2006 TOYOTA RAV4 transaxle

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–171
AX
24. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY
(a) Using a chisel and hammer, unstake and remove
the manual valve lever spacer.
(b) Using a pin punch and hammer, tap out the manual
valve lever shaft spring pin.
HINT:
Slowly drive out the pin so that it will not fall into the
transaxle.
(c) Remove the manual valve lever shaft and manual
valve lever.
25. REMOVE PARKING LOCK ROD SUB-ASSEMBLY
(a) Remove the parking lock rod from the manual valve
lever.
26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Using a screwdriver, pry out the oil seal from the
transaxle.
27. INSPECT INPUT SHAFT END PLAY (See page AX-
185)
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AX–172U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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28. REMOVE NO. 1 TRANSAXLE CASE PLUG
(a) Remove the 2 plugs.
(b) Remove the 2 O-rings from the plug.
29. REMOVE TRANSAXLE HOUSING
(a) Remove the 16 bolts.
(b) Tap on the circumference of the transaxle housing
with a plastic-faced hammer to remove the
transaxle housing from the transaxle.
NOTICE:
Differential may be accidentally removed when
the transaxle housing is removed.
30. REMOVE UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Using SST, remove the cylindrical roller bearing
from the transaxle.
SST 09514-35011
31. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Remove the oil seal ring from the transaxle housing.
32. REMOVE OIL PUMP ASSEMBLY
(a) Remove the 7 bolts and oil pump assembly from the
transaxle.
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U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–173
AX
33. REMOVE THRUST NEEDLE ROLLER BEARING
(a) Remove thrust needle roller bearing from the
underdrive planetary gear.
34. REMOVE NO. 2 THRUST BEARING UNDERDRIVE
RACE
(a) Remove the thrust bearing race from the underdrive
planetary gear.
35. REMOVE FRONT DIFFERENTIAL ASSEMBLY
(a) Remove the front differential from the transaxle.
36. REMOVE OVERDRIVE BRAKE GASKET
(a) Remove the 2 overdrive brake gaskets from the
transaxle.
37. REMOVE FORWARD CLUTCH ASSEMBLY
(a) Remove the forward clutch from the transaxle.
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AX–174U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(b) Remove the thrust bearing from the forward clutch.
38. REMOVE MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Remove the thrust bearing, multiple clutch hub,
needle roller bearing and bearing race from the
transaxle.
39. REMOVE UNDERDRIVE PLANETARY GEAR
ASSEMBLY
(a) Remove the bolt and parking pawl shaft clamp.
(b) Remove the parking lock pawl shaft.
(c) Push the parking lock pawl.
HINT:
Failure to do so will cause the interference when the
underdrive planetary gear is removed.
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U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–175
AX
(d) Remove the underdrive planetary gear from the
transaxle.
NOTICE:
Be careful so that the underdrive planetary gear
assembly will not fall out.
(e) Remove the spring, pawl pin and parking lock pawl.
40. REMOVE UNDERDRIVE CLUTCH ASSEMBLY
(a) Remove the underdrive clutch assembly, needle
roller bearing, thrust bearing underdrive race from
the transaxle.
41. REMOVE UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Using a screwdriver, pry out the snap ring from the
transaxle.
(b) Remove the 1-way clutch from the transaxle.
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AX–176U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
AX
(c) Remove the outer race retainer from the 1-way
clutch.
42. REMOVE NO. 2 UNDERDRIVE CLUTCH DISC
(a) Using a screwdriver, pry out the snap ring from the
transaxle.
(b) Remove the flange, 3 discs and 3 plates from the
transaxle.
43. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC (See
page AX-186)
44. REMOVE UNDERDRIVE BRAKE RETURN SPRING
SUB-ASSEMBLY
(a) Using SST, a snap ring expander and press, remove
the snap ring from the transaxle.
SST 09387-00020
(b) Remove the underdrive brake return spring from the
underdrive brake piston.
45. INSPECT UNDERDRIVE BRAKE RETURN SPRING
SUB-ASSEMBLY (See page AX-186)
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U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–177
AX
46. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Remove the 2 oil seal rings from the transaxle.
47. REMOVE NO. 1 TRANSAXLE CASE PLUG
(a) Remove the 2 plugs from the transaxle rear cover.
(b) Remove the 2 O-rings from the 2 plugs.
48. REMOVE REAR TRANSAXLE COVER SUB-
ASSEMBLY
(a) Remove the 11 bolts.
(b) Tap the circumference of the rear cover with a
plastic-faced hammer to remove the transaxle rear
cover from the transaxle.
(c) Remove the 2 outer rear clutch oil seal rings from
the transaxle rear cover.
(d) Using a T30 ''torx'' socket wrench, remove the 2
screws and transaxle rear cover plate.
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AX–178U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(e) Using SST, remove the needle-roller bearing from
the transaxle rear cover.
SST 09387-00041 (09387-01010, 09387-01030,
09387-01040)
49. REMOVE UNDERDRIVE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi)
to the transaxle case to remove the underdrive
brake piston.
(b) Remove the 2 O-rings from the underdrive brake
piston.
50. REMOVE BRAKE APPLY TUBE
(a) Remove the bolt, clamp and 2 brake apply tubes.
(b) Remove the brake apply tube from the clamp.
51. REMOVE FRONT CLUTCH APPLY TUBE
52. REMOVE NO. 1 GOVERNOR APPLY GASKET
(a) Using a screwdriver, remove the 2 governor apply
gaskets.
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