LEXUS ES300 2005 Repair Manual

D03916
SST
Counter Drive
GearTransaxle
Case
2nd Brake Hub
w/ Front Planetary
Gear Assy
SST
D03917
D03596
SST
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Using SST and a press, press-fit the front planetary gear
assy.
SST 09950- 60010 (09951- 00500), 09950- 70010
(09951-07100)
NOTICE:

Do not apply excessive pressure to it.

Press the inner race of LH tapered roller bearing,
counter gear and front planetary gear assembly to the
position where no pre-load should be applied to one
pair of tapered roller bearings (left and right).
(c) Install the new washer, as shown in the illustration.
(d) Using SST, install the nut.
SST 09387-00030, 09387-00080
Torque: 210 - 350 NVm
(2,141 kgfVcm, 155 ftVlbf - 3,569 kgfVcm, 258 ftVlbf)
NOTICE:
Assemble the washer after pressing each part, then tighten
the nut to minimum tightening torque.

D03918
SST
D08074
Lock Washer
C89123
C
BA
Input Sun Gear
D
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(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 val-
ue.
SST 09387-00080
Turning torque at 60 rpm:
New Bearing
0.51 - 1.02 NVm (5.1 - 10.0 kgfVcm, 4.4 - 8.7 in.Vlbf)
Used Bearing
0.26 - 0.51 NVm (2.7 - 5.2 kgfVcm, 2.3 - 4.5 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
(f) Tighten the nut gradually until the specified rotation
torque of tapered roller bearing is measured.
Torque: 350 NVm (3,569 kgfVcm, 258 ftVlbf) (a limit)
(g) Using a chisel and hammer, stake the front lock washer.
98. INSTALL INPUT SUN GEAR
(a) Coat the 2 thrust bearings with ATF.
(b) Install the 2 thrust bearings, the bearing race and the front
planetary sun gear to the front planetary gear assy.
NOTICE:

Install the bearing race on the side of the front plane-
tary carrier. Be careful about the orientation of the
race.

Installing thrust bearing and front sun gears, be care-
ful about the orientation of the parts.

Install the bearing race on the side of the front sun
gear. Be careful about the orientation of the race.

Install the thrust bearing and the race after holding
the parts on the rear planetary carrier by applying
grease. Be sure the assembling order.

D26591Rear Planetary Gear Assy
D03616
Snap Ring
D26413
Disc
Plate
D26452
A
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
Thrust bearing and bearing race diameter: mm (in.)
insideoutside
Thrust Bearing, A32.5 (1.28)56.5 (2.224)
Bearing Race, B40.2 (1.583)59.3 (2.335)
Thrust Bearing, C38.6 (1.520)59.7 (2.35)
Bearing Race, D38.6 (1.520)59.3 (2.335)
99. INSTALL REAR PLANETARY GEAR ASSY
(a) Install the rear planetary gear assy to the rear planetary
ring gear.
(b) Using a screwdriver, install the snap ring.
NOTICE:
Confirm the snap ring is fixed in the groove of the 1st & re-
verse brake hub correctly.
100. INSTALL 1ST & REVERSE BRAKE CLUTCH DISC
(a) Coat the 6 discs with ATF.
(b) Install the 6 plates and 6 discs.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
101. INSPECT PACK CLEARANCE OF FIRST & REVERSE
BRAKE
(a) Using vernier calipers, measure the distance between the
disc surface and the contact surface of the 2nd brake cyl-
inder and transaxle case(Dimension A).
(b) Select an appropriate flange so that the pack clearance
will meet the specified value.
Pack clearance: 1.16 - 1.35 mm (0.0457 - 0.0531 in.)
HINT:
Piston stroke = Dimension A -Flange thickness

D03815
D26396Second Brake Piston Assy
D08058
Snap Ring
C929771-W ay Clutch Sleeve Outer
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
Flange thickness: mm (in.)
MarkThicknessMarkThickness
11.8 (0.071)52.2 (0.087)
21.9 (0.075)62.3 (0.091)
32.0 (0.079)72.4 (0.094)
42.1 (0.083)82.5 (0.098)
(c) Install the flange.
102. INSTALL SECOND BRAKE PISTON ASSY
(a) Install the second brake piston assy to the transaxle case.
(b) Install the snap ring and measure the inside diameter.
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 meet the specified value,
replace the snap ring with new one.

After assembling, confirm that there is no clearance
between the second brake cylinder and the fitting sur-
face of the cylinder in the transaxle case.
103. INSTALL 1WAY CLUTCH SLEEVE OUTER
(a) Install the 1-way clutch sleeve outer to the 2nd brake cyl-
inder assy.
NOTICE:
Check the positioning direction of the outer sleeve.

D03909
1-W ay Clutch
Inner Race
D09638
Free
D03588
Thrust Needle
Roller Bearing
1-W ay Clutch Assy
D26394
Planetary Carrier
Thrust Washer No.1
D26393
Planetary Carrier Thrust Washer No.2
Rear Planetary Sun Gear
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
104. INSTALL 1 WAY CLUTCH ASSY
(a) Install the 1-way clutch inner race to the 1-way clutch.
NOTICE:

Check the direction of the inner race.

Confirm that the discrimination mark can be seen by
the worker.
(b) Check the rotating direction of 1-way clutch for the lock
or free operation, as shown in the illustration.
(c) Install the 1-way clutch and thrust needle roller bearing
to the 1-way clutch sleeve outer.
Bearing diameter: mm (in.)
InsideOutside
Bearing53.6 (2.110)69.4 (2.732)
NOTICE:
Install the thrust bearing properly so that no-colored race
will be visible.
105. INSTALL PLANETARY CARRIER THRUST WASHER
NO.1
(a) Coat the planetary carrier thrust washer No. 1 with yellow
petrolatum, install it onto the planetary sun gear assy.
NOTICE:
After assembling, confirm that the projection should be
fixed surely in the hole of the planetary sun gear assembly.
106. INSTALL REAR PLANETARY SUN GEAR ASSY
(a) Coat the planetary carrier thrust washer No. 2 with yellow
petrolatum, install it onto the rear planetary sun gear.

D26404
BA
D26714Rear Planetary Sun Gear Assy
D26412
Plate Disc
D26453
B 40-54
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Coat the bearing with yellow petrolatum, install it onto the
rear planetary sun gear.
Bearing diameter: mm (in.)
InsideOutside
Race, A33.0 (1.299)45.4 (1.787)
Bearing, B31.85 (1.254)45.2 (1.78)
(c) Install the rear planetary sun gear assy to the rear plane-
tary gear.
NOTICE:
Installing the rear planetary sun gear assembly, confirm
that the B1 discs engage.
107. INSTALL 2ND BRAKE CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs and 4 plates to the transaxle case.
(c) Temporarily install the snap ring.
108. INSPECT PACK CLEARANCE OF SECOND BRAKE
(a) Using a vernier calipers, measure the distance between
the disc surface and snap ring surface (Dimension B).
(b) Select an appropriate flange so that the pack clearance
will meet the specified value.
Pack clearance: 0.62 - 0.91 mm (0.0244 - 0.0358 in.)
HINT:
Piston stroke = Dimension B - Flange thickness - Snap ring
thickness 1.6 mm (0.063 in.)
Flange thickness: mm (in.)
MarkThicknessMarkThickness
13.0 (0.118)53.4 (0.134)
23.1 (0.122)63.5 (0.138)
33.2 (0.126)73.6 (0.142)
43.3 (0.130)8-

D03623
Snap Ring
D26392
BA
Overdrive Direct
Clutch Hub
D26403
Thrust Bearing
Direct Clutch Assy
D26469
C
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) 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.
109. I N S TA L L O V E R D R E V E D I R E C T C L U T C H H U B
SUB-ASSY
(a) Install the direct clutch hub to the planetary gear assy.
NOTICE:
Be careful not to damage the bush inside of the overdrive
clutch hub during instaling.
(b) Coat the thrust bearing with ATF.
(c) Install the bearing race and the thrust bearing to the direct
clutch hub.
NOTICE:
Installing the bearing, hold the part on the side of the over-
drive clutch hub.
Bearing and race diameter: mm (in.)
InsideOutside
Bearing, A24.7 (0.972)39.5 (1.555)
Race, B23.6 (0.929)38.0 (1.496)
110. INSTALL DIRECT CLUTCH ASSY
(a) Coat the thrust bearing with ATF.
(b) Install the direct clutch assy and thrust bearing to the rear
planetary sun gear assy.
NOTICE:
The disc in the direct clutch should completely match with
the hub attached outside the rear planetary sun gear.
Otherwise, the rear cover can not be installed.
(c) Clean the connecter part of the transaxle case and the
rear cover.
(d) As shown in the illustration, place a straight edge on the
direct clutch drum and measure the distance between
transaxle case and the straight edge using vernier cali-
pers (Dimension C).

D26470
D
D26390
D03923
D26391
Brake Apply
Tube
Clutch Apply Tube
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(e) Using vernier calipers and a simple straightedge, mea-
sure the position shown in the illustration.
(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: 0.244 - 0.901 mm (0.0096 - 0.0355 in.)
NOTICE:
Make sure that the no colored race side is facing the direct
clutch assy.
HINT:
End play = Dimension D - Dimension C
Bearing thickness and diameter : mm (in.)
ThicknessInsideOutside
3.6 (0.1417)56.3 (2.217)75.7 (2.980)
3.8 (0.1496)56.3 (2.217)75.7 (2.980)
111. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Install the 3 new governor apply gaskets No. 1 to the
transaxle case.
112. INSTALL BRAKE APPLY TUBE
(a) Install the clamp to the brake apply tube.
NOTICE:
Make sure to install the clamp to the apply tube before
installing the apply tube to the transaxle case. This pre-
vents the apply tube from being deformed or damaged.
(b) Install the clutch apply tube.
(c) Install the brake apply tube and a bolt to the transaxle
case.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
NOTICE:
Each pipe should be securely inserted until it reaches the
stopper.

D26766
SST
D26389
Rear Clutch
Oil Seal
Ring Outer
D26388
D26454
FIPG
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
113. INSTALL NEEDLE ROLLER BEARING
(a) Using SST and a press, install the needle roller bearing
to the transaxle rear cover.
SST 09950-60010 (09951-00230, 09952-06010)
Press fit depth: 20.55 - 21.25 mm (0.8091 - 0.8366 in.)
NOTICE:

Face the inscribed mark side of the bearing race up.

Repeat the press fit until the specified value is ob-
tained.
(b) Coat a needle roller bearing with ATF.
114. INSTALL REAR CLUTCH OIL SEAL RING OUTER
(a) Coat the 3 new rear clutch oil seal rings with ATF, install
them to the transaxle rear cover.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
115. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Install the 4 new O-ring to the 4 transaxle case No. 1
plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle
rear cover.
Torque: 7.4 NVm (75 kgfVcm, 65 in.Vlbf)
116. INSTALL TRANSAXLE REAR COVER SUB-ASSY
(a) Remove any packing material and be careful not to get oil
on the contacting surfaces of the transaxle rear cover or
the transaxle case.
(b) Apply FIPG to the cover.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equiva-
lent.
NOTICE:
Concerning about the amount of the FIPG application, the
amount should be controlled to from even sealing film on
entire flange surface and have slight protrusion of the FIPG
all around of the connecting area. The FIPG shall be ap-
plied continuously on the flange. (Reference value of the
section diameter: f1.2)

D26387AA
D26414
Flange
Plate Disc
D26466
Snap Ring
D08082
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Apply liquid sealer to the ºAº bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent.
(d) Install the 11 bolts.
Torque:
Bolt A: 19.0 NVm (190 kgfVcm, 14 ftVlbf)
Other bolt: 25.0 NVm (250 kgfVcm, 18 ftVlbf)
117. INSTALL UNDERDRIVE CLUTCH DISC NO.2
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs, 4 plates and flange to the transaxle
case.
NOTICE:
Be careful about the order of discs, plate and flange assem-
bly.
(c) Using a screwdriver, install the snap ring.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
118. INSPECT PACK CLEARANCE OF UNDERDRIVE
BRAKE
(a) Using a dial indicator, measure the underdrive brake pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance: 1.81 - 2.20 mm (0.0713 - 0.0866 in.)
HINT:
Select an appropriate flange from the table below so that it will
meet the specified value.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
13.0 (0.118)43.1 (0.122)
23.2 (0.126)53.3 (0.130)
33.4 (0.134)--
(b) Temporally remove the snap ring and attach to the flange.
(c) Restore the snap ring.