LEXUS ES300 2005 Repair Manual

D30511D30668
C88136
C88136
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- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E)
2527 Author
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Remove the 8 bolts.
(d) Separate and remove the automatic transaxle.
15. REMOVE TORQUE CONVERTER CLUTCH ASSY
16. REMOVE TRANSAXLE CASE COVER UPPER
(a) Remove the 3 bolts and transmission case cover.
17. INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE PAGE 40-17)
SST 09350-32014 (09351-32010, 09351-32020)
18. INSTALL TRANSAXLE CASE COVER UPPER
(a) Install the transmission case cover with the 3 bolts.
Torque: 12 NVm (122 kgfVcm, 9 ftVlbf)

C83051
D31341Dimension B
B
D30511D31482
AA
A
A
BA
CC
D30472
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
19. INSTALL TORQUE CONVERTER CLUTCH ASSY
(a) Install the torque converter clutch to the automatic trans-
axle.
(b) Using vernier calipers, measure dimension ºAº between
the transaxle fitting part and the converter fitting part of
the drive plate.
(c) Using vernier calipers and a straight edge, measure di-
mension ºBº shown in the illustration and check that ºBº
is greater than ºAº measured in (b).
Standard: A + 1 mm or more
NOTICE:
Do not add the thickness of the straight edge.
20. INSTALL AUTOMATIC TRANSAXLE ASSY
(a) Install the automatic transaxle and 8 bolts to the engine.
Torque:
Bolt A: 64 NVm (653 kgfVcm, 47 ftVlbf)
Bolt B: 46 NVm (470 kgfVcm, 34 ftVlbf)
Bolt C: 37 NVm (377 kgfVcm, 27 ftVlbf)
(b) Apply a few drops of adhesive to each 2 threads on the
tip of the 6 torque converter clutch mounting bolts.
Adhesive: Part No. 08833-00070, THREE BOND 1324
or equivalent
(c) Install the 6 torque converter clutch mounting bolts.
Torque: 41 NVm (418 kgfVcm, 30 ftVlbf)
HINT:
First install green colored bolt, and then install the other 5 bolts.

D31340
D25420
C88135
D31339
Breather Hose
C88278
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 NVm (80 kgfVcm, 69 in.Vlbf)
21. INSTALL ENGINE MOUNTING BRACKET FR
(a) Install the engine mounting bracket FR with the 3 bolts to
the automatic transaxle.
Torque: 64 NVm (653 kgfVcm, 47 ftVlbf)
22. INSTALL TRANSMISSION OIL FILLER TUBE
SUB-ASSY
(a) Coat a new O-ring with ATF, and install it to the oil filler
tube.
(b) Install the oil filler tube with the bolt to the automatic trans-
axle.
Torque: 5.5 NVm (56 kgfVcm, 49 in.Vlbf)
(c) Install the ATF level gauge.
(d) Connect the breather hose to the wire harness bracket.
23. INSTALL TRANSMISSION CONTROL CABLE
BRACKET NO.1
(a) Install the control cable bracket No.1 with the 2 bolts.
Torque: 12 NVm (122 kgfVcm, 9 ftVlbf)
24. INSTALL OIL COOLER INLET TUBE NO.1
(a) Temporarily install the oil cooler outlet tube No.1.
(b) Temporarily install the oil cooler inlet tube No.1.

C91745
Oil cooler tube cushion
C92540
SST
D30864
Transmission
Wire Connector
Park/neutral Position Switch Connector
Transmission Revolution
Sensor Connectors
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Install the oil cooler tube clamp with the bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
HINT:
Install them so that the oil cooler tube cushion is positioned as
shown in the illustration.
(d) Using SST and spanner, tighten the oil cooler inlet tube
No.1.
Torque: 34 NVm (350 kgfVcm, 25 ftVlbf)
SST 09023-12701
25. INSTALL OIL COOLER OUTLET TUBE NO.1
(a) Using SST and spanner, tighten the oil cooler outlet tube No.1.
Torque: 34 NVm (350 kgfVcm, 25 ftVlbf)
SST 09023-12701
26. CONNECT CONNECTORS
(a) Connect the transmission wire connector.
(b) Connect the park/neutral position switch connector.
(c) Connect the 2 transmission revolution sensor connec-
tors.

D30464
D30466
D31338
C91731
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
27. INSTALL STARTER ASSY
(a) Install the starter assy with the 2 bolts.
Torque: 37 NVm (377 kgfVcm, 27 ftVlbf)
(b) Connect the connecter.
(c) Install the starter wire and nut.
Torque: 9.8 NVm (100 kgfVcm, 87 inVlbf)
28. INSTALL WIRE HARNESS
(a) Install the wire harness and bolt.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
29. INSTALL WIRE HARNESS CLAMP
(a) Install the 2 clamps and 2 bolts.
Torque: 8.4 NVm (86 kgfVcm, 74 in.Vlbf)
(b) Connect the wire harnesses to the clamps.
30. INSTALL TRANSMISSION CONTROL CABLE
BRACKET NO.2
(a) Install the transmission control cable bracket No.2 with a
bolt.
Torque: 12 NVm (122 kgfVcm, 9 ftVlbf)
31. INSTALL FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-8)
32. INSTALL FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-8)
33. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 14-29)
34. RESET MEMORY(SEE PAGE 05-604)

40063-10
AT0953
SST
AT3306
Hold
TurnLock
Free
D25367
Sample showing minimum amount of
powders in ATF
Actual Size
- AUTOMATIC TRANSMISSION / TRANSTORQUE CONVERTER CLUTCH AND DRIVE PLATE
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
TORQUE CONVERTER CLUTCH AND DRIVE PLATE
INSPECTION
1. INSPECT TORQUE CONVERTER CLUTCH ASSY
(a) Inspect the one-way clutch.
(1) Set SST into the inner race of the one-way clutch.
SST 09350-32014 (09351-32010)
(2) Install SST so that it fits in the notch of the converter
hub and outer race of the one-way clutch.
SST 09350-32014 (09351-32020)
(3) With the torque converter clutch setting up on its
side, check that the one-way clutch locks when it is
turned counterclockwise, and rotates clockwise
smoothly.
If necessary, clean the converter and retest the one- way
clutch.
Replace the converter if the one-way clutch still fails the test.
(b) Determine the condition of the torque converter clutch
assy.
(1) If the inspection result of the torque converter clutch
assy meets the following item, replace the torque
converter clutch.
Malfunction item:
Any metallic sound is heard from the torque convert-
er clutch during stall test or when the shift lever is in
neutral position.
One-way clutch is free or locked in both directions.
Fine powders exceeding the sample limit is identified
in ATF. (See the sample.)
HINT:
The sample shows the auto fluid of approx. 0.25 liters (0.26 US
qts, 0.22 Imp. qts) that is taken out from the removed torque
converter clutch
(c) Replace the ATF in the torque converter clutch.
(1) If the ATF is discolored and/or has a foul odor, com-
pletely stir the ATF in the torque converter clutch
and drain it with the face for installation facing up.

C11090
D25368
OK NG
The Bottom is
Damaged
C81014
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Clean and check the oil cooler and oil pipe line.
(1) If the torque converter clutch is inspected or the ATF
is exchanged, clean the oil cooler and oil pipe line.
HINT:

Spray compressed air of 196 kPa (2 kgf/cm2, 28 psi) from
the inlet hose.

If plenty of fine powders are identified in the ATF, add new
ATF using a bucket pump and clean it again.
(2) If the ATF is cloudy, inspect the oil cooler (radiator).
(e) Prevent deformation of the torque converter clutch and
damage to the oil pump gear.
(1) When any marks due to interference are found on
the end of the bolt for the torque converter clutch
and on the bottom of the bolt hole, replace the bolt
and the torque converter clutch.
(2) All of the bolts must be have the same length.
(3) No missing spring washer.
2. INSPECT DRIVE PLATE & RING GEAR SUB-ASSY
(a) Set up a dial indicator and measure the drive plate runout.
(b) Check the damage of the ring gear.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification or ring gear is dam-
aged, replace the drive plate.

40060-08
C90569
C90570
C90570
C90569
- AUTOMATIC TRANSMISSION / TRANSSPEED SENSOR
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
SPEED SENSOR
REPLACEMENT
1. REMOVE BATTERY
2. REMOVE AIR CLEANER ASSY
3. REMOVE AIR CLEANER HOSE NO.1
4. REMOVE SPEED SENSOR (NT SENSOR)
(a) Disconnect the speed sensor connector.
(b) Remove the bolt and speed sensor.
5. REMOVE SPEED SENSOR (NC SENSOR)
(a) Disconnect the speed sensor connector.
(b) Remove the bolt and speed sensor.
6. INSTALL SPEED SENSOR (NC SENSOR)
(a) Coat O-ring with ATF.
(b) Install the speed sensor with the bolt.
Torque: 11.3 NVm (115 kgfVcm, 8 ftVlbf)
HINT:
Make sure of the manufacturer's name.
(c) Connect the speed sensor connector.
7. INSTALL SPEED SENSOR (NT SENSOR)
(a) Coat O-ring with ATF.
(b) Install the speed sensor with the bolt.
Torque: 11.3 NVm (115 kgfVcm, 8 ftVlbf)
HINT:
Make sure of the manufacturer's name.
(c) Connect the speed sensor connector.

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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
8. INSTALL AIR CLEANER HOSE NO.1
9. INSTALL AIR CLEANER ASSY
Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf)
10. INSTALL BATTERY

4010V-04
C91925
D30865
AT0103
C91927
- AUTOMATIC TRANSMISSION / TRANSTRANSMISSION WIRE (U151E)
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
TRANSMISSION WIRE (U151E)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER NO.1
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket, and drain ATF.
(b) Install a new gasket and drain plug.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
3. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB-ASSY
(a) Remove the 18 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Remove all the pan
bolts, and carefully remove the oil pan assembly.
(b) Remove the 2 magnets from the oil pan.
(c) Examine particles in pan.
(1) Use the removed magnets to collect steel chips.
Look carefully at the chips and particles in the pan
and the magnet to anticipate the type of wear you
will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non-magnetic): bearing wear
4. DISCONNECT TRANSMISSION WIRE
(a) Disconnect the 7 shift solenoid valve connectors.
(b) Remove the bolt and lock plate, and disconnect the ATF
temperature sensor.