TOYOTA SIENNA 2007 Service Repair Manual

AX–200U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(b) Remove the 2 O-rings from the underdrive brake
piston.
75. REMOVE NEEDLE ROLLER BEARING
(a) Using SST, remove the needleroller bearing from
the transaxle case.
SST 09387-00041 (09387-01010, 09387-01030,
09387-01040)
76. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Remove the 2 oil seal rings from the transaxle case.
77. REMOVE TRANSAXLE CASE NO.1 PLUG
(a) Remove the 2 transaxle case No.1 plugs.
(b) Remove the 2 O-rings from the 2 transaxle case
No.1 plugs.
78. REMOVE UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Using SST, remove the underdrive cylindrical roller
bearing from the transaxle case.
SST 09514-35011
D003794E01
D003605E01
D003914E01
D026383
D003606E01

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–201
AX
79. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Remove the oil seal ring from the transaxle housing.
80. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Remove the bolt, transaxle apply tube clamp and
differential gear lube apply tube from the transaxle
housing.
NOTICE:
Do not bend the tubes.
INSPECTION
1. INSPECT MULTIPLE DISC CLUTCH HUB
(a) Using a dial indicator, measure the inside diameter
of the forward clutch hub bushing
Standard inside diameter:
23.025 to 23.046 mm (0.9065 to 0.9073 in.)
Maximum inside diameter:
23.09 mm (0.9091 in.)
NOTICE:
Check the contact surface of the bushing in the
direct clutch shaft. If any scratch or
discoloration is found, replace the direct clutch
sub-assembly with a new one.
If the inside diameter is greater than the maximum,
replace the forward clutch hub with a new one.
2. INSPECT UNDERDRIVE CLUTCH DISC NO.2
(a) Check if the sliding surfaces of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
• 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.
D003915E05
D026400E02
D003829E02
D009196

AX–202U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
3. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-
ASSEMBLY
(a) Using a dial indicator, measure the inside diameter
of the forward clutch hub bushing.
Standard inside diameter:
23.025 to 23.046 mm (0.9065 to 0.9073 in.)
Maximum inside diameter:
23.09 mm (0.9091 in.)
NOTICE:
Check the contact surface of the bushing in the
direct clutch shaft. If any scratch or
discoloration is found, replace the direct clutch
sub-assembly with a new one.
If the inside diameter is greater than the maximum,
replace the forward clutch hub with a new one.
4. INSPECT 2ND BRAKE CLUTCH DISC
(a) Check if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
• 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.
5. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC
(a) Check if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
• 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.
6. INSPECT 1ST AND REVERSE BRAKE RETURN
SPRING SUB-ASSEMBLY
(a) Using a vernier calipers, measure the free length of
the spring together with the spring seat.
Standard free length:
17.61 mm (0.6933 in.)
HINT:
If the result is not as specified, replace the spring.
D003829E01
D026717
D009189
D030852E07

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–203
AX
7. INSPECT UNDERDRIVE BRAKE RETURN SPRING
SUB-ASSEMBLY
(a) Using a vernier calipers, measure the free length of
the spring together with the spring seat.
Standard free length:
13.24 mm (0.5213 in.)
HINT:
If the result is not as specified, replace the spring.
8. INSPECT PACK CLEARANCE OF 1ST AND
REVERSE BRAKE
(a) Using vernier calipers, measure the distance
between the disc surface and the contact surface of
the 2nd brake cylinder and transaxle case
(Dimension A).
(b) Select an appropriate flange so that the pack
clearance will meet the specified value.
Pack clearance:
1.16 to 1.35 mm (0.0457 to 0.0531 in.)
HINT:
Piston stroke = Dimension A - Flange thickness
Flange thickness: mm (in.)
(c) Install the flange.
9. INSPECT PACK CLEARANCE OF 2ND BRAKE
(a) Using a vernier calipers, measure the distance
between the disc surface and snap ring surface
(Dimension B).
(b) Select an appropriate flange so that the pack
clearance will meet the specified value.
Pack clearance:
0.62 to 0.91 mm (0.0244 to 0.0358 in.)
HINT:
Piston stroke = Dimension B - Flange thickness -
Snap ring thickness 1.6 mm (0.063 in.)
Flange thickness: mm (in.)
D030852E01
D026452E01
Mark Thickness Mark Thickness
1 1.8 (0.071) 5 2.2 (0.087)
2 1.9 (0.075) 6 2.3 (0.091)
3 2.0 (0.079) 7 2.4 (0.094)
4 2.1 (0.083) 8 2.5 (0.098)
D026453E01
Mark Thickness Mark Thickness
1 3.0 (0.118) 5 3.4 (0.134)
2 3.1 (0.122) 6 3.5 (0.138)
3 3.2 (0.126) 7 3.6 (0.142)
4 3.3 (0.130) 8 -

AX–204U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
10. 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.
11. INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the underdrive clutch assembly to the 1-way
clutch.
(b) Rotate the underdrive 1-way clutch assembly to
check the rotating direction for the lock or free
operation.
HINT:
If the result is not as specified, replace the
underdrive 1-way clutch.
12. INSPECT INPUT SHAFT END PLAY
(a) Using a dial indicator, measure the input shaft end
play.
End play:
0.262 to 1.244 mm (0.01 to 0.049 in.)
HINT:
If the result is not as specified, replace the input
shaft or thrust needle roller bearing.
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) - -
D003925E01
D008091

AX–246U151F AUTOMATIC TRANSAXLE – FORWARD CLUTCH
AX
(d) Remove the forward clutch return spring from the
input shaft.
4. REMOVE FORWARD CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Place the forward clutch drum onto the oil pump.
(b) Holding the forward clutch piston by hand, apply
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil pump to remove the forward clutch piston.
HINT:
When the piston cannot be removed as it is slanted,
blow air again with the protruding side pushed, or
remove the piston using the needle nose pliers with
vinyl tape on the tip.
5. REMOVE INPUT SHAFT OIL SEAL RING
(a) Remove the input shaft oil seal ring from the input
shaft.
INSPECTION
1. INSPECT PACK CLEARANCE OF FORWARD
CLUTCH
(a) Install the forward clutch on the oil pump.
NOTICE:
Be careful not to damage the oil seal ring of oil
pump.
(b) Using a dial indicator, measure the forward clutch
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:
1.00 to 1.25 mm (0.0394 to 0.4921 in.)
If the clearance is not as specified, inspect the
discs, plates and flange.
HINT:
If the opening is large, cover it with a shop rug or a
piece of cloth to prevent the compressed air from
being released.
D026708E01
D003664
C056374
D026715E01

U151F AUTOMATIC TRANSAXLE – FORWARD CLUTCHAX–247
AX
2. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
(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 FORWARD CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Using vernier calipers, measure the free length of
the spring together with the spring seat.
Standard free length:
26.74 mm (1.0528 in.)
4. INSPECT PACK CLEARANCE OF FORWARD
CLUTCH
(a) Using a dial indicator, measure the forward clutch
pack clearance while applying and releasing
compressed air (392 kgf/cm
2, 4.0 kPa, 57 psi).
Pack clearance:
1.00 to 1.25 mm (0.0394 to 0.4921 in.)
If the piston stroke is less than the minimum, parts
may be assembled incorrectly. Check and
reassemble the parts again.
If the clearance is not as specified, select another
flange.
HINT:
There are 5 different thicknesses of flanges
available.
Flange thickness: mm (in.)
5. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
(a) Check if the disc lightly rotates when rotating the
forward clutch assembly after inserting the multiple
disc clutch into it.
NOTICE:
Do not place the forward clutch assembly in a
vise.
D009189
D009211E01
D026715E01
No. Thickness No. Thickness
1 3.00 (0.1181) 4 3.45 (0.1358)
2 3.15 (0.1240) 5 3.60 (0.1417)
3 3.30 (0.1299) - -
D003672

AX–236U151F AUTOMATIC TRANSAXLE – OIL PUMP
AX
TRANSMISSION
U151F AUTOMATIC TRANSAXLE
OIL PUMP
COMPONENTS
C114866E01

U151F AUTOMATIC TRANSAXLE – OIL PUMPAX–237
AX
DISASSEMBLY
1. INSPECT OIL PUMP ASSEMBLY
HINT:
(See page AX-238)
2. REMOVE CLUTCH DRUM OIL SEAL RING
(a) Remove the 2 clutch drum oil seal rings.
3. REMOVE STATOR SHAFT ASSEMBLY
(a) Using a "torx" socket (T30), remove the 11 bolts and
stator shaft.
4. INSPECT CLEARANCE OF OIL PUMP ASSEMBLY
HINT:
(See page AX-238)
5. REMOVE FRONT OIL PUMP DRIVE GEAR
(a) Remove the front oil pump drive gear.
6. REMOVE FRONT OIL PUMP DRIVEN GEAR
(a) Remove the front oil pump driven gear.
D003650E01
D003651E01
D009206E02
C119012

AX–238U151F AUTOMATIC TRANSAXLE – OIL PUMP
AX
7. REMOVE FRONT OIL PUMP BODY O-RING
(a) Using a screwdriver, remove the O-ring.
HINT:
Tape the screwdriver before use.
8. REMOVE FRONT OIL PUMP OIL SEAL
(a) Mount the oil pump in a soft jaw vise.
(b) Using SST, remove the oil seal from the oil pump
body.
SST 09308-00010
INSPECTION
1. INSPECT OIL PUMP ASSEMBLY
(a) Turn the drive gear with the 2 screwdrivers and
make sure that it rotates smoothly.
NOTICE:
Be careful not to damage the oil seal lip.
2. INSPECT CLEARANCE OF OIL PUMP ASSEMBLY
(a) Push the driven gear to one side of the body.
(b) Using a feeler gauge, measure the clearance.
Standard body clearance:
0.10 to 0.17 mm (0.0039 to 0.0067 in.)
Side clearance:
0.02 to 0.05 mm (0.001 to 0.002 in.)
Maximum body clearance:
0.17 mm (0.0067 in.)
If the body clearance is greater than the maximum,
replace the oil pump body sub-assembly.
(c) Using a feeler gauge, measure the tip clearance
between the driven gear teeth and drive gear teeth.
Standard tip clearance:
0.07 to 0.15 mm (0.0028 to 0.0059 in.)
Maximum tip clearance:
0.15 mm (0.0059 in.)
If the tip clearance is greater than the maximum,
replace the oil pump body sub-assembly.
D025586E01
D003647E01
D009205
D009207E01
D009208