LEXUS ES300 2005 Manual PDF

02-4
- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
13 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
09950-00030Bearing Remover AttachmentFRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09950-4001 1Puller B SetFRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
(09957-04010)AttachmentFRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09950-60010Replacer SetFRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
(09951-00230)Replacer 23AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09951-00260)Replacer 26UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
(09951-00320)Replacer 32AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
(09951-00450)Replacer 45AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09951-00480)Replacer 48FRONT DIFFERENTIAL
ASSY(U151F)
(09951-00490)Replacer 49FRONT DIFFERENTIAL
ASSY(U151E)
(09951-00500)Replacer 50AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)

- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02-5
14 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(09951-00590)Replacer 59AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09951-00600)Replacer 60FRONT DIFFERENTIAL
ASSY(U151F)
(09952-06010)AdapterAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09950-60020Replacer Set No.2FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
(09951-00730)Replacer 73FRONT DIFFERENTIAL
ASSY(U151F)
(09951-00750)Replacer 75AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09951-00810)Replacer 81AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09951-00890)Replacer 89FRONT DIFFERENTIAL
ASSY(U151E)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
(09951-00910)Replacer 91FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09951-01030)Replacer 103AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09950-70010Handle SetFRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

02-6
- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
15 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(09951-07100)Handle 100FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
(09951-07150)Handle 150FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
Recomended Tools
09031-00030Pin PunchAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09031-00040Pin Punch .FRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)
09905-00012Snap Ring No.1 ExpanderAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FORWARD CLUTCH
ASSY(U151E/U151F)
DIRECT CLUTCH
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09905-00013Snap Ring PliersUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
Equipment
Dial indicator with magnetic base
Feeler gauge
Vernier calipers
Torque wrench
Plastic hammer
Straight edge
Press
Seal packing 2403, THREE BOND 2403 or equivalent
Seal packing 2430, THREE BOND 2430 or equivalent
Lubricant
item
U151E / U151F
Automatic transaxle fluid
Dry fill
Drain and refill
6.8 liter (7.2 USqts, 6.0 lmp.qts)
2.9 liter (3.1 USqts, 2.6 lmp.qts)ATF type T-IV

- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02-7
16 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
SSM (Special Service Materials)
08826-00090Seal Packing 1281,
THREE BOND 1281 or equivalent
(FIPG)
08833-00080Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalent

030JK-02
V06821
Mark
Mark Class
Class
Hexagon head
bolt
Bolt
head No.4-
5-
6-
7-
8-
9-
10-
11 -4T
5T
6T
7T
8T
9T
10T
11 T
No mark
No mark Hexagon
flange bolt
w/ washer
hexagon bolt4T
4T
5T
6T
7T
8T Hexagon head
bolt
Hexagon
flange bolt
w/ washer
hexagon bolt
Hexagon head
bolt
Hexagon head
bolt2
Protruding
lines
2
Protruding
lines
3
Protruding
lines
4
Protruding
linesHexagon
flange bolt
w/ washer
hexagon bolt
Hexagon
flange bolt
w/ washer
hexagon bolt
Hexagon
flange bolt
w/ washer
hexagon bolt
Stud bolt
Welded bolt4
Protruding
lines
5
Protruding
lines
6
Protruding
lines
No mark
Grooved9T
10T
11 T
4T
6T
4T
- SERVICE SPECIFICATIONSSTANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL03-1
17 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
STANDARD BOLT FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
HOW TO DETERMINE BOLT STRENGTH

030JL-02
V00079
ClassDiameter
mmPitch
mmSpecified torque
Hexagon head bolt
Hexagon flange bolt
N´m kgf´cm
ft´lbf N´mkgf´cm
ft´lbf
in.´lbf
in.´lbf
in.´lbfin.´lbf
in.´lbf
in.´lbf 03-2
- SERVICE SPECIFICATIONSSTANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL
18 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
SPECIFIED TORQUE FOR STANDARD BOLTS

030JM-02
6N
8N
10N
11 N
12N
B06432
Nut Type
Present Standard
Hexagon Nut
Cold Forging Nut Cutting Processed NutClass
4N
5N (4T)
6N
7N (5T)
8N
10N (7T)
11 N
12N Old Standard Hexagon Nut
No Mark (w/ Washer)No Mark
*
No Mark (w/ Washer)
No Mark
No Mark
*: Nut with 1 or more marks on one side surface of the nut.
- SERVICE SPECIFICATIONSSTANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL03-3
19 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
HOW TO DETERMINE NUT STRENGTH
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more

0305K-1 1
03-4
- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
20 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
AUTOMATIC TRANSMISSION / TRANSAXLE
SERVICE DATA
Oil pump
Body clearance STD
Max.0.10 - 0.17 mm (0.0039 - 0.0067 in.)
0.17 mm (0.0067 in.)
Tip clearance STD
Max.0.07 - 0.15 mm (0.0028 - 0.0059 in.)
0.15 mm (0.0059 in.)
Side clearance STD
Max.0.02 - 0.05 mm (0.0008 - 0.0020 in.)
0.05 mm (0.0020 in.)
Drive gear thickness Mark
A
B
C
D
E
11.690 - 11.699 mm (0.4602 - 0.4606 in.)
11.700 - 11.709 mm (0.4606 - 0.4610 in.)
11.710 - 11.720 mm (0.4610 - 0.4614 in.)
11.721 - 11.730 mm (0.4615 - 0.4618 in.)
11.731 - 11.740 mm (0.4619 - 0.4622 in.)
Driven gear thickness Mark
A
B
C
D
E
11.690 - 11.699 mm (0.4602 - 0.4606 in.)
11.700 - 11.709 mm (0.4606 - 0.4610 in.)
11.710 - 11.720 mm (0.4610 - 0.4614 in.)
11.721 - 11.730 mm (0.4615 - 0.4618 in.)
11.731 - 11.740 mm (0.4619 - 0.4622 in.)
Pump body bushing inside diameter STD
Max.38.113 - 38.138 mm (1.50050 - 1.50149 in.)
38.188 mm (1.50346 in.)
Stator shaft bushing inside diameter STD
Max.21.500 - 21.526 mm (0.84646 - 0.84748 in.)
21.57 mm (0.8492 in.)
Multiple disc clutch
Inside diameter STD
Max.23.025 - 23.045 mm (0.9065 - 0.9073 in.)
23.09 mm (0.9091 in.)
Forward clutch
Pack clearance1.00 - 1.25 mm (0.0394 - 0.4921 in.)
Return spring free length26.74 mm (1.0528 in.)
Flange thickness Mark
1
2
3
4
5
3.00 mm (0.1181 in.)
3.15 mm (0.1240 in.)
3.30 mm (0.1299 in.)
3.45 mm (0.1358 in.)
3.60 mm (0.1417 in.)
Reverse clutch
Pack clearance:0.60 - 0.82 mm (0.02362 - 0.03228 in.)
Flange thickness Mark
1
2
3
4
5
6
7
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)
3.2 mm (0.126 in.)
3.3 mm (0.130 in.)
3.4 mm (0.134 in.)
3.5 mm (0.138 in.)
3.6 mm (0.142 in.)

- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
03-5
21 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U) Direct clutch & O/D clutch
Pack clearance0.61 - 0.83 mm (0.02401 - 0.03268 in.)
Return spring free length25.91 mm (1.0201 in.)
Flange thickness Mark
0
1
2
3
4
5
6
2.5 mm (0.098 in.)
2.6 mm (0.102 in.)
2.7 mm (0.106 in.)
2.8 mm (0.110 in.)
2.9 mm (0.114 in.)
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)
2nd brake
Pack clearance0.62 - 0.91 mm (0.0244 - 0.0358 in.)
Return spring free length16.61 mm (0.6539 in.)
Flange thickness Mark
1
2
3
4
5
6
73.0 mm (0.118 in.)
3.1 mm (0.122 in.)
3.2 mm (0.126 in.)
3.3 mm (0.130 in.)
3.4 mm (0.134 in.)
3.5 mm (0.138 in.)
3.6 mm (0.142 in.)
U/D clutch
Pack clearance1.51 - 1.71 mm (0.0594 - 0.0673 in.)
U/D clutch drum bushing inside diameter STD
Max.37.06 - 37.08 mm (1.4591 - 1.4598 in.)
37.13 mm (1.4618 in.)
Return spring free length17.14 mm (0.6752 in.)
Flange thickness Mark
1
2
3
4
5
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)
3.2 mm (0.126 in.)
3.3 mm (0.130 in.)
3.4 mm (0.134 in.)
U/D brake
Pack clearance1.81 - 2.20 mm (0.0713 - 0.0866 in.)
Return spring free length14.04 mm (0.5528 in.)
Flange thickness Mark
1
2
3
3.0 mm (0.118 in.)
3.2 mm (0.126 in.)
3.4 mm (0.134 in.)
1st & reverse brake
Pack clearance1.16 - 1.35 mm (0.0457 - 0.0531in.)
Return spring free length15.53 mm (0.6114 in.)
Flange thickness Mark
1
2
3
4
5
6
7
8
1.8 mm (0.071 in.)
1.9 mm (0.075 in.)
2.0 mm (0.079 in.)
2.1 mm (0.083 in.)
2.2 mm (0.087 in.)
2.3 mm (0.091 in.)
2.4 mm (0.094 in.)
2.5 mm (0.098 in.)

03-6
- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
22 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U) U/D planetary gear
Preload (at 60 rpm)0.50 - 1.42 NVm (5.1 - 14.5 kgfVcm, 0.06 - 0.17 in.Vlbf)
Front planetary gear
Turning torque (at 60 rpm) New Bearing
Used Bearing0.51 - 1.02 NVm (5.1 - 10.0 kgfVcm, 4.4 - 8.7 in.Vlbf)
0.26 - 0.51 NVm (2.7 - 5.2 kgfVcm, 2.3 - 4.5 in.Vlbf)
Input shaft
End play0.262 - 1.249 mm (0.0103 - 0.0492 in.)
Transaxle rear cover
Bearing press fit depth20.55 - 21.25 mm (0.8091 - 0.8366 in.)
Transmission valve body
Valve body installation bolt length A
B
C41 mm (1.614 in.)
57 mm (2.244 in.)
25 mm (0.984 in.)
Accumulator
SpringFree length/Outer diameterColor
B3Inner
Outer62.00 (2.4409) / 15.50 (0.610)
74.23 (2.9224) / 16.50 (0.649)Purple
Purple
C260.96 (2.3999) / 14.10 (0.555)Yellow
C372.20 (2.8425) / 19.0 (0.748)Colorless
Front differential(U151E)
Backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thrust washer thickness Mark
-
-
-
1.625 mm (0.0640 in.)
1.725 mm (0.0679 in.)
1.825 mm (0.0719 in.)
Praload (at 60 rpm) New bearing
Used bearing0.20 - 0.69 NVm (2.0 - 7.0 kgfVcm, 1.8 - 6.1 in.Vlbf)
0.10 - 0.35 NVm (1.0 - 3.6 kgfVcm, 0.9 - 3.1 in.Vlbf)
Flange thickness Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.)
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)
Front differential (U151F)
Side gear backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)