TOYOTA SIENNA 2007 Service Repair Manual

U151F AUTOMATIC TRANSAXLE – OIL PUMPAX–239
AX
(d) Using a straightedge and feeler gauge, measure the
side clearance of both gears.
Standard side clearance:
0.02 to 0.05 mm (0.0008 to 0.0020 in.)
Maximum side clearance:
0.05 mm (0.0020 in.)
Drive gear thickness: mm (in.)
Driven gear thickness: mm (in.)
3. INSPECT FRONT OIL PUMP AND GEAR BODY SUB-
ASSEMBLY
(a) Using a dial indicator, measure the inside diameter
of the oil pump body bushing.
Standard inside diameter:
38.113 to 38.138 mm (1.50051 to 1.50149 in.)
Maximum inside diameter:
38.188 mm (1.50346 in.)
If the inside diameter is greater than the maximum,
replace the oil pump body sub-assembly.
4. INSPECT STATOR SHAFT ASSEMBLY
(a) Using a dial indicator, measure the inside diameter
of the stator shaft.
Standard inside diameter:
21.500 to 21.526 mm (0.84646 to 0.84748 in.)
Maximum inside diameter:
21.57 mm (0.8492 in.)
If the inside diameter is greater than the maximum,
replace the stator shaft.
REASSEMBLY
1. INSTALL FRONT OIL PUMP OIL SEAL
(a) Using SST and a hammer, install a new oil seal to
the oil pump body.
SST 09350-32014 (09351-32140)
HINT:
The seal end should be flat with the outer edge of
the oil pump.
(b) Coat the lip of the oil seal with MP grease.
D009209
Mark Thickness
A 11.690 to 11.699 (0.4602 to 0.4606)
B 11.700 to 11.709 (0.4606 to 0.4610)
C 11.710 to 11.720 (0.4610 to 0.4614)
D 11.721 to 11.730 (0.4615 to 0.4618)
E 11.731 to 11.740 (0.4619 to 0.4622)
Mark Thickness
A 11.690 to 11.699 (0.4602 to 0.4606)
B 11.700 to 11.709 (0.4606 to 0.4610)
C 11.710 to 11.720 (0.4610 to 0.4614)
D 11.721 to 11.730 (0.4615 to 0.4618)
E 11.731 to 11.740 (0.4619 to 0.4622)
D003648
D003653
D003654E01

AX–240U151F AUTOMATIC TRANSAXLE – OIL PUMP
AX
2. INSTALL FRONT OIL PUMP BODY O-RING
(a) Coat new O-ring with ATF, and install it to the oil
pump body.
NOTICE:
Make sure that the O-ring is not twisted or
pinched. Moreover, apply enough ATF to the O-
ring before installation.
3. INSTALL FRONT OIL PUMP DRIVEN GEAR
(a) Coat the front oil pump driven gear with ATF, and
install it to the oil pump body with the marked side
facing upward.
4. INSTALL FRONT OIL PUMP DRIVE GEAR
(a) Coat the front oil pump drive gear with ATF, and
install it to the oil pump body with the marked side
facing upward.
5. INSTALL STATOR SHAFT ASSEMBLY
(a) Set the stator shaft and align it with each bolt hole.
(b) Using a "torx" socket (T30), install the 11 bolts.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
6. INSTALL CLUTCH DRUM OIL SEAL RING
(a) Coat 2 new clutch drum oil seal rings with ATF.
(b) Install 2 new clutch drum oil seal rings.
NOTICE:
Do not expand the ring ends excessively.
7. INSPECT OIL PUMP ASSEMBLY
HINT:
(See page AX-238)
C055817E02
C119012E01
D009206E04
D003651E01
D026627E01

AX–248U151F AUTOMATIC TRANSAXLE – FORWARD CLUTCH
AX
REASSEMBLY
1. INSTALL INPUT SHAFT OIL SEAL RING
(a) Compress a new input shaft oil seal ring from both
sides to reduce dimension A.
Dimension A:
5 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the
input shaft.
NOTICE:
Do not expand the end gap of the oil seal ring
too much. Fix the hooks firmly.
2. INSTALL FORWARD CLUTCH PISTON SUB-
ASSEMBLY
(a) Coat the forward clutch piston with ATF, and install it
to the input shaft.
NOTICE:
Be careful not to damage the lip of the forward
clutch piston.
3. INSTALL FORWARD CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Install the return spring to the input shaft.
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 input shaft.
NOTICE:
• Be careful not to damage the lip of the
forward clutch balancer.
• Make sure that the clutch balancer is not
pinched and that there are no other defects at
the lip.
• Apply sufficient ATF to the sealing lip before
installation.
D025587E01
D026707E01
D026708E01
D026709E02

U151F AUTOMATIC TRANSAXLE – FORWARD CLUTCHAX–249
AX
(d) Place SST on the clutch balancer, and compress
the clutch balancer with a press.
SST 09387-00020
(e) Install the snap ring with a snap ring expander.
(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 piston as
shown in the illustration.
NOTICE:
The end gap of the snap ring should not align
with any of the stoppers.
4. INSTALL FORWARD MULTIPLE DISC CLUTCH DISC
(a) Coat the 5 discs with ATF.
(b) Install the 5 plates, 5 discs and flange input 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.
5. INSPECT PACK CLEARANCE OF FORWARD
CLUTCH
HINT:
(See page AX-247)
6. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
HINT:
(See page AX-247)
D026418E01
D026788E02
D026415E01
D026753E01

AX–272U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
AX
DISASSEMBLY
1. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place the match-marks on the ring gear and
differential case.
(b) Remove the 16 bolts.
(c) Using a plastic hammer, tap ring gear to remove it
from the case.
2. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the differential LH case from the differential
case assembly.
(b) Remove the differential case No.2 from the
differential case LH.
C050182E01
C050183E01
C050184E01
C050187E01
C050188E01

U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–273
AX
(c) Remove the front differential side gear, front
differential side gear thrust washer, conical spring
and center differential side gear thrust washer No.2
from the differential case LH.
(d) Using a snap ring expander, remove the pinion shaft
spacer snap ring.
(e) Using a pin punch and hammer, remove 3 straight
pins.
(f) Remove the center differential pinion shaft and 2
differential pinion shafts.
(g) Remove 4 front differential pinions, 4 front
differential pinion thrust washers, front differential
pinion shaft holder, front differential planetary ring
and differential side gear thrust washer No.1.
C050189E01
D025610E01
C050190E01
C050191E01
C050943E01

AX–274U151F 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
(09951-00480)
(b) Using SST, remove the front differential case rear
tapered roller bearing outer race and differential
case washer.
SST 09308-00010
4. REMOVE CENTER DIFFERENTIAL PINION
(a) Using torx socket (T50), remove the 15 bolts.
(b) Place the matchmarks on the differential
intermediate case and differential case.
(c) Remove the differential intermediate case from the
differential case RH.
(d) Remove the center differential side gear, conical
spring washer and center differential side gear
thrust washer No.1 RH from the differential case
RH.
D025597E05
D025598E03
C050193E01
C050230E01
C050196E01

U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–275
AX
(e) Remove the differential spider, 5 center differential
pinions and 5 center differential pinion thrust
washers from the differential intermediate case.
5. REMOVE FRONT DIFFERENTIAL CASE FRONT
TAPERED ROLLER BEARING
(a) Using SST, remove the front differential case front
tapered roller bearing from the differential case.
SST 09950-00020, 09950-00030
SST 09950-60010 (09951-00600)
(b) Using SST, remove the front differential case front
tapered roller bearing outer race and differential
case washer.
SST 09308-00010
6. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100)
SST 09649-17010
7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100), 09608-10010
C050194E01
D025611E01
D025596E03
D025599E02
D025600E02

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