2006 TOYOTA RAV4 transaxle

U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–195
AX
(d) Install the flange.
12. INSPECT PACK CLEARANCE OF 1ST AND
REVERSE BRAKE
13. 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.
14. 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 outer race sleeve.
Standard bearing diameter
NOTICE:
Install the thrust bearing properly so that no
colored race will be visible.
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Item Inside Outside
Bearing 53.6 mm (2.110 in.) 69.6 mm (2.740 in.)

AX–196U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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15. INSTALL REAR PLANETARY SUN GEAR ASSEMBLY
(a) Coat the No. 1 planetary carrier 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
(c) Install the rear planetary sun gear to the rear
planetary gear.
16. INSTALL 2ND BRAKE CLUTCH DISC
(a) Install the 3 discs and 3 plates to the transaxle.
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 piston
stroke will meet the specified value.
Standard pack clearance:
0.62 to 0.91 mm (0.0244 to 0.0358 in.)
HINT:
Piston stroke = Clearance - Flange thickness -Snap
ring thickness 1.6 mm (0.063 in.)
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Item Inside Outside
Bearing 33.8 mm (1.331 in.) 48.2 mm (1.898 in.)
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U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–197
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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.
17. INSTALL DIRECT CLUTCH
(a) Install the bearing race to the direct clutch.
Standard bearing diameter
(b) Install the direct clutch and thrust needle roller
bearing to the rear planetary sun gear.
NOTICE:
The disc in the direct clutch should completely
align 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).
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 -
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Item Inside Outside
Bearing race 30.3 mm (1.193 in.) 46.0 mm (1.811 in.)
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AX–198U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(e) Measure the 2 places of the rear cover as shown in
the illustration and 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 (0.00800 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
18. INSTALL NO. 1 GOVERNOR APPLY GASKET
(a) Install 2 new apply gaskets to the transaxle.
19. 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.
20. 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.
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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 (2.763 in.)
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U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–199
AX
(b) Install the 2 apply tubes 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.
21. 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)
22. INSTALL TRANSAXLE REAR COVER SUB-
ASSEMBLY
(a) Using SST and a press, press in the bearing.
SST 09950-60010 (09951-00230, 09951-00350)
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, install the transaxle rear
cover plate with the 2 screws.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
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AX–200U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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(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 seal packing to the cover.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or Equivalent
(g) Coat the needle roller bearing with ATF.
(h) Apply adhesive to the threads of the bolts labeled A.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or Equivalent
(i) Install the 11 bolts.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A
25 N*m (255 kgf*cm, 18 ft.*lbf) for other
bolt
23. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Install 2 new oil seals to the transaxle.
24. INSTALL UNDERDRIVE BRAKE PISTON
(a) Wind a vinyl tape around SST at the 4.0 mm (0.157
in.) above from the bottom end until the thickness of
the wound tape is about 5.0 mm (0.197 in.).
SST 09550-60010 (09951-00320)
NOTICE:
Clean SST to remove deposited oil before
winding a vinyl tape.
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U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–201
AX
(b) Using SST and a press, press in the needle-roller
bearing to the transaxle until the wound vinyl tape
contacts the transaxle case.
SST 09550-60010 (09951-00320), 09950-70010
(09951-07100), 09387-00020
(c) Coat 2 new O-rings with ATF, and install them to the
underdrive brake piston.
(d) Install the underdrive brake piston to the transaxle.
25. INSTALL UNDERDRIVE BRAKE RETURN SPRING
SUB-ASSEMBLY
(a) Install the underdrive brake return spring to the
underdrive brake piston.
(b) Using SST, a snap ring expander and press, press
the return spring and install the snap ring to the
transaxle.
SST 09387-00020
NOTICE:
Do not apply excessive pressure.
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AX–202U241E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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26. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC
(a) Install the 3 discs and 3 plates to the transaxle.
Install in order:
P - D - P - D - P - D
HINT:
D = Disc
P = Plate
(b) Using a screwdriver, install the snap ring.
(c) Using a dial indicator, measure the underdrive brake
piston stroke while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Standard piston stroke:
1.81 to 2.20 mm (0.0713 to 0.0866 in.)
HINT:
Select an appropriate flange from the table below so
that it will meet the specified value.
Standard flange thickness
(d) Temporarily remove the snap ring and attach the
flange. Restore the snap ring.
27. INSTALL UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
(a) Install the outer race retainer to the 1-way clutch.
C129391E01
D008050E01
D008082E01Mark Thickness Mark Thickness
1 3.0 mm (0.118 in.) 3 3.4 mm (0.134 in.)
2 3.2 mm (0.126 in.) - -
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