LEXUS ES300 2005 Repair Manual
Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 101 of 969
D03579
Underdrive
Planetary
Gear Assy
D26386
D03580
Thrust Bearing
Bearing Race
D03581Snap Ring
D03627
Underdrive
1-W ay
Clutch
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(d) Remove the underdrive planetary gear assy from the
transaxle case.
NOTICE:
Be careful so that the underdrive planetary gear assy will
not fall out.
40. REMOVE PARKING LOCK PAWL
(a) Remove the spring, pawl pin and parking lock pawl.
41. REMOVE UNDERDRIVE CLUTCH ASSY
(a) Remove the underdrive clutch assy, thrust bearing and
bearing race from the transaxle case.
42. REMOVE UNDERDRIVE 1 WAY CLUTCH ASSY
(a) Using a screwdriver, remove the snap ring from the trans-
axle case.
(b) Remove the underdrive 1-way clutch from the transaxle
case.
Page 102 of 969
D03907
Outer Race
Retainer
D26466
Snap
Ring
D26385
Flange
D09196
D26387
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(c) Remove the outer race retainer from the 1-way clutch.
43. REMOVE UNDERDRIVE CLUTCH DISC NO.2
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 4 discs and 4 plates from the trans-
axle case.
44. INSPECT UNDERDRIVE CLUTCH DISC NO.2
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
If the lining of the disc comes off or discolors, or even
if a part of the groove is defaced, replace all discs.
Before assembling new discs, soak them in ATF for
at least 15 minutes.
45. REMOVE TRANSAXLE REAR COVER SUB-ASSY
(a) Remove the 11 bolts.
(b) Tap in the circumference of the rear cover with a plastic
hammer to remove the transaxle rear cover from the
transaxle case.
Page 103 of 969
D26388
Rear Clutch
Oil Seal
Ring Outer
D26389
D26472
SST
D26390
D26391
Brake Apply Tube
Clutch Apply Tube
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46. REMOVE TRANSAXLE CASE NO.1 PLUG
(a) Remove the 4 transaxle case No.1 plugs from the trans-
axle rear cover.
(b) Remove the 4 O-rings from the 4 transaxle case No.1
plugs.
47. REMOVE REAR CLUTCH OIL SEAL RING OUTER
(a) Remove the 3 rear clutch oil seal rings from the transaxle
rear cover.
48. REMOVE NEEDLE ROLLER BEARING
(a) Using SST, remove the needle-roller bearing from the
transaxle rear cover.
SST 09387- 00041 (09387- 01021, 09387- 01030,
09387-01040)
49. REMOVE GOVERNOR APPLY GASKET NO.1
(a) Using a screwdriver, remove the 3 apply gaskets.
50. REMOVE BRAKE APPLY TUBE
(a) Remove the bolt, clamp and brake apply tube.
(b) Remove the clutch apply tube.
(c) Remove the brake apply tube from the clamp.
Page 104 of 969
D26403
Thrust Bearing
Direct Clutch Assy
D26392
Thrust Bearing
Thrust Bearing Race
Overdrive Direct Clutch Hub
D03829
Overdrive
Direct Clutch
Drum Sub-assy
Dial Indicator
D26714Rear Planetary Sun Gear Assy
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
51. REMOVE DIRECT CLUTCH ASSY
(a) Remove the thrust bearing and the direct clutch assy from
the transaxle case.
52. REMOVE OVERDREVE DIRECT CLUTCH HUB
SUB-ASSY
(a) Remove the thrust bearing race, thrust bearing and over-
drive direct clutch hub from the planetary gear assy.
53. INSPECT OVERDRIVE DIRECT CLUTCH DRUM
SUB-ASSY
(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.
54. REMOVE REAR PLANETARY SUN GEAR ASSY
(a) Remove the rear planetary sun gear assy from the trans-
axle case.
Page 105 of 969
D26404
Thrust Needle Roller Bearing
Thrust Bearing Race
D26393
Planetary
Carrier
Thrust
Washer
No.2
Rear
Planetary
Sun Gear
D26598
Thrust Needle
Roller Bearing
1-W ay Clutch Assy
D03909
1-W ay
Clutch
Inner Race
D03589
1-W ay Clutch
Sleeve Outer
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(b) Remove the thrust needle roller bearing and thrust bear-
ing race from the rear planetary sun gear assy.
(c) Remove the planetary carrier thrust washer No.2 from the
rear planetary sun gear assy.
55. REMOVE 1 WAY CLUTCH ASSY
(a) Remove the 1-way clutch assy and the thrust needle roll-
er bearing from the transaxle case.
(b) Remove the 1-way clutch inner race from the 1-way
clutch assy.
56. REMOVE 1WAY CLUTCH SLEEVE OUTER
(a) Remove the 1-way clutch sleeve outer from the transaxle
case.
Page 106 of 969
D26394
Planetary Carrier
Thrust Washer No.1
D26395
Snap Ring
D26717
D08058
Snap Ring
D26396
Second Brake
Piston Assy
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
57. REMOVE PLANETARY CARRIER THRUST WASHER
NO.1
(a) Remove the planetary carrier thrust washer No.1 from the
planetary gear assy.
58. REMOVE 2ND BRAKE CLUTCH DISC
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 4 discs and 4 plates from the trans-
axle case.
59. INSPECT 2ND BRAKE CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
If the lining of the disc comes off or discolors, or even
if a part of the groove is defaced, replace all discs.
Before assembling new discs, soak them in ATF for
at least 15 minutes.
60. REMOVE SECOND BRAKE PISTON ASSY
(a) Using a screwdriver, remove the snap ring.
(b) Remove the second brake piston assy from the transaxle
case.
Page 107 of 969
D03616
Snap Ring
D26591
Rear Planetary
Gear Assy
D03873
Thrust Bearing
Race No.2
Thrust Needle Roller BearingInput
Sun
Gear
D26397
D09189
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61. REMOVE REAR PLANETARY GEAR ASSY
(a) Using a screwdriver, remove the snap ring.
(b) Remove the rear planetary gear assy from the transaxle
case.
62. REMOVE INPUT SUN GEAR
(a) Remove the 2 thrust needle roller bearings, thrust bearing
race No.2 and input sun gear from the transaxle case.
63. REMOVE 1ST & REVERSE BRAKE CLUTCH DISC
(a) Remove the flange, 6 discs and 6 plates from the trans-
axle case.
64. INSPECT 1ST & REVERSE BRAKE CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
If the lining of the disc comes off or discolors, or even
if a part of the groove is defaced, replace all discs.
Before assembling new discs, soak them in ATF for
at least 15 minutes.
Page 108 of 969
D03595
Lock Washer
D03596
SST
D26398
SST
D26763
Front Planetary
Gear Assy
Brake Hub
D03615
Front Planetary Ring Gear
Brake Hub
Snap Ring
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65. REMOVE FRONT PLANETARY GEAR ASSY
(a) Using a chisel and hammer, unstake the lock washer.
NOTICE:
Push down all claws of the washer. Otherwise SST cannot
be fully pressed against the nut, and cannot loosen the nut.
(b) Using SST, remove the nut.
SST 09387-00030, 09387-00080
(c) Using SST and a press, remove the front planetary gear
assy from the counter drive gear.
SST 09950- 60010 (09951- 00450), 09950- 70010
(09951-07100)
(d) Remove the front planetary gear assy from the brake hub.
66. REMOVE FRONT PLANETARY RING GEAR
(a) Using a screwdriver, remove the snap ring and front plan-
etary ring gear from the brake hub.
Page 109 of 969
D03600
SST
C89128
D26405
1st & Reverse Brake Piston
D26713
O-ringO-ring
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
67. REMOVE 1ST & REVERSE BRAKE RETURN SPRING
SUB-ASSY
(a) Place SST on the return spring, and compress the return
spring with a press.
SST 09387-00070
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
Stop the press when the spring sheet is lowered 1 -
2 mm (0.039 - 0.078 in.) from the snap ring groove, to
prevent the spring sheet from deforming.
Do not expand the snap ring excessively.
68. INSPECT 1ST & REVERSE BRAKE RETURN SPRING
SUB-ASSY
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 17.61 mm (0.6933 in.)
69. REMOVE 1ST & REVERSE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
transaxle case to remove 1st & reverse brake 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.
(b) Remove the 2 O-rings from the 1st & reverse brake pis-
ton.
Page 110 of 969
C89120
SST
SST
D03602
D03603
SST
HoldTurn
D26467
Snap Ring
C89121
SST
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
70. REMOVE COUNTER DRIVE GEAR
(a) Using SST and a press, remove the counter drive gear
from the transaxle case.
SST 09950- 60010 (09951- 00590), 09950- 70010
(09951-07100)
(b) As shown in the illustration, tighten 2 bolts evenly and
make clearance of approx. 20.0 mm (0.797 in.) between
the counter drive gear and the inner race.
(c) Using SST, remove the tapered roller bearing.
SST 09950- 60010 (09951- 00590), 09950- 70010
(09951-07100), 09950-00020, 09950-00030,
09950-4001 1 (09957-04010)
71. REMOVE COUNTER DRIVE GEAR BEARING
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a press, remove the bearing outer race.
SST 09950- 60020 (09951- 00910), 09950- 70010
(09951-07100)