2006 TOYOTA RAV4 transaxle

U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–217
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8. INSTALL UNDERDRIVE BRAKE PISTON
(a) Coat 2 new O-rings with ATF, and install them to the
underdrive brake piston.
NOTICE:
• Make sure that the O-rings are not twisted or
pinched when they are installed.
• Apply sufficient ATF to the O-ring before
installing.
(b) Coat the underdrive brake piston with ATF.
(c) Install the underdrive brake piston to the transaxle
case.
NOTICE:
Be careful not to damage the O-ring.
9. INSTALL UNDERDRIVE BRAKE RETURN SPRING
SUB-ASSEMBLY
(a) Place SST on the return spring and compress the
return spring with a press.
SST 09387-00020
NOTICE:
• Stop the press when the spring seat is
lowered to a position 1 to 2 mm (0.039 to
0.078 in.) from the snap ring groove to
prevent the spring seat from being deformed.
• After installing the return spring, check that
all the return spring's springs fit in the piston
correctly.
(b) Using a snap ring expander, press in the snap ring
to the transaxle case.
NOTICE:
The snap ring must be fully engaged in the
groove of the transaxle case.
10. INSTALL NO. 2 BREATHER PLUG
11. INSTALL COUNTER DRIVE GEAR BEARING
(a) Coat the counter drive gear bearing with ATF.
(b) Using SST and a press, press in the bearing outer
race.
SST 09950-60020 (09951-01030), 09950-70010
(09951-07150), 09649-17010
NOTICE:
• Do not apply excessive pressure to the
bearing.
• Press-fit the bearing outer race until it
contacts the transaxle case.
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AX–218U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(c) Using a snap ring expander, install the snap ring.
NOTICE:
The white mark side of the snap ring should face
upward.
12. INSTALL COUNTER DRIVE GEAR
(a) Coat the counter drive gear with ATF.
(b) Using SST and a press, press in the tapered roller
bearing to the counter drive gear.
SST 09950-70010 (09951-07150), 09649-17010
NOTICE:
Do not apply excessive pressure to the bearing.
(c) Using SST and a press, press in the counter drive
gear and bearing to the transaxle case.
SST 09950-70010 (09951-07150), 09223-15030,
09527-17011, 09950-60020 (09951-00750)
NOTICE:
Do not apply excessive pressure to the counter
drive gear.
13. INSTALL 1ST AND REVERSE BRAKE PISTON
(a) Coat 2 new O-rings with ATF.
(b) Install the 2 O-rings to the 1st and reverse brake
piston.
NOTICE:
• Make sure that the O-rings are not twisted or
pinched when they are installed.
• Apply sufficient ATF to the O-ring prior to
assembling.
D026467E02
D026410E01
C089122E04
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U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–219
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(c) Coat the 1st and reverse brake piston with ATF, and
install it to the transaxle case.
NOTICE:
Be careful not to damage the O-ring.
14. INSTALL 1ST AND REVERSE BRAKE RETURN
SPRING SUB-ASSEMBLY
(a) Place SST on the return spring and compress the
return spring with a press.
SST 09387-00070
NOTICE:
• Stop the press when the spring seat is
lowered to a position 1 to 2 mm (0.039 to
0.078 in.) from the snap ring groove to
prevent the spring seat from being deformed.
• After installing the return spring, check that
all the return spring's springs fit in the piston
correctly.
(b) Using a snap ring expander, press in the snap ring
to the transaxle case.
NOTICE:
• The snap ring must be fully engaged in the
groove of the transaxle case.
• Fix the snap ring to the inside of the claw of
the spring seat firmly.
15. INSTALL FRONT PLANETARY RING GEAR
(a) Using a screwdriver, install the front planetary ring
gear and snap ring to the brake hub.
NOTICE:
Confirm that the snap ring is engaged in the
groove of the brake hub correctly.
16. INSTALL FRONT PLANETARY GEAR ASSEMBLY
(a) Install the front planetary gear to the brake hub.
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D003600E01
D003615E03
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AX–220U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(b) Using SST and a press, press-fit the front planetary
gear.
SST 09950-60010 (09951-00500), 09950-70010
(09951-07100)
NOTICE:
• Do not apply excessive pressure to the
planetary gear.
• Press the inner race of the LH tapered roller
bearing, counter gear and front planetary
gear to the position where no preload should
be applied to one pair of tapered roller
bearings (left and right).
(c) Install a new washer as shown in the illustration.
(d) Using SST, install the nut.
SST 09387-00030, 09387-00080
Torque: 280 N*m (3,355 kgf*cm, 207 ft.*lbf)
NOTICE:
Assemble the washer after pressing each part,
then tighten the nut to the standard torque.
(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 as
specified, gradually tighten the nut until it reaches
the specified value.
SST 09387-00080
Standard 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 bearing
0.26 to 0.51 N*m (2.7 to 5.2 kgf*cm, 2.3 to 4.5
in.*lbf) for used bearing
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D003917E01
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U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–221
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(f) Tighten the nut gradually until the specified turning
torque of the tapered roller bearing is measured.
Torque: 350 N*m (3,569 kgf*cm, 258 ft.*lbf)
(g) Using a chisel and hammer, stake the front lock
washer.
17. INSTALL INPUT SUN GEAR
(a) Coat the 2 thrust bearings with ATF.
(b) Install the 2 thrust bearings, bearing race and input
sun gear to the front planetary gear.
NOTICE:
• Install the bearing race on the side of the
front planetary carrier. Be careful of the
direction of the race.
• When installing the thrust bearing and front
sun gears, be careful about the direction of
the parts.
• When installing the bearing race on the side
of the front sun gear, be careful of the
direction of the race.
• Install the thrust bearing and the race after
holding the parts on the input sun gear by
applying grease. Make sure that the
assembling order is correct.
Standard thrust bearing and bearing race
diameter
18. INSTALL REAR PLANETARY GEAR ASSEMBLY
(a) Install the rear planetary gear to the rear planetary
ring gear.
D008074E01
C089123E02
Item Inside Outside
Thrust Bearing, A 32.5 mm (1.28 in.) 56.5 mm (2.224 in.)
Thrust Bearing, C 38.6 mm (1.520 in.) 59.7 mm (2.35 in.)
Bearing Race, B 40.2 mm (1.583 in.) 59.3 mm (2.335 in.)
Bearing Race, D 38.6 mm (1.520 in.) 59.3 mm (2.335 in.)
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AX–222U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(b) Using a screwdriver, install the snap ring.
NOTICE:
Confirm that the snap ring is fixed in the groove
of the 1st and reverse brake hub correctly.
19. INSTALL 1ST AND REVERSE BRAKE CLUTCH DISC
(a) Coat the 6 discs with ATF.
(b) Install the 6 plates and 6 discs.
NOTICE:
Make sure that the plates and discs are installed
as shown in the illustration.
20. INSPECT PACK CLEARANCE OF FIRST AND
REVERSE BRAKE
(a) Using a vernier caliper, 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.
Standard pack clearance:
1.16 to 1.35 mm (0.0457 to 0.0531 in.)
HINT:
Piston stroke = Dimension A - Flange thickness
Standard flange thickness
(c) Install the flange.
D003616E02
C136370E01
D026452E01
Mark Thickness Mark Thickness
1 1.8 mm (0.071 in.) 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.)
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U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–223
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21. INSTALL SECOND BRAKE PISTON ASSEMBLY
(a) Install the second brake piston to the transaxle
case.
(b) Install the snap ring and measure the inside
diameter.
Inside diameter:
Greater than 167 mm (6.57 in.)
NOTICE:
• Make sure that the taper snap ring is installed
in the correct direction.
• When the diameter does not meet the
specified value, replace the snap ring with a
new one.
• After installing the snap ring, confirm that
there is no clearance between the 2nd brake
cylinder and the fitting surface of the cylinder
in the transaxle case.
22. INSTALL 1-WAY CLUTCH SLEEVE OUTER
(a) Install the 1-way clutch sleeve outer to the 2nd
brake cylinder.
NOTICE:
Make sure that the outer sleeve is installed in
the correct direction.
23. INSTALL 1-WAY CLUTCH ASSEMBLY
(a) Install the 1-way clutch inner race to the 1-way
clutch.
NOTICE:
• Make sure that the inner race is installed in
the correct direction.
• Confirm that the discrimination mark is
visible.
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D008058E03
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AX–224U151F AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(b) Check that the 1-way clutch locks when turned
clockwise and rotates freely when turned
counterclockwise as shown in the illustration..
HINT:
If the result is not as specified, replace the 1-way
clutch.
(c) Install the 1-way clutch and thrust needle roller
bearing to the 1-way clutch sleeve outer.
Standard bearing diameter
NOTICE:
Install the thrust bearing properly so that the
non-colored race will be visible.
24. INSTALL NO. 1 PLANETARY CARRIER THRUST
WA S HE R
(a) Coat the planetary carrier thrust washer with yellow
petrolatum, and install the washer onto the
planetary sun gear.
NOTICE:
After installing the washer, confirm that the
projection of the washer is fixed firmly in the
hole of the planetary sun gear.
25. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY
(a) Coat the planetary carrier thrust washer with yellow
petrolatum, and install the washer onto the rear
planetary sun gear.
(b) Coat the bearing with yellow petrolatum, and install
the bearing onto the rear planetary sun gear.
Standard bearing diameter
D009638E03
D003588E02
Item Inside Outside
Bearing 53.6 mm (2.110 in.) 69.4 mm (2.732 in.)
D026394E07
D026393E05
D026404E07
Item Inside Outside
Race 33.0 mm (1.299 in.) 45.4 mm (1.787 in.)
Bearing 31.85 mm (1.254 in.) 45.2 mm (1.78 in.)