2006 TOYOTA RAV4 transaxle

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–193
AX
(d) Using SST, install the nut.
SST 09387-00030, 09387-00080
Torque: 280 N*m (2,855 kgf*cm, 206 ft.*lbf)
(e) Using SST and a torque wrench, measure the
turning torque of the bearing while rotating SST at
60 rpm. When the measured value is not within the
specified value, gradually tighten the nut until it
reaches the specified value.
SST 09387-00080
Torque: Turning torque at 60 rpm
0.51 to 1.02 N*m (5.1 to 10.0 kgf*cm, 4.4
to 8.7 in.*lbf) for new
0.3 to 0.5 N*m (3.1 to 5.1 kgf*cm, 27 to
4.4 in.*lbf) for used
HINT:
Use a torque wrench with a fulcrum length of 160
mm (6.3 in.).
(f) Using a chisel and hammer, stake the front
planetary gear washer.
14. INSTALL INPUT SUN GEAR
(a) Install the 2 thrust bearings, bearing race and front
planetary sun gear to the front planetary gear.
Standard bearing and race diameter
D003596E01
D003918E01
D008074E02
D003873E03
Item Inside Outside
Bearing 34.6 mm (1.362 in.) 52.2 mm (2.055 in.)
Race 40.3 mm (1.587 in.) 58.0 mm (2.283 in.)
Bearing 38.6 mm (1.52 in.) 60.0 mm (2.362 in.)

AX–194U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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15. INSTALL REAR PLANETARY GEAR ASSEMBLY
(a) Coat the bearing race with ATF, and install it to the
rear planetary gear assembly.
Standard bearing race diameter
(b) Install the No. 2 thrust washer.
(c) Install the rear planetary gear to the rear planetary
ring gear.
(d) Using a screwdriver, install the snap ring.
16. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC
(a) Install the 5 plates and 5 discs.
Install in order:
P - D - P - D - P - D - P - D - P - D
HINT:
P = Plate
D = Disc
D003593E01
Item Inside Outside
Race 38.6 mm (1.520 in.) 58.0 mm (2.83 in.)
D003910E01
D008062E01
D003616E02
C129389E01

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–195
AX
(b) Using a vernier caliper, measure the distance
between the disc surface and the contact surface of
the 2nd brake cylinder and transaxle (Dimension A).
(c) Select an appropriate flange so that the pack
clearance will meet the specified value.
0.745 to 1.21 mm (0.0293 to 0.0476 in.)
HINT:
Piston stroke = Dimension A - Flange thickness
Standard flange thickness
(d) Install the flange.
17. INSTALL 2ND BRAKE PISTON ASSEMBLY
(a) Install the 2nd brake piston to the transaxle.
(b) Install the snap ring and measure the inside
diameter.
Standard inside diameter:
More than 167 mm (6.57 in.)
NOTICE:
• Because the taper snap ring has the
positioning direction, check it when
installing.
• When the diameter does not satisfy the
specified value, replace the snap ring with a
new one.
18. INSTALL 1-WAY CLUTCH SLEEVE OUTER
(a) Install the 1-way clutch outer sleeve to the 2nd
brake cylinder.
NOTICE:
Check the positioning direction of the outer
sleeve.
D003618E01Mark Thickness Mark Thickness
1 1.8 mm (0.071in.) 5 2.2 mm (0.087 in.)
2 1.9 mm (0.075 in.) 6 2.3 mm (0.091 in.)
3 2.0 mm (0.079 in.) 7 2.4 mm (0.094 in.)
4 2.1 mm (0.083 in.) 8 2.5 mm (0.098 in.)
D003815E01
D003619E01
D008078E01

AX–196U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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19. INSTALL 1-WAY CLUTCH ASSEMBLY
(a) Install the inner race to the 1-way clutch.
NOTICE:
Check the direction of the inner race.
(b) Check the rotating direction of the 1-way clutch for
the lock or free operation, as shown in illustration.
(c) Install the 1-way clutch and bearing to the 1-way
clutch sleeve outer.
Standard bearing diameter
NOTICE:
Install the thrust bearing properly so that no-
colored race will be visible.
20. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY
(a) Coat the No. 1 thrust washer with petroleum jelly,
and install it onto the rear planetary sun gear.
(b) Coat the bearing with petroleum jelly, and install it
onto the rear planetary sun gear.
Standard bearing diameter
D003909E02
D009638E02
D003588E02
Item Inside Outside
Bearing 53.6 mm (2.110 in.) 69.6 mm (2.740 in.)
D003908E01
D003791E01
Item Inside Outside
Bearing 33.8 mm (1.331 in) 48.2 mm (1.898 in.)

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–197
AX
(c) Install the rear planetary sun gear to the rear
planetary gear.
21. INSTALL 2ND BRAKE CLUTCH DISC
(a) Install the 3 discs and 3 plates to the transaxle.
Standard install in order:
P - D - P - D - P - D
HINT:
P = Plate
D = Disc
(b) Temporarily install the snap ring.
(c) Using a vernier caliper, measure the distance
between the disc surface and snap ring surface.
(d) Select an appropriate flange so that the pack
clearance will meet the specified value.
Standard pack clearance:
0.50 to 0.91 mm (0.0197 to 0.0358 in.)
HINT:
Piston stroke = Clearance - Flange thickness - Snap
ring thickness 1.6 mm (0.063 in.)
Standard flange thickness
(e) Temporarily remove the snap ring, attach the
selected flange and restore the snap ring.
NOTICE:
Secure the snap ring so that its gap is visible
through the groove of the transaxle case.
D003587E01
C129390E01
D009163E01
Mark Thickness Mark Thickness
1 3.0 mm (0.118 in.) 5 3.4 mm (0.134 in.)
2 3.1 mm (0.122 in.) 6 3.5 mm (0.138 in.)
3 3.2 mm (0.126 in.) 7 3.6 mm (0.142 in.)
4 3.3 mm (0.130 in) 8 -
D003623E02

AX–198U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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22. INSTALL DIRECT CLUTCH
(a) Install the bearing race to the direct clutch.
Standard bearing race diameter
(b) Install the direct clutch and thrust bearing to the rear
planetary sun gear.
NOTICE:
The disc in the direct clutch should completely
mate with the hub attached outside the rear
planetary sun gear. Otherwise, the rear cover
cannot be installed.
(c) Clean the connector part of the transaxle case and
rear cover.
(d) As shown in the illustration, place a straightedge on
the direct clutch drum and measure the distance
between the transaxle case and the straightedge
using a vernier caliper (Dimension B).
(e) Measure the 2 places of the rear cover as shown in
the illustration. Calculate a dimension C using the
following formula.
HINT:
Dimension C = Dimension (1) - Dimension (2)
(f) Calculate the end play value using the following
formula. Select a thrust bearing which satisfies the
end play value and install it.
End play:
0.198 to 0.936 mm (0.00780 to 0.03685 in.)
NOTICE:
Make sure that the colored race side is facing
the direct clutch assembly.
HINT:
End play = Dimension C - Dimension B
Standard bearing thickness and diameter
D003802E01
Item Inside Outside
Bearing race 30.3 mm (1.193 in.) 46.0 mm (1.811 in.)
D003586E01
D003624E01
D003922E01
Thickness Inside Outside
3.58 mm (0.1409 in.) 53.6 mm (2.110 in.) 69.6 mm (2.740 in.)
3.88 mm (0.1528 in.) 53.6 mm (2.110 in.) 70.18 mm (2.768 in.)

U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–199
AX
23. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Install 2 new governor apply gaskets.
24. INSTALL FRONT CLUTCH APPLY TUBE
(a) Install the clamp to the front clutch apply tube.
NOTICE:
Make sure to install the clamp to the apply pipe
before installing the apply pipe to the transaxle
case. This prevents the apply pipe from being
deformed or damaged.
25. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.
NOTICE:
Make sure to install the clamp to the apply pipe
before installing the apply pipe to the transaxle
case. This prevents the apply pipe from being
deformed or damaged.
(b) Install the 2 apply tubes and to the transaxle with
the bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
NOTICE:
Each pipe should be securely inserted until it
reaches the stopper.
26. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Install 2 new O-rings to the 2 plugs.
(b) Install the 2 plugs to the transaxle rear cover.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
D003591E01
D003923E01
D003923E01
D025510E01
C134984

AX–200U140F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
27. INSTALL TRANSAXLE REAR COVER SUB-
ASSEMBLY
(a) Using SST and a press, press in the bearing.
SST 09950-60010 (09951-00230, 09952-06010)
Standard depth:
12.05 to 12.75 mm (0.4744 to 0.5020 in.)
NOTICE:
• Face the inscribed mark side of the bearing
race up.
• Repeat the press-fit until the specified value
is obtained.
(b) Apply adhesive to the 2 screws.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or Equivalent
(c) Using a T30 ''torx'' socket wrench, install the
transaxle rear cover plate with the 2 screws.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(d) Coat 2 new oil seal rings with ATF, and install them
to the transaxle rear cover.
(e) Remove any packing material and be careful not to
get oil on the contacting surfaces of the transaxle
rear cover or the transaxle.
(f) Apply FIPG to the cover.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or Equivalent
(g) Coat the needle roller bearing with ATF.
D009193E01
C083140E01
D003584E01
D009946E01