2006 TOYOTA RAV4 transaxle

DS–40DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)
DS
REMOVAL
(2005/11-2006/01)
1. REMOVE FRONT WHEEL
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Drain the automatic transaxle fluid for U140F (see
page AX-147).
(b) Drain the automatic transaxle fluid for U241E (see
page AX-146).
3. REMOVE FRONT AXLE HUB NUT (See page AH-6)
4. DISCONNECT FRONT SPEED SENSOR LH (See page
BC-191)
5. DISCONNECT FRONT SPEED SENSOR RH
HINT:
Use the same procedures described for the LH side.
6. DISCONNECT FRONT DISC BRAKE CYLINDER
ASSEMBLY LH (See page BR-40)
7. DISCONNECT FRONT DISC BRAKE CYLINDER
ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
8. DISCONNECT FRONT STABILIZER LINK ASSEMBLY
LH (See page SP-9)
9. DISCONNECT FRONT STABILIZER LINK ASSEMBLY
RH
HINT:
Use the same procedures described for the LH side.
10. DISCONNECT FRONT SUSPENSION LOWER NO. 1
ARM SUB-ASSEMBLY LH (See page AH-7)
11. DISCONNECT FRONT SUSPENSION LOWER NO. 1
ARM SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
12. DISCONNECT STEERING KNUCKLE WITH AXLE
HUB LH
(a) Put matchmarks on the drive shaft and axle hub.
NOTICE:
Do not punch the marks.
(b) Using a plastic-faced hammer, disconnect the
steering knuckle with axle hub.
NOTICE:
Be careful not to damage the boot and speed
sensor rotor.
Do not excessively push out the drive shaft from the
axle assembly.
13. DISCONNECT STEERING KNUCKLE WITH AXLE
HUB RH
HINT:
Use the same procedures described for the LH side.
C129488E01

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)DS–41
DS
14. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
(See page PS-42)
15. DISCONNECT TIE ROD END SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
16. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
(a) Using SST, remove the front drive shaft.
SST 09520-01010, 09520-24010 (09520-32040)
NOTICE:
• Be careful not to damage the transaxle case
oil seal, inboard joint boot and drive shaft
dust cover.
• Be careful not to drop the drive shaft.
17. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
(a) Using a brass bar and hammer, set the brass bar
against position (1) as shown in the illustration and
remove the drive shaft.
NOTICE:
• Do not damage the oil seal.
• Do not damage the drive shaft boot.
• Do not allow the drive shaft to fall off.
(b) Squeeze the ends of the snap ring, and remove the
snap ring from the bearing bracket.
(c) Remove the bearing bracket bolt and remove the
front drive shaft from the bearing bracket.
NOTICE:
• Do not damage the oil seal.
• Do not damage the boot.
• Do not allow the drive shaft to fall off.
HINT:
If the connection is stiff, use a brass bar and
hammer to lightly tap the edge of the inboard joint
RH and remove it.
18. FIX FRONT AXLE ASSEMBLY
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the
vehicle with the drive shaft removed. Therefore, if it
is absolutely necessary to place the vehicle weight
on the hub bearing, first support it with SST.
SST 09608-16042 (09608-02021, 09608-02041)
C127631E01
C127633E01
C127640
C129482E01

DS–42DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)
DS
REMOVAL
(2006/01- )
1. REMOVE FRONT WHEEL
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Drain the automatic transaxle fluid for U140F (see
page AX-147).
(b) Drain the automatic transaxle fluid for U241E (see
page AX-146).
(c) Drain the automatic transaxle fluid for U151F (see
page AX-173).
3. REMOVE FRONT AXLE HUB NUT (See page AH-8)
4. DISCONNECT FRONT SPEED SENSOR LH (See page
BC-191)
5. DISCONNECT FRONT SPEED SENSOR RH
HINT:
Use the same procedures described for the LH side.
6. DISCONNECT FRONT DISC BRAKE CYLINDER
ASSEMBLY LH (See page BR-40)
7. DISCONNECT FRONT DISC BRAKE CYLINDER
ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
8. DISCONNECT FRONT STABILIZER LINK ASSEMBLY
LH (See page SP-30)
9. DISCONNECT FRONT STABILIZER LINK ASSEMBLY
RH
10. DISCONNECT FRONT SUSPENSION LOWER NO. 1
ARM SUB-ASSEMBLY LH (See page SP-22)
11. DISCONNECT FRONT SUSPENSION LOWER NO. 1
ARM SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
12. DISCONNECT STEERING KNUCKLE WITH AXLE
HUB LH
(a) Put matchmarks on the drive shaft and axle hub.
NOTICE:
Do not punch the marks.
(b) Using a plastic-faced hammer, disconnect the
steering knuckle with axle hub.
NOTICE:
Be careful not to damage the boot and speed
sensor rotor.
Do not excessively push out the drive shaft from
the axle assembly.
13. DISCONNECT STEERING KNUCKLE WITH AXLE
HUB RH
HINT:
Use the same procedures described for the LH side.
C129488E01

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)DS–43
DS
14. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
(See page PS-42)
15. DISCONNECT TIE ROD END SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
16. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
(a) Using SST, remove the front drive shaft.
SST 09520-01010, 09520-24010 (09520-32040)
NOTICE:
• Be careful not to damage the transaxle case
oil seal, inboard joint boot and drive shaft
dust cover.
• Be careful not to drop the drive shaft.
17. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
(a) Squeeze the ends of the snap ring, and remove the
snap ring from the bearing bracket.
(b) Remove the bearing bracket bolt and remove the
front drive shaft from the bearing bracket.
NOTICE:
• Do not damage the oil seal.
• Do not damage the boot.
• Do not allow the drive shaft to fall off.
HINT:
If the connection is stiff, use a brass bar and
hammer to lightly tap the edge of the inboard joint
RH and remove it.
18. FIX FRONT AXLE ASSEMBLY
NOTICE:
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the
vehicle with the drive shaft removed. Therefore, if it
is absolutely necessary to place the vehicle weight
on the hub bearing, first support it with SST.
SST 09608-16042 (09608-02021, 09608-02041)
C127631E01
C127640
C129482E01

DS–66DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)
DS
12. CONNECT FRONT SPEED SENSOR RH
HINT:
Use the same procedures described for the LH side.
13. INSTALL FRONT AXLE HUB NUT (See page AH-10)
14. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
15. ADD AUTOMATIC TRANSAXLE FLUID
(a) Add automatic transaxle fluid for U140F (see page
AX-152).
(b) Add automatic transaxle fluid for U241E (see page
AX-151).
16. CHECK FOR AUTOMATIC TRANSAXLE FLUID
LEAKAGE
17. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust front wheel alignment (see page
SP-3).
INSTALLATION
(2006/01- )
1. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
(a) Coat the spline of the inboard joint shaft with gear
oil.
(b) Align the shaft splines and tap in the drive shaft with
a brass bar and hammer.
NOTICE:
• Set the snap ring with the opening side facing
downwards.
• Be careful not to damage the oil seal, boot
and dust cover.
2. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
(a) Coat the spline of the inboard joint shaft with gear
oil.
(b) Align the shaft splines and securely insert the drive
shaft.
NOTICE:
Do not damage the oil seal.
(c) Squeeze the ends of the bracket hole snap ring and
install it to the bearing bracket.
(d) Install the bearing bracket bolt.
Torque: 32.4 N*m (330 kgf*cm, 24 ft.*lbf)
C127700
C127640

DRIVE SHAFT – FRONT DRIVE SHAFT ASSEMBLY (for 4WD)DS–67
DS
3. CONNECT STEERING KNUCKLE WITH AXLE HUB
LH
(a) Align the shaft splines in the drive shaft to the
steering knuckle with axle hub, and connect the
steering knuckle with axle hub.
4. CONNECT STEERING KNUCKLE WITH AXLE HUB
RH
HINT:
Use the same procedures described for the LH side.
5. CONNECT FRONT SUSPENSION LOWER NO. 1 ARM
SUB-ASSEMBLY LH (See page SP-24)
6. CONNECT FRONT SUSPENSION LOWER NO. 1 ARM
SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
7. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
(See page SP-31)
8. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
9. INSTALL TIE ROD END SUB-ASSEMBLY LH (See
page PS-45)
10. INSTALL TIE ROD END SUB-ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
11. CONNECT FRONT SPEED SENSOR LH
(a) Connect the speed sensor (see page BC-193).
12. CONNECT FRONT SPEED SENSOR RH
HINT:
Use the same procedures described for the LH side.
13. INSTALL FRONT AXLE HUB NUT (See page AH-11)
14. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
15. ADD AUTOMATIC TRANSAXLE FLUID
(a) Add automatic transaxle fluid for U140F (see page
AX-152).
(b) Add automatic transaxle fluid for U241E (see page
AX-151).
(c) Add automatic transaxle fluid for U151F (see page
AX-178).
16. CHECK FOR AUTOMATIC TRANSAXLE FLUID
LEAKAGE
17. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (see
page SP-3).
C129488E04

AXLE – FRONT AXLE HUBAH–9
AH
REMOVAL
(2006/01- )
HINT:
• Use the same procedures for the RH side and LH side.
• The procedures listed below are the LH side.
1. REMOVE FRONT WHEEL
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Drain the automatic transaxle fluid for U140F (see
page AX-147).
(b) Drain the automatic transaxle fluid for U241E (see
page AX-146).
(c) Drain the automatic transaxle fluid for U151E (see
page AX-172).
(d) Drain the automatic transaxle fluid for U151F (see
page AX-173).
3. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
4. REMOVE FRONT AXLE HUB LH NUT
(a) Using SST and a hammer, unstake the staked part
of the nut.
SST 09930-00010
NOTICE:
Loosen the staked part of the nut completely,
otherwise the screw of the drive shaft may be
damaged.
(b) While applying the brakes, remove the lock axle hub
nut.
5. REMOVE FRONT SPEED SENSOR LH (See page BC-
191)
6. REMOVE FRONT DISC BRAKE CYLINDER
ASSEMBLY LH (See page BR-40)
7. REMOVE FRONT DISC (See page BR-42)
8. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
(See page PS-42)
9. DISCONNECT FRONT SUSPENSION NO. 1 LOWER
ARM SUB-ASSEMBLY LH
(a) Remove the bolt and 2 nuts.
(b) Disconnect the lower arm from the ball joint.
C129483E01
C127531

AH–14AXLE – FRONT AXLE HUB
AH
(b) Using a chisel and hammer, stake the hub nut.
11. ADD AUTOMATIC TRANSAXLE FLUID
(a) Add the automatic transaxle for U140F (see page
AX-152).
(b) Add the automatic transaxle for U241E (see page
AX-151).
(c) Add the automatic transaxle for U151E (see page
AX-177).
(d) Add the automatic transaxle for U151F (see page
AX-178).
12. CHECK FOR AUTOMATIC TRANSAXLE FLUID
LEAKAGE
13. INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
14. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (see
page SP-3).
15. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
16. CHECK SPEED SENSOR SIGNAL
(a) Check the speed sensor signal (see page BC-44).
C129484