTALL MANUAL DETENT SPRING SUB-
ASSEMBLY
(a) Install the manual detent spring and cover with the 2
bolts.
NOTICE:
Make sure to install the manual detent spring
and cover in this order.
HINT:
Tighten bolt A first, and then bolt B.
To r q u e : B o l t A
20 N*m (205 kgf*cm, 15 ft.*lbf)
D003564
D026765
D003559
D003561E01
D003560E01

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–229
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Bolt B
12 N*m (120 kgf*cm, 9 ft.*lbf)
Bolt length:
Bolt A:
27 mm (1.063 in.)
Bolt B:
16 mm (0.630 in.)
59. INSTALL B-3 ACCUMULATOR PISTON
(a) Coat a new O-ring with ATF, install it to the B-3
accumulator piston.
NOTICE:
Make sure that the O-ring is not twisted and that
it does not protrude abnormally from the
accumulator piston. Apply sufficient ATF before
installing the O-ring. The O-ring must be
installed in the correct position.
(b) Coat the piston with ATF, install it to the transaxle
case.
NOTICE:
Install the springs to each accumulator piston,
checking the identification color or each spring.
Accumulator spring:
60. INSTALL REVERSE CLUTCH ACCUMULATOR
PISTON
(a) Coat 2 new O-rings with ATF, install them to the
reverse accumulator piston.
NOTICE:
Make sure that the O-ring is not twisted and that
it does not protrude abnormally from the
accumulator piston. Apply sufficient ATF before
installing the O-ring. The O-ring must be
installed in the correct position.
(b) Coat the piston with ATF, install it to the transaxle
case.
NOTICE:
Install the springs to each accumulator piston,
checking the identification color or each spring.
Accumulator spring:
D003904E01
D025512E01
Free length
Outer diameter mm (in.)Color
Inner 62.00 (2.4409) /
15.50 (0.610)Purple
Outer 74.23 (2.9224) /
21.70 (0.854)Purple
D026402E05
C092978E02
Free length
Outer diameter mm (in.)Color
60.96 (2.3999) /
14.10 (0.555)Ye l l o w

AX–230U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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61. INSTALL C-3 ACCUMULATOR PISTON
(a) Coat a new O-ring with ATF, install it to the C-3
accumulator piston.
NOTICE:
Make sure that the O-ring is not twisted and that
it does not protrude abnormally from the
accumulator piston. Apply sufficient ATF before
installing the O-ring. The O-ring must be
installed in the correct position.
(b) Coat the piston with ATF, install it to the transaxle
case.
NOTICE:
Install the springs to each accumulator piston,
checking the identification color or each spring.
Accumulator spring:
(c) Install the spring to the C-3 accumulator piston.
NOTICE:
Install the springs to each accumulator piston,
checking the identification color or each spring.
62. INSTALL CHECK BALL BODY
(a) Coat the check ball body with ATF.
(b) Install the check ball body and spring.
NOTICE:
Be sure to place the spring in the hole in the
check ball body. Be careful about the direction
of the parts.
63. INSTALL BRAKE DRUM GASKET
(a) Coat a new brake drum gasket with ATF, install it to
the transaxle case.
NOTICE:
Be sure not to damage the lip of the transaxle
case brake gasket when inserting the gasket to
the case. Apply sufficient ATF to the gasket
before installation. Be careful about the
direction of parts.
D003902E01
C083146
Free length
Outer diameter mm (in.)Color
72.20 (2.8425) /
19.0 (0.748)Colorless
D003555
D003554E01
C083129

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–231
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64. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with
ATF, and install it to the transaxle case.
NOTICE:
Be sure not to damage the lip of the transaxle
case brake gasket when inserting the gasket to
the case. Apply sufficient ATF to the gasket
before installation. Be careful about the
direction of parts.
65. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Coat a new governor apply gasket No.1 with ATF,
and install it to the transaxle case.
NOTICE:
Be sure not to damage the lip of the transaxle
case brake gasket when inserting the gasket to
the case. Apply sufficient ATF to the gasket
before installation. Be careful about the
direction of parts.
66. INSTALL TRANSMISSION WIRE
(a) Coat a new O-ring with ATF, and install it to the
transmission wire.
NOTICE:
Make sure that the O-ring is not twisted,
protruded, or pinched when installing the wire
transmission to the transaxle case. Apply
sufficient ATF to the O-ring before installation.
(b) Install the transmission wire retaining bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
67. CONNECT TRANSMISSION WIRE
(a) Coat an O-ring of the ATF temperature sensor with
AT F.
(b) Install the ATF temperature sensor with the lock
plate and bolt.
Torque: 6.6 N*m (67 kgf*cm, 58 in.*lbf)
(c) Connect the 7 solenoid connectors.
NOTICE:
• Connect the connectors A, B, C, D, E, F, G, in
the order from shortest to longest.
• Apply ATF to the bolt.
C083128
C083127
D003636E01
D003547E06
C091927E05

AX–232U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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68. INSTALL TRANSMISSION VALVE BODY ASSEMBLY
(a) While positioning the manual valve lever position,
install the valve body to the transaxle case with the
17 bolts.
Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
Bolt length:
Bolt A:
41 mm (1.614 in.)
Bolt B:
57 mm (2.244 in.)
Bolt C:
25 mm (0.984 in.)
NOTICE:
• Push the valve body against the accumulator
piston spring and the check ball body to
install the valve body.
• When installing the valve body to the
transaxle case, do not hold the solenoids.
• Temporarily tighten the bolts marked with (1)
in the illustration first because they are
positioning bolts.
69. INSTALL VALVE BODY OIL STRAINER ASSEMBLY
(a) Coat a new O-ring with ATF and install it to the oil
strainer.
NOTICE:
Make sure that the O-ring is not twisted or
pinched. Apply sufficient ATF to the O-ring
before installation.
(b) Install the oil strainer and 3 bolts to the valve body.
Torque: 11 N*m (110 kgf*cm, 8 ft.*lbf)
NOTICE:
Apply ATF to the bolts.
70. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-
ASSEMBLY
(a) Install the 2 magnets to the oil pan.
(b) Apply seal packing or equivalent to new 18 bolts.
Seal packing:
THREE BOND 2430 or equivalent
C091933E02
C091932E01
C091931
C086316E03

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–233
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(c) Install the oil pan and new oil pan gasket to the
transaxle case with the 18 bolts.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
NOTICE:
• Tighten the bolts within 10 minutes of sealant
application.
• Completely remove any oil or grease from the
contact surface of the transaxle case and the
oil pan with the gasket before installing the oil
pan to the case.
71. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Coat 4 new O-rings with ATF, and install them to the
4 transaxle case No.1 plugs.
(b) Install the 4 transaxle case No.1 plugs to the
transaxle case.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
72. INSTALL SPEED SENSOR
(a) Coat 2 new O-rings with ATF and install them to the
2 sensors.
(b) Install the 2 sensors to the transaxle case with the 2
bolts.
Torque: 11.0 N*m (115 kgf*cm, 8 ft.*lbf)
73. INSTALL OIL COOLER TUBE UNION (OUTLET OIL
COOLER UNION)
(a) Coat a new O-ring with ATF, and install it to the
elbow.
(b) Install the elbow to the transaxle case.
Torque: 27 N*m (276 kgf*cm, 20 ft.*lbf)
74. INSTALL OIL COOLER TUBE UNION (INLET OIL
COOLER UNION)
(a) Coat a new O-ring with ATF, and install it to the
union.
(b) Install the union to the transaxle case.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
75. INSTALL BREATHER PLUG HOSE
(a) Install the breather plug hose to the transaxle case
firmly.
C091925
D026716
D030672E02
C083144E01
C083143E01

AX–234U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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76. INSTALL PARK/NEUTRAL POSITION SWITCH
ASSEMBLY
(a) Install the park/neutral position switch onto the
manual valve lever shaft, and temporarily install the
2 adjusting bolts.
(b) Install a new nut stopper and nut.
Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
(c) Temporarily install the control shaft lever.
(d) Turn the lever counterclockwise until it stops, and
then turn it clockwise 2 notches.
(e) Remove the control shaft lever.
(f) Align the groove with the neutral basic line.
(g) Tighten the 2 bolts.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
(h) Using a screwdriver, stake the nut with the nut
stopper.
D009639
D009640E01
D009641
D009642
D009643

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–235
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(i) Install the control shaft lever, washer and nut.
Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
77. INSTALL SPEEDOMETER DRIVEN HOLE (ATM)
COVER SUB-ASSEMBLY
(a) Coat a new O-ring with ATF and install it to the
speedometer driven hole cover.
(b) Install the bolt and speedometer driven hoke cover
sub assembly to the transaxle assembly.
Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
D009644

AX–172U151F AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATE
AX
TORQUE CONVERTER CLUTCH
AND DRIVE PLATE
INSPECTION
1. INSPECT TORQUE CONVERTER CLUTCH
ASSEMBLY
(a) Inspect the one-way clutch.
(1) Set SST into the inner race of the one-way
clutch.
SST 09350-32014 (09351-32010)
(2) Install SST so that it fits in the notch of the
converter hub and outer race of the one-way
clutch.
SST 09350-32014 (09351-32010, 09351-
32020)
(3) Stand the torque converter up and turn the
SST.
Standard:
If the one-way clutch is turned clockwise,
it rotates freely and if turned
counterclockwise, it locks.
(b) Determine the condition of the torque converter
clutch assembly.
(1) If the inspection result of the torque converter
clutch assembly satisfies the following
conditions, replace the torque converter clutch
assembly.
Malfunction item:
A metallic sound is emitted from the
torque converter clutch assembly during
the stall test or when the shift lever is
moved to the N position.
The one-way clutch is free or locked in
both directions.
The amount of powder in the ATF is
greater than the sample shown on the
illustration (see the sample).
HINT:
The sample shows the auto fluid of
approximately 0.25 liters (0.26 US qts, 0.22
Imp. qts) that is taken out from the removed
torque converter clutch.
(c) Exchange the ATF in the torque converter clutch.
(1) If the ATF is discolored and/or has a foul odor,
completely stir the ATF in the torque converter
clutch and drain it with the torque converter
facing up.
AT00953E02
AT03306E02
D025367E07

U151F AUTOMATIC TRANSAXLE – TORQUE CONVERTER CLUTCH AND DRIVE PLATEAX–173
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(d) Clean and check the oil cooler and oil pipe line.
(1) If the torque converter clutch is inspected or the
ATF is exchanged, clean the oil cooler and oil
pipe line.
HINT:
• Spray compressed air of 196 kPa (2 kgf/cm
2, 28 psi) from the inlet hose.
• If plenty of fine powders are identified in the
ATF, add new ATF using a bucket pump and
clean it again.
(2) If the ATF is cloudy, inspect the oil cooler
(radiator).
(e) Prevent deformation of the torque converter clutch
and damage to the oil pump gear.
(1) When there is any damage on the end of the
bolt for the torque converter clutch and on the
bottom of the bolt hole, replace the bolt and the
torque converter clutch.
(2) All of the bolts must be same length.
(3) Bolts with washers must be used.
2. INSPECT DRIVE PLATE & RING GEAR SUB-
ASSEMBLY
(a) Set up a dial indicator with a roller instrument and
measure the drive plate runout.
(b) Check for damage of the ring gear.
Maximum runout:
0.20 mm (0.0079 in.)
If runout is not within specification or ring gear is
damaged, replace the drive plate.
C011090
D025368E08
C081014