TOYOTA SIENNA 2007 Service Repair Manual

AX–286U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
AX
9. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Wind a vinyl tape around SST at the place 6.0 mm
(0.236 in.) above from the bottom end until the
thickness of the wound tape is about 5.0 mm (0.197
in.).
SST 09950-60020 (09951-00730)
NOTICE:
Remove foreign matter such as grease on the
SST before winding the tape.
(b) Coat the rip of oil seal with a little MP grease.
(c) Using SST, install a new oil seal.
SST 09950-60020 (09951-00730), 09950-70010
(09951-07150)
Standard press in depth:
5.5 - 6.5 mm (0.217 - 0.256 in.)
NOTICE:
Stop pressing when the would vinyl tape is
contact with the transaxle housing.
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AX–250U151F AUTOMATIC TRANSAXLE – DIRECT CLUTCH
AX
TRANSMISSION
U151F AUTOMATIC TRANSAXLE
DIRECT CLUTCH
COMPONENTS
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U151F AUTOMATIC TRANSAXLE – DIRECT CLUTCHAX–251
AX
DISASSEMBLY
1. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
HINT:
(See page AX-253)
2. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
AND OVERDRIVE CLUTCH
HINT:
(See page AX-253)
3. REMOVE DIRECT MULTIPLE DISC CLUTCH
(a) Using a screwdriver, remove the snap ring from the
intermediate shaft.
(b) Remove the flange, 3 discs, 3 plates and cushion
plate from the intermediate shaft.
4. REMOVE OVERDRIVE DIRECT CLUTCH DISC
(a) Using a screwdriver, remove the snap ring from the
intermediate shaft.
(b) Remove the flange, 4 discs and 4 plates from the
intermediate shaft.
5. REMOVE OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Place SST on the clutch balancer and compress the
spring with a press.
SST 09387-00020
(b) Using a snap ring expander, remove the snap ring
from the direct clutch drum.
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.
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AX–252U151F AUTOMATIC TRANSAXLE – DIRECT CLUTCH
AX
• This prevents the spring seat from being
deformed.
• Do not expand the snap ring excessively.
(c) Remove the clutch balancer from the direct clutch
drum.
(d) Remove the overdrive clutch return spring from the
direct clutch drum.
6. REMOVE OVERDRIVE DIRECT CLUTCH PISTON
(a) Install the intermediate shaft on the transaxle rear
cover.
(b) Holding the direct clutch piston with your hand,
apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the transaxle rear cover to remove the direct
clutch piston.
7. REMOVE OVERDRIVE DIRECT CLUTCH DRUM SUB-
ASSEMBLY
(a) Holding the direct clutch drum by hand, apply
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
transaxle rear cover to remove the direct clutch
drum.
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U151F AUTOMATIC TRANSAXLE – DIRECT CLUTCHAX–253
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8. REMOVE OVERDRIVE DIRECT CLUTCH O-RING
(a) Using a screwdriver, remove the O-ring from the
direct clutch drum.
INSPECTION
1. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the intermediate shaft and needle roller
bearing onto the transaxle rear cover.
(b) Using a dial indicator, measure the reverse clutch
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:
0.60 to 0.82 mm (0.02362 to 0.03228 in.)
If the pack clearance is not as specified, inspect the
discs, plates and flange.
2. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
AND OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch and
overdrive clutch pack clearance while applying and
releasing compressed air (392 kPa, 4.0 kgf/cm
2, 57
psi).
Pack clearance:
0.61 to 0.83 mm (0.02401 to 0.03268 in.)
If the pack clearance is not as specified, inspect the
discs, plates and flange.
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AX–254U151F AUTOMATIC TRANSAXLE – DIRECT CLUTCH
AX
3. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC
(a) Check if the sliding surfaces 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.
4. INSPECT OVERDRIVE DIRECT 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.
5. INSPECT OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Using vernier calipers, measure the free length of
the spring together with the spring seat.
Standard free length:
25.91 mm (1.0201 in.)
6. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the intermediate shaft onto the transaxle rear
cover.
(b) Using a dial indicator, measure the direct clutch
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Clearance:
0.60 to 0.82 mm (0.02362 to 0.03228 in.)
If the pack clearance is less than the minimum,
parts may have been assembled incorrectly, so
check and reassemble again. If the clearance is not
as specified, select another flange.
HINT:
There are 7 flanges of different thickness.
Flange thickness: mm (in.)
D026718
D026719
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No. Thickness No. 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) - -

U151F AUTOMATIC TRANSAXLE – DIRECT CLUTCHAX–255
AX
7. INSPECT PACK CLEARANCE OF DIRECT CLUTCH
AND OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch &
overdrive clutch pack clearance while applying and
releasing compressed air (392 kPa, 4.0 kgf/cm
2, 57
psi).
Clearance:
0.61 to 0.83 mm (0.02401 to 0.03268 in.)
If the pack clearance is less than the minimum,
parts may have been assembled incorrectly, so
check and reassemble again. If the clearance is not
as specified, select another flange.
HINT:
There are 7different thicknesses of flanges
available.
Flange thickness: mm (in.)
(b) Check that the disc rotates when rotating the disc
after inserting the rear planetary sun gear.
NOTICE:
Do not place the rear planetary sun gear in a
vise.
REASSEMBLY
1. INSTALL OVERDRIVE DIRECT CLUTCH O-RING
(a) Coat an O-ring with ATF, and install it to the direct
clutch drum.
NOTICE:
Make sure that the O-ring is not twisted or
pinched when it is installed.
2. INSTALL OVERDRIVE DIRECT CLUTCH DRUM SUB-
ASSEMBLY
(a) Coat the direct clutch drum with ATF, and install it to
the intermediate shaft.
NOTICE:
• Be careful not to damage the O-ring.
• Be careful not to damage the lip of the direct
clutch drum.
No. Thickness No. Thickness
0 2.5 (0.098) 4 2.9 (0.114)
1 2.6 (0.102) 5 3.0 (0.118)
2 2.7 (0.106) 6 3.1 (0.122)
3 2.8 (0.110) - -
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AX–256U151F AUTOMATIC TRANSAXLE – DIRECT CLUTCH
AX
3. INSTALL OVERDRIVE DIRECT CLUTCH PISTON
(a) Coat the overdrive direct clutch piston with ATF, and
install it to the direct clutch drum.
4. INSTALL OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Install the overdrive clutch return spring to the direct
clutch drum.
NOTICE:
Installing the spring sub-assembly, check that
all of the springs are fit in piston correctly.
(b) Coat the clutch balancer with ATF.
(c) Install the clutch balancer to the direct clutch drum.
NOTICE:
• Be careful not to damage the lip of the direct
clutch balancer.
• Make sure that the lip of the seal is not
pinched and that it has no other defects.
• Apply sufficient ATF to the sealing lip before
installing the clutch balancer.
(d) Place SST on the clutch balancer and compress the
overdrive clutch return spring with a press.
SST 09387-00020
(e) Using a snap ring expander, install the snap ring to
the direct 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.
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U151F AUTOMATIC TRANSAXLE – DIRECT CLUTCHAX–257
AX
(g) Set the end gap of the snap ring in the piston shown
in the illustration.
NOTICE:
The end gap of the snap ring should not align
with any of the stoppers.
5. INSTALL OVERDRIVE DIRECT CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the
intermediate 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.
6. INSTALL DIRECT MULTIPLE DISC CLUTCH DISC
(a) Coat the 3 disc with ATF.
(b) Install the cushion plate, 3 plates, 3 disc and flange
to the intermediate shaft.
NOTICE:
• Install the cushion plate with the mark on the
white surface facing to plate.
• Be careful about the order of discs, plate and
flange assembly.
(c) Using a screwdriver, install the snap ling.
(d) Check that the end gap of the snap ling is not
aligned with one of the cutouts.
NOTICE:
The slap ring should be fixed certainly in the
groove of the drum.
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AX–258U151F AUTOMATIC TRANSAXLE – UNDERDRIVE PLANETARY GEAR
AX
TRANSMISSION
U151F AUTOMATIC TRANSAXLE
UNDERDRIVE PLANETARY GEAR
COMPONENTS
C114868E03