TOYOTA SIENNA 2007 Service Repair Manual

U151F AUTOMATIC TRANSAXLE – UNDERDRIVE CLUTCHAX–269
AX
4. INSTALL UNDERDRIVE CLUTCH DISC NO.1
(a) Coat the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the
underdrive clutch drum.
NOTICE:
Make sure that the plates, discs, and flange are
installed as shown in the illustration.
5. INSTALL 1ST & REVERSE BRAKE RETURN SPRING
SHAFT SNAP RING
(a) Using a screwdriver, install the underdrive clutch
flange No.2 hole snap ring.
(b) Check that the end gap of 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. INSPECT UNDERDRIVE PACK CLEARANCE
HINT:
(See page AX-266)
D026431E01
D003701

AX–276U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
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INSPECTION
1. INSPECT FRONT DIFFERENTIAL
(a) Using a dial indicator, measure the backlash of one
pinion gear while holding the front differential side
gear toward the case.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
NOTICE:
Do not mount the surface of front differential
case which contacts with bushing in a vise.
If the backlash is not within the specified value, refer
to the table below and select a thrust washer which
will ensure that the backlash is within the specified
value.
Thrust washer thickness: mm (in.)
(b) Engage the front differential side to the above
mentioned front differential case.
(c) Install the differential case LH to the front differential
case and measure its center.
(d) After that, remove the differential case LH.
(e) Using a straight edge and feeler gauge, measure
the clearance between the front differential case
and the front differential side gear.
HINT:
• t= Thrust washer thickness
• L= Clearance
• t= L-0.162 - 0.265 mm (0.0064 - 0.0104 in.)
If the clearance is not within the specified value,
refer to the table below and select a thrust washer
which will ensure that the clearance is within the
specified value.
Thrust washer thickness: mm (in.)
C050216E01
Mark Thickness Mark Thickness
A 0.95 (0.0373) F 1.20 (0.0472)
B 1.00 (0.0393) G 1.25 (0.0492)
C 1.05 (0.0413) H 1.30 (0.0512)
D 1.10 (0.0433) J 1.35 (0.0532)
E 1.15 (0.0453) K 1.40 (0.0552)
C050213E01
C050214E01
Mark Thickness Mark Thickness
A 0.95 (0.0373) F 1.20 (0.0472)
B 1.00 (0.0393) G 1.25 (0.0492)
C 1.05 (0.0413) H 1.30 (0.0512)
D 1.10 (0.0433) J 1.35 (0.0532)
E 1.15 (0.0453) K 1.40 (0.0552)

U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–277
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If the clearance is not within the specified value,
parts may have been assembled incorrectly, so
check and reassemble it.
2. INSPECT CENTER DIFFERENTIAL
(a) Pressing and holding the differential spider toward
the differential case RH, measure the pinion's
backlash with a dial indicator as illustrated.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specified value, refer
to the table below and select a thrust washer which
will ensure that the backlash is within the specified
value.
Thrust washer thickness: mm (in.)
(b) Temporarily install the differential side gear thrust
washer No.2 LH, center differential side gear conical
spring washer and differential case No.2 to the
differential case LH.
HINT:
Ensure that the conical washers is installed
correctly.
(c) Install the differential intermediate case to the above
and fix them with 4 bolts.
C050205E01
Mark Thickness Mark Thickness
MA 0.80 (0.0313) MH 1.15 (0.0453)
MB 0.85 (0.0333) MJ 1.20 (0.0472)
MC 0.90 (0.0353) MK 1.25 (0.0492)
MD 0.95 (0.0373) ML 1.30 (0.0512)
ME 1.00 (0.0393) MM 1.35 (0.0532)
MF 1.05 (0.0413) MN 1.40 (0.0552)
MG 1.10 (0.0433) - -
C050206E01
C050207E01

AX–278U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
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(d) remove the differential spider, 5 center differential
pinions and 5 center differential pinion thrust
washers from the differential case RH. Put them in
the differential intermediate case and fix the case.
(e) Pressing and holding the differential spider toward
the differential intermediate case, measure the
pinion's backlash with a dial indicator.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specified value, refer
to the table below and select a thrust washer which
will ensure that the backlash is within the specified
value.
Thrust washer thickness: mm (in.)
(f) Remove the 4 bolts and disconnect the differential
case LH from the differential intermediate case.
(g) Remove the differential case No.2 from the
differential case LH.
C050208E01
C050209E01
Mark Thickness Mark Thickness
MA 0.80 (0.0313) MH 1.15 (0.0453)
MB 0.85 (0.0333) MJ 1.20 (0.0472)
MC 0.90 (0.0353) MK 1.25 (0.0492)
MD 0.95 (0.0373) ML 1.30 (0.0512)
ME 1.00 (0.0393) MM 1.35 (0.0532)
MF 1.05 (0.0413) MN 1.40 (0.0552)
MG 1.10 (0.0433) - -
C050210E01
C051468E01

U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–279
AX
3. ADJUST TAPERED ROLLER BEARING PRELOAD
(a) Install the intermediate case to the differential case
LH and fix them with 4 bolts.
(b) Install the differential assembly to the transaxle
case.
(c) Clean the matching surfaces of the transaxle case
and transaxle housing.
(d) Install the transaxle housing to the transaxle case
and tighten them with the 16 bolts.
Torque: Bolt A
25 N*m (255 kgf*cm, 18 ft.*lbf)
Bolt B
33 N*m (337 kgf*cm, 24 ft.*lbf)
Bolt C
29 N*m (295 kgf*cm, 21 ft.*lbf)
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
HINT:
Usually, bolt A is a non-reusable bolt. In the case,
however, it can be used after cleaning it.
(e) Using SST, turn the differential assembly right and
left 2 or 3 times to allow the bearing settle.
SST 09564-32011
(f) Using SST and a torque wrench, measure the
turning torque of the differential case assembly.
SST 09564-32011
Torque: New bearing (*)
0.2 to 0.69 N*m (2.0 to 7.0 kgf*cm, 1.8 to
601 in.*lbf)
Used bearing (*)
0.10 to 0.35 N*m (1.0 to 3.6 kgf*cm, 0.9
to 3.1 in.*lbf)
HINT:
• (*): Turning torque at 60 rpm
• If the turning torque is not within the specified
value, refer to the table below and select a thrust
washer which turning torque is within the
specified value.
Flange thickness: mm (in.)
C050224E01
D003568E02
C050227E01
Mark Thickness Mark Thickness
0 2.00 (0.0787) 9 2.45 (0.0965)
1 2.05 (0.0807) A 2.50 (0.0984)
2 2.10 (0.0827) B 2.55 (0.1004)
3 2.15 (0.0846) C 2.60 (0.1024)
4 2.20 (0.0866) D 2.65 (0.1043)
5 2.25 (0.0886) E 2.70 (0.1063)

AX–280U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
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(g) Remove the 16 bolts and the transaxle housing.
(h) Remove the differential assembly.
REASSEMBLY
1. INSTALL DIFFERENTIAL CASE SUB-ASSEMBLY
NO.2
(a) Coat the front differential side gear thrust washer
No.1, front differential planetary ring gear, front
differential pinion No.2, front differential pinion thrust
washer No.2, front differential pinion shaft holder,
front differential pinion shaft and 2 differential pinion
shafts with ATF, install them to the differential case
No.2.
(b) Using a pin punch and a hammer, install 3 straight
pins.
6 2.30 (0.0906) F 2.75 (0.1083)
7 2.35 (0.0925) G 2.80 (0.1102)
8 2.40 (0.0945) H 2.00 (0.1122) Mark Thickness Mark Thickness
D025614E01
C050224E02
C050943E02
C050217E01

U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–281
AX
(c) Using a snap ring expander, install the pinion shaft
spacer snap ring.
2. INSPECT FRONT DIFFERENTIAL
HINT:
(See page AX-276)
3. INSTALL CTR DIFFERENTIAL PLANETARY GEAR
ASSEMBLY
(a) Install the center differential side gear, conical
spring washer and center differential side gear
thrust washer No.2 RH from the differential case
RH.
HINT:
Ensure that the conical washers is installed
correctly.
(b) Hold the differential case RH by vice. Install the
center differential pinion and pinion thrust washer to
the differential spider and install them to the
differential case RH.
NOTICE:
When holding the differential case RH by vise,
be sure to place an aluminum sheet between
them and use a minimum force
(c) Pressing and holding the differential spider toward
the differential case RH, measure the pinion's
backlash with a dial indicator as illustrated.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specified value, refer
to the table below and select a thrust washer which
will ensure that the backlash is within the specified
value.
Thrust washer thickness: mm (in.)
D025610E02
C051252E01
C050950E01
C050205E01
Mark Thickness Mark Thickness
MA 0.80 (0.0313) MH 1.15 (0.0453)
MB 0.85 (0.0333) MJ 1.20 (0.0472)
MC 0.90 (0.0353) MK 1.25 (0.0492)
MD 0.95 (0.0373) ML 1.30 (0.0512)
ME 1.00 (0.0393) MM 1.35 (0.0532)
MF 1.05 (0.0413) MN 1.40 (0.0552)
MG 1.10 (0.0433) - -

AX–282U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
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(d) Temporarily install the differential side gear thrust
washer No.2 LH, center differential side gear conical
spring washer and differential case No.2 to the
differential case LH.
HINT:
Ensure that the conical washers is installed
correctly.
(e) Install the differential intermediate case to the above
and fix them with 4 bolts.
(f) remove the differential spider, 5 center differential
pinions and 5 center differential pinion thrust
washers from the differential case RH. Put them in
the differential intermediate case and fix the case.
(g) Pressing and holding the differential spider toward
the differential intermediate case, measure the
pinion's backlash with a dial indicator.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specified value, refer
to the table below and select a thrust washer which
will ensure that the backlash is within the specified
value.
Thrust washer thickness: mm (in.)
C050206E01
C050207E01
C050208E01
C050209E01
Mark Thickness Mark Thickness
MA 0.80 (0.0313) MH 1.15 (0.0453)
MB 0.85 (0.0333) MJ 1.20 (0.0472)
MC 0.90 (0.0353) MK 1.25 (0.0492)
MD 0.95 (0.0373) ML 1.30 (0.0512)
ME 1.00 (0.0393) MM 1.35 (0.0532)
MF 1.05 (0.0413) MN 1.40 (0.0552)
MG 1.10 (0.0433) - -

U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASEAX–283
AX
(h) Remove the 4 bolts and disconnect the differential
case LH from the differential intermediate case.
(i) Remove the differential case No.2 from the
differential case LH.
(j) Install the selected differential side gear thrust
washer No.2 LH and center differential planetary
gear to the differential case LH.
(k) Install the differential case No.2 to the differential
case LH again.
(l) install the adjusted differential case RH to the
intermediate case and tighten the 15 bolts using a
torx socket wrench(T50).
Torque: 63 N*m (642 kgf*cm, 46 ft.*lbf)
NOTICE:
Align the matchmarks.
C050210E01
C051468E01
C051469E01
C050188E02
C050193E02

AX–284U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL CASE
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4. INSTALL FRONT DIFFERENTIAL CASE FRONT
TAPERED ROLLER BEARING
(a) Using SST and a press, install the front differential
case tapered roller bearing FR to the differential
case.
SST 09950-70010 (09951-07100), 09649-17010
NOTICE:
Do not make a damage on the bearing cage
during the bearing inner race installation.
(b) Using SST, install the outer race of the tapered roller
bearing FR.
SST 09527-17011, 09950-60020 (09951-01030)
NOTICE:
Clearance is not allowed between the plate
washer and transaxle housing.
5. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Using SST and a press, install the front differential
case tapered roller bearing RR to the differential
case.
SST 09316-20011, 09214-76011
NOTICE:
Do not make a damage on the bearing cage
during the bearing inner race installation.
(b) Install the front differential case shim RR to the
transaxle case.
If the bearing is new, check to select a front
differential case shim RR of proper thickness
starting from the thinner ones. If the bearing is
reused, check to select a front differential case shim
RR starting from the same thickness as one
installed before disassembly.
(c) Using SST, install the outer race of the front
differential case tapered roller bearing RR.
SST 09950-60020 (09951-00890), 09950-70010
(09951-07100)
NOTICE:
Clearance is not allowed between the differential
case shim and transaxle case.
6. ADJUST TAPERED ROLLER BEARING PRELOAD
HINT:
(See page AX-279)
D025612E01
D025603E01
D025613E01
D025601E01