LEXUS ES300 2005 Owners Manual
Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 91 of 969
C83143
Union
O-ring
C83144
Elbow
O-ring
D03900D30672
Speed Sensor
D26716
D09176
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40-19
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
4. REMOVE OIL COOLER TUBE UNION (INLET OIL
COOLER UNION)
(a) Remove the union.
(b) Remove the O-ring from the union.
5. REMOVE OIL COOLER TUBE UNION (OUTLET OIL
COOLER UNION)
(a) Remove the elbow.
(b) Remove the O-ring from the elbow.
6. REMOVE SPEED SENSOR
(a) Remove the 2 bolts and the 2 speed sensors from the
transaxle assy.
7. REMOVE TRANSAXLE CASE NO.1 PLUG
(a) Remove the 4 transaxle case No. 1 plugs from the trans-
axle case.
(b) Remove the 4 O-rings from the 4 transaxle case No.1
plugs.
8. FIX AUTOMATIC TRANSAXLE ASSY
(a) Fix the transaxle assy.
Page 92 of 969
C91925
C86316
Magnet
AT0103
Magnet
C91927
Temperature
Sensor
D03547
Transmission Wire
40-20
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
9. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB-ASSY
(a) Remove the 18 bolts, oil pan and gasket.
(b) Remove the 2 magnets from the oil pan.
10. INSPECT TRANSMISSION OIL CLEANER MAGNET
(a) Remove the magnets and use them to collect any steel
chips. Examine the chips and particles in the pan and on
the magnet to determine what type of wear has occurred
in the transaxle:
Steel (magnetic).... bearing, gear and plate wear
Brass (non-magnetic).... bushing wear
11. DISCONNECT TRANSMISSION WIRE
(a) Remove the 7 connectors from the shift solenoid valves.
(b) Remove the bolt, lock plate and ATF temperature sensor.
12. REMOVE TRANSMISSION WIRE
(a) Remove the bolt and transmission wire from the transaxle
case.
Page 93 of 969
C91931
Valve Body Oil
Strainer Assy
C91932
O-ring
C91933
C83127
C83128
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
13. REMOVE VALVE BODY OIL STRAINER ASSY
(a) Remove the 3 bolts and oil strainer.
(b) Remove the O-ring from the oil strainer.
14. REMOVE TRANSMISSION VALVE BODY ASSY
(a) Support the valve body assy and remove the 17 bolts and
valve body assy.
15. REMOVE GOVERNOR APPLY GASKET NO.1
(a) Remove the governor apply gasket No.1 from the trans-
axle case.
16. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET
(a) Remove the transaxle case 2nd brake gasket from the
transaxle case.
Page 94 of 969
C83129
D03554
Check Ball
D03555
D03556
D03902
O-ring
C-3 Accumulator Piston 40-22
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
17. REMOVE BRAKE DRUM GASKET
(a) Remove the brake drum gasket from the transaxle case.
18. REMOVE CHECK BALL BODY
(a) Remove the check ball body and spring from the trans-
axle case.
19. REMOVE C-3 ACCUMULATOR PISTON
(a) Remove the spring from the C-3 accumulator piston.
(b) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil hole and remove the C-3 accumulator piston.
NOTICE:
Blowing off the air may cause the piston to jump-out.
When removing the piston, hold it by your hand using
a waste cloth.
Take care not to splash ATF when air-blowing.
(c) Remove the O-ring from the C-3 accumulator piston.
Page 95 of 969
D26401
D26402
O-ring
O-ring Reverse clutch Accumulator Piston
D03558
D03904
O-ring
B-3 Accumulator Piston
D03559
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
20. REMOVE REVERSE CLUTCH ACCUMULATOR
PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil hole and remove the reverse accumulator piston and
spring.
NOTICE:
Blowing off the air may cause the piston to jump-out.
When removing the piston, hold it by your hand using
a waste cloth.
Take care not to splash ATF when air-blowing.
(b) Remove the 2 O-rings from the reverse clutch accumula-
tor piston.
21. REMOVE B-3 ACCUMULATOR PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil hole and remove the B-3 accumulator piston and 2
springs.
NOTICE:
Blowing off the air may cause the piston to jump-out.
When removing the piston, hold it by your hand using
a waste cloth.
Take care not to splash ATF when air-blowing.
(b) Remove the O-ring from the B-3 accumulator piston.
22. REMOVE MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using a needle-nose pliers, remove the manual valve le-
ver shaft retainer spring.
Page 96 of 969
D03560
C56727
D03563
D03564
D03565
40-24
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
23. REMOVE MANUAL DETENT SPRING SUB-ASSY
(a) Remove the 2 bolts, the manual detent spring sub-assy
and cover.
24. REMOVE PARKING LOCK PAWL BRACKET
(a) Remove the 2 bolts and parking lock pawl bracket.
25. REMOVE MANUAL VALVE LEVER SUB-ASSY
(a) Using a chisel and hammer, cut off and remove the
spacer.
(b) Using a pin punch (f35 mm) and hammer, drive out the
pin.
HINT:
Slowly drive out the pin so that it will not fall into the transaxle
case.
(c) Remove the manual valve lever shaft and manual valve
lever.
Page 97 of 969
D26382
Parking Lock Rod Sub-assy
D03566
D08046Oil Pump Assy
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
26. REMOVE PARKING LOCK ROD SUB-ASSY
(a) Remove the parking lock rod from the manual valve lever.
27. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Using a screwdriver, remove the oil seal from the trans-
axle case.
28. FIX AUTOMATIC TRANSAXLE ASSY
(a) Fix the transaxle case with the oil pump side facing up.
29. INSPECT INPUT SHAFT ENDPLAY
(a) Using a dial indicator, measure the input shaft endplay.
Endplay: 0.262 - 1.244 mm (0.01 - 0.049 in.)
Page 98 of 969
D25608
U151E:
U151F:
D03569
Oil Pump Assy
D25505
Thrust Needle
Roller Bearing
Differential Gear Assy Forward Clutch Assy
D25506
Thrust Bearing Underdrive Race No.2
Differential
Gear Assy
Forward Clutch Assy
Underdrive Planetary Gear Assy
40-26
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
30. REMOVE TRANSAXLE HOUSING
(a) Remove the 16 bolts.
(b) Tap on the circumference of the transaxle housing with a
plastic hammer to remove the transaxle housing from the
transaxle case.
NOTICE:
Differential may be accidentally removed when the trans-
axle housing is removed.
31. REMOVE OIL PUMP ASSY
(a) Remove the 7 bolts and oil pump from the transaxle case.
32. REMOVE THRUST NEEDLE ROLLER BEARING
(a) Remove the thrust needle roller bearing from the under-
drive planetary gear assy.
33. REMOVE THRUST BEARING UNDERDRIVE RACE
NO.2
(a) Remove the thrust bearing underdrive race No. 2 from the
underdrive planetary gear assy.
Page 99 of 969
D26450
Differential
Gear Assy
D03573
D03574
Forward Clutch
Assy
D03906
Thrust Needle
Roller Bearing
D26787
Multiple Disc
Clutch Clutch
HubThrust Needle
Roller Bearing
Thrust Needle
Roller Bearing
Thrust
Bearing
Race
No.1
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
34. REMOVE DIFFERENTIAL GEAR ASSEMBLY
(a) Remove the differential gear assy from the transaxle
case.
35. REMOVE OVERDRIVE BRAKE GASKET
(a) Remove the 2 overdrive brake gaskets from the transaxle
case.
36. REMOVE FORWARD CLUTCH ASSY
(a) Remove the forward clutch assy from the transaxle case.
(b) Remove the thrust needle roller bearing from the forward
clutch.
37. REMOVE MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Remove the thrust needle roller bearing, multiple disc
clutch clutch hub, thrust needle roller bearing and thrust
bearing race No.1 from the transaxle case.
Page 100 of 969
D03829
Dial Indicator
Forward Clutch Hub
D03576
Pawl Shaft Clamp
D09652
D09689
40-28
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
52 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
38. INSPECT MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Using a dial indicator, measure the inside diameter of the
forward clutch hub bushing
Standard inside diameter:
23.025 - 23.046 mm (0.9065 - 0.9073 in.)
Maximum inside diameter: 23.09 mm (0.9091 in.)
NOTICE:
When the diameter is over the maximum, replace the
multiple disc clutch hub with new one.
Check the contact surface of the bush in the direct
clutch shaft. If any scratch or discolor is identified, re-
place the direct clutch sub-assy with new one.
If the inside diameter is greater than the maximum, replace the
forward clutch hub.
39. REMOVE UNDERDRIVE PLANETARY GEAR ASSY
(a) Remove the bolt and pawl shaft clamp.
(b) Remove the parking lock pawl shaft.
(c) Push the parking lock pawl.
HINT:
Failure to do so will cause interference when the underdrive
planetary gear is removed.