differential LEXUS ES300 2005 Repair Manual

Illustration:
what to do and whereTask heading: what to do
Detailed text:
how to do task
Set part No.Component part No.
87. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing front inner race to the differential
case.
SST 09316-60011 (09316-00011)
Illustration:
what to do and whereTask heading: what to do
Detailed text:
how to do task
Set part No.Component part No.
87. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing front inner race to the differential
case.
SST 09316-60011 (09316-00011)
D26831
01-2- INTRODUCTIONHOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR
MANUAL
2 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Tightening torque, oil applying position, and non-reusable parts are described as important points in
the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustration. In that case, all the
information such as torque, oil, etc are described in the illustration.
(e) Installing procedure of operation item is performed in the reverse order of the removing, and only the
important points are described.
(f) Only items with points are described in the procedure, and the operational portion and content are
placed using an illustration. In the explanations, details of the operational method, standard value and
notice are placed.
(g) There may be a case where the illustrations of similar models are used. In that case the details may
be different from the actual vehicle.
(h) The procedures are presented in a step-by-step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce-
dure to look up your specifications. The specifications are also found in the Service Specifications sec-
tion for a quick reference.
6. TERMS DEFINITION
CAUTIONIndicate the possibility of injury to you or other people.
NOTICEIndicate the possibility of damage to the components being repaired.
HINTProvide additional information to help you perform the repair efficiently.

01-8- INTRODUCTIONTERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
8 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U) ISC
Idle Speed Control-
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure-
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Light
MSTManifold Surface temperature-
MVZManifold Vacuum Zone-
NVRAMNon-V olatile Random Access Memory-
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn-Board DiagnosticOn-Board Diagnostic (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Converter (OC), CC0
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module-
PNPPark/Neutral Position-
PROMProgrammable Read Only Memory-
PSPPower Steering Pressure-
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module-
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger Bypass-
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter-
SRIService Reminder Indicator-
SRTSystem Readiness Test-
STScan Tool-
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter
TCMTransmission Control ModuleTransmission ECU (Electronic Control Unit)
TPThrottle PositionThrottle Position
TRTransmission Range-
TVVThermal Vacuum ValveBimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
TWCThree-W ay Catalytic ConverterThree-W ay Catalytic (TWC)
CC
RO
TWC+OCThree-W ay + Oxidation Catalytic ConverterCCR + CCO
VA FVolume Air FlowAir Flow Meter
VRVoltage RegulatorVoltage Regulator
VSSVehicle Speed SensorVehicle Speed Sensor (Read Switch Type)
WOTWide Open ThrottleFull Throttle

022FX-01
- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02-1
10 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
AUTOMATIC TRANSMISSION / TRANS
PREPARATION
SST
09214-7601 1Crankshaft Pulley ReplacerFRONT DIFFERENTIAL
ASSY(U151F)
09215-00013Crankshaft Bearing Remover &
Replacer Set BFRONT DIFFERENTIAL
ASSY(U151E)
(09215-00471)Camshaft Bearing Remover &
ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
09223-15020Oil Seal & Bearing ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)
09223-15030Oil Seal & Bearing ReplacerAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09308-00010Oil Seal PullerFRONT DIFFERENTIAL
ASSY(U151E)
OIL PUMP ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09316-12010Transfer Bearing ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
09316-2001 1Transfer Bearing ReplacerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09350-32014TOYOTA Automatic Transmission
Tool SetOIL PUMP ASSY(U151E/U151F)
UNDERDRIVE CLUTCH
ASSY(U151E/U151F)
(09351-32070)No.2 Piston Spring CompressorUNDERDRIVE CLUTCH
ASSY(U151E/U151F)
(09351-32140)Oil Seal ReplacerOIL PUMP ASSY(U151E/U151F)
09387-00020Direct Clutch WrenchAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FORWARD CLUTCH
ASSY(U151E/U151F)
DIRECT CLUTCH
ASSY(U151E/U151F)

02-2
- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
11 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
09387-00030Counter Drive Gear Holding ToolAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09387-00041Bearing Puller AssemblyAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01010)Claw No.1AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01021)Claw No.2AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01030)PinAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01040)Bearing Puller BodyAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09387-00050Under Drive Gear PullerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09387-00060Second Brake WrenchSECOND BRAKE PISTON
ASSY(U151E/U151F)
09387-00070First & Reverse Brake WrenchAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09387-00080Counter Drive Gear Nut WrenchAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09502-12010Differential Bearing ReplacerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09506-35010Differential Drive Pinion Rear
Bearing ReplacerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09514-3501 1Rear Wheel Bearing PullerAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)

- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02-3
12 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
09527-1701 1Rear Axle Shaft Bearing RemoverAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09550-60010Differential Side Bearing
ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
(09951-00490)Replacer 49FRONT DIFFERENTIAL
ASSY(U151E)
09564-3201 1Differential Preload AdaptorFRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)
09608-10010Steering Knuckle Oil Seal
ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)
09649-17010Steering Knuckle ToolAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09710-30050Suspension Arm Bushing ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
09726-40010Lower Control Shaft Bearing
ReplacerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09930-00010Drive Shaft Nut ChiselUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
(09931-00010)HandleUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
(09931-00020)Nut ChiselUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09950-00020Bearing RemoverFRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

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

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.)

0305L-1 1
03-8
- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
24 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
TORQUE SPECIFICATION
Part TightenedNVmkgfVcmftVlbf
Differential gear lube apply tube x Transaxle housing9.810087 in.Vlbf
Front planetary gear lock nut210-3502141-3569155-258
Brake apply tube clamp x Transaxle case5.45548 in.Vlbf
Transaxle case No. 1 plug x Transaxle rear cover7.47565 in.Vlbf
Transaxle rear cover x Transaxle case Bolt A
Other bolt19
25190
25014
18
Pawl shaft clamp x Transaxle case9.810087 in.Vlbf
Oil pump assy x Transaxle case2222616
Transaxle housing x Transaxle case Bolt A
Bolt B
Bolt C
Bolt D25
33
29
22255
337
295
22618
24
21
16
Automatic transmission case plug x Transaxle housing7.47565 in.Vlbf
Automatic transmission case plug x Transaxle case7.47565 in.Vlbf
Parking lock pawl bracket x Transaxle case2020515
Manual detent spring x Transaxle case Bolt A
Bolt B20
12205
12015
9
Transmission wire x Transaxle housing5.45548 in.Vlbf
Transmission valve body x Transaxle case1111 08
ATF temperature sensor clamp x Transmission valve body6.66758 inVlbf
Valve body oil strainer assy x Transmission valve body1111 08
Automatic transaxle oil pan sub-assy x Transaxle case7.88069 in.Vlbf
Drain plug x Automatic transaxle oil pan sub-assy4950036
Speed sensor x Transaxle case1111 58
Oil cooler tube union x Transaxle case Union
Elbow27
27276
27620
20
Park/neutral start switch x nut6.97061 in.Vlbf
Park/neutral start switch x Bolt5.45548 in.Vlbf
Park/neutral start switch x Control shaft lever131309
Speedometer driven hole cover sub-assy x Transaxle case6.97061
Oil pump body x Stator shaft assy9.810087 in.Vlbf
Line pressure control solenoid assy x Transmission valve body assy6.66758 in.Vlbf
Shift solenoid valve SL1x Transmission valve body assy6.66758 in.Vlbf
Shift solenoid valve SL2x Transmission valve body assy10.811 08
Shift solenoid valve SL3x Transmission valve body assy6.66758 in.Vlbf
Shift solenoid valve S4x Transmission valve body assy10.811 08
Shift solenoid valve DSL x Transmission valve body assy10.811 08
Front differential case x Front differential ring gear95.197070