LEXUS ES300 2005 Repair Manual
Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 141 of 969
D03554
Check Ball
C83129
C83128
C83127
D03636AT F
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143. INSTALL CHECK BALL BODY
(a) Coat the check ball body with ATF.
(b) Install the check ball body and spring.
NOTICE:
Regarding the installation of the spring for the check ball
body, be sure to place the spring in the hole in the ball body.
Be careful about the parts orientation.
144. INSTALL BRAKE DRUM GASKET
(a) Coat a new brake drum gasket with ATF, install it to the
transaxle case.
NOTICE:
Be sure not to damage the lip portion of the transaxle case
brake gasket when inserting the gasket to the case. More-
over, apply enough ATF to the gasket prior to assembling.
Also, be careful about the parts orientation.
145. INSTALL TRANSAXLE CASE 2ND BRAKE GASKET
(a) Coat a new transaxle case 2nd brake gasket with ATF,
install it to the transaxle case.
NOTICE:
Be sure not to damage the lip portion of the transaxle case
brake gasket when inserting the gasket to the case. More-
over, apply enough ATF to the gasket prior to assembling.
Also, be careful about the parts orientation.
146. INSTALL GOVERNOR APPLY GASKET NO.1
(a) Coat a new governor apply gasket No. 1 with ATF, install
it to the transaxle case.
NOTICE:
Be sure not to damage the lip portion of the transaxle case
brake gasket when inserting the gasket to the case. More-
over, apply enough ATF to the gasket prior to assembling.
Also, be careful about the parts orientation.
147. INSTALL TRANSMISSION WIRE
(a) Coat a new O-ring with ATF, install it to the transmission
wire.
NOTICE:
Be careful about the O-ring not to have a twist, a protrusion
and a pinching during installing the wire transmission to
the transaxle case. Moreover, apply enough ATF to the O-
ring prior to assembling.
Page 142 of 969
D03547
Transmission Wire
C91927
GFE
A
B
C
D
C91933
A
CB
B
A
C
C91932
O-ring
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(b) Install the transmission wire retaining bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
148. CONNECT TRANSMISSION WIRE
(a) Coat a O-ring of the ATF temperature sensor with ATF.
(b) Install the ATF temperature sensor, with the lock plate and
bolt.
Torque: 6.6 NVm (67 kgfVcm, 58 in.Vlbf)
(c) Connect the 7 solenoid connectors.
NOTICE:
Connect the connector to A, B, C, D, E, F, G, from
shorter one.
Apply ATF to the bolt.
149. INSTALL TRANSMISSION VALVE BODY ASSY
(a) Make sure that the manual valve lever position, install the
valve body with 17 bolts to the transaxle case.
Torque: 11 NVm (110 kgfVcm, 8 ftVlbf)
Bolt length:
Bolt A: 41 mm (1.614 in.)
Bolt B: 57 mm (2.244 in.)
Bolt C: 25 mm (0.984 in.)
NOTICE:
Push the valve body against the accumulator piston
spring and the check ball body to install it.
When installing the valve body to the transaxle case,
do not hold the solenoids.
Tighten temporarily those bolts marked by in the il-
lustration first because they are positioning bolts.
150. INSTALL VALVE BODY OIL STRAINER ASSY
(a) Coat a new O-ring with ATF, install it to the oil strainer.
NOTICE:
Assemble the O-ring carefully not to have a twist and a
pinching. Moreover, apply enough ATF to the O-ring prior
to assembling.
Page 143 of 969
C91931
Valve Body Oil
Strainer Assy.
C86316
Magnet
C91925
D26716
D03900D30672
Speed Sensor
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(b) Install the oil strainer and 3 bolts to the valve body.
Torque: 11 NVm (110 kgfVcm, 8 ftVlbf)
NOTICE:
Apply ATF to the bolts.
151. I N S TA L L A U TO M AT I C T R A N S A X L E O I L PA N
SUB-ASSY
(a) Install the 2 magnets in the oil pan.
(b) Apply seal packing or equivalent to new 18 bolts.
Seal packing:
THREE BOND 2430 or equivalent
(c) Install the new oil pan gasket with the 18 bolts to the trans-
axle case.
Torque: 7.8 NVm (80 kgfVcm, 69 in.Vlbf)
NOTICE:
Because the bolts should be seal bolts, apply seal
packing to new bolts and tighten them within 10 min-
utes after application.
Remove any oil or grease from the contacting surface
of the transaxle case and the oil pan with the gasket
completely before the oil pan to the case.
152. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Coat the 4 new O-rings with ATF, install them to the 4
transaxle case No. 1 plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle
case.
Torque: 7.4 NVm (75 kgfVcm, 65 in.Vlbf)
153. INSTALL SPEED SENSOR
(a) Install them to the 2 sensors.
(b) Install the 2 sensors to the transaxle case with the 2 bolts.
Torque: 11.0 NVm (115 kgfVcm, 8 ftVlbf)
Page 144 of 969
C83144
Elbow
O-ring
C83143
Union
O-ring
D09639
D09640Control Shaft Lever
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154. INSTALL OIL COOLER TUBE UNION (OUTLET OIL
COOLER UNION)
(a) Coat a new O-ring with ATF, install it to the elbow.
(b) Install the elbow to the transaxle case.
Torque: 27 NVm (276 kgfVcm, 20 ftVlbf)
155. INS TALL OIL CO O LE R TUBE UNIO N (INLE T OIL
COOLER UNION)
(a) Coat a new O-ring with ATF, install it to the union.
(b) Install the union to the transaxle case.
Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)
156. INSTALL BREATHER PLUG HOSE
(a) Install the breather plug hose into the transaxle case certainly.
157. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY
(a) Install the park/neutral position switch onto the manual
valve lever shaft and temporarily install the 2 adjusting
bolts.
(b) Install a new nut stopper and nut.
Torque: 6.9 NVm (70 kgfVcm, 61 in.Vlbf)
(c) Temporarily install control shaft lever.
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D09641
D09642
D09643
D09644
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(d) Turn the lever counterclockwise until it stops, and then
turn it clockwise 2 notches.
(e) Remove the control shaft lever.
(f) Align the groove with neutral basic line.
(g) Tighten the 2 bolts.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(h) Using a screwdriver, stake the nut with the nut stopper.
(i) Install the control shaft lever, washer and nut.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
158. INSTALL SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSY
(a) Coat a new O-ring with ATF and install it to the speedometer driven hole cover.
(b) Install the bolt and speedometer driven hole cover sub-assy to the transaxle assy.
Torque: 6.9 NVm (70 kgfVcm, 61 ftVlbf)
Page 146 of 969
4006F-03
D09205
D03650
Clutch
Drum Oil
Seal Ring
D03651
D09207
Oil Pump Drive GearOil Pump
Driven Gear
40-74
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OIL PUMP ASSY (U151E/U151F)
OVERHAUL
1. INSPECT OIL PUMP ASSY
(a) Turn the drive gear with 2 screwdrivers and make sure it
rotates smoothly.
NOTICE:
Be careful not to damage the oil seal lip.
2. REMOVE CLUTCH DRUM OIL SEAL RING
(a) Remove the 2 clutch drum oil seal rings.
3. REMOVE STATOR SHAFT ASSY
(a) Using a torx socket (T30), remove the 11 bolts and stator
shaft.
(b) Keep the gears in assembling order.
4. INSPECT CLEARANCE OF OIL PUMP ASSEMBLY
(a) Push the driven gear to one side of the body.
(b) Using a feeler gauge, measure the clearance.
Standard body clearance:
0.10 - 0.17 mm (0.0039 - 0.0067 in.)
Side clearance: 0.02 - 0.05 mm (0.001 - 0.02 in.)
Maximum body clearance: 0.17 mm (0.0067 in.)
If the body clearance is greater than the maximum, replace the
oil pump body sub-assy.
Page 147 of 969
D09208
D09209
D09206
D09206
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(c) Using a feeler gauge measure the tip clearance between
the driven gear teeth and drive gear teeth.
Standard tip clearance:
0.07 - 0.15 mm (0.0028 - 0.0059 in.)
Maximum tip clearance: 0.15 mm (0.0059 in.)
If the tip clearance is greater than the maximum, replace the oil
pump body sub-assy.
(d) Using a straight edge and feeler gauge, measure the side
clearance of both gears.
Standard side clearance:
0.02 - 0.05 mm (0.0008 - 0.0020 in.)
Maximum side clearance: 0.05 mm (0.0020 in.)
Drive gear thickness: mm (in.)
MarkThickness
A11.690 - 11.699 (0.4602 - 0.4606)
B11.700 - 11.709 (0.4606 - 0.4610)
C11.710 - 11.720 (0.4610 - 0.4614)
D11.721 - 11.730 (0.4615 - 0.4618)
E11.731 - 11.740 (0.4619 - 0.4622)
Driven gear thickness: mm (in.)
MarkThickness
A11.690 - 11.699 (0.4602 - 0.4606)
B11.700 - 11.709 (0.4606 - 0.4610)
C11.710 - 11.720 (0.4610 - 0.4614)
D11.721 - 11.730 (0.4615 - 0.4618)
E11.731 - 11.740 (0.4619 - 0.4622)
5. REMOVE FRONT OIL PUMP DRIVE GEAR
(a) Remove the front oil pump drive gear.
6. REMOVE FRONT OIL PUMP DRIVEN GEAR
(a) Remove the front oil pump driven gear.
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D25586
O-ring
D03647
SST
D03648
D03653
D03654
SST
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7. REMOVE FRONT OIL PUMP BODY O-RING
(a) Using a screwdriver, remove the O-ring.
HINT:
Tape the screwdriver before use.
8. REMOVE FRONT OIL PUMP OIL SEAL
(a) Mount oil pump in a soft jaw vise.
(b) Using SST, remove the oil seal from the oil pump body.
SST 09308-00010
9. INSPECT FR OIL PUMP & GEAR BODY SUB-ASSY
(a) Using a dial indicator, measure the inside diameter of the
oil pump body bushing.
Standard inside diameter:
38.113 - 38.138 mm (1.50051 - 1.50149 in.)
Maximum inside diameter: 38.188 mm (1.50346 in.)
If the inside diameter is greater than the maximum, replace the
oil pump body sub-assy.
10. INSPECT STATOR SHAFT ASSY
(a) Using a dial indicator, measure the inside diameter of the
stator shaft.
Standard inside diameter:
21.500 - 21.526 mm (0.84646 - 0.84748 in.)
Maximum inside diameter: 21.57 mm (0.8492 in.)
If the indicator diameter is greater than maximum, replace the
stator shaft.
11. INSTALL FRONT OIL PUMP OIL SEAL
(a) Using SST and a hammer, install a new oil seal to the oil
pump body.
SST 09350-32014 (09351-32140)
HINT:
The seal end should be flat with the outer edge of the oil pump.
(b) Coat the lip of the oil seal with MP grease.
Page 149 of 969
C55817
O-ring
D09206
MarkOil Pump
Driven
Gear
D09206
Mark
Oil
Pump
Drive
Gear
D03651
D26627
Clutch Drum
Oil Seal Ring
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12. INSTALL FRONT OIL PUMP BODY O-RING
(a) Coat the new O-ring with ATF, install it to the oil pump
body.
NOTICE:
Assemble the O-ring carefully not to have a twist and a
pinching. Moreover, apply enough ATF to the O-ring prior
to assembling.
13. INSTALL FRONT OIL PUMP DRIVEN GEAR
(a) Coat the front oil pump driven gear with ATF, install it to
the oil pump body with the marked side up.
14. INSTALL FRONT OIL PUMP DRIVE GEAR
(a) Coat the front oil pump drive gear with ATF, install it to the
oil pump body with the marked side up.
15. INSTALL STATOR SHAFT ASSY
(a) Set the stator shaft aligned with each bolt hole.
(b) Using a torx socket (T30), install the 11 bolts.
Torque: 9.8 NVm (100 kgfVcm, 87 in.Vlbf)
16. INSTALL CLUTCH DRUM OIL SEAL RING
(a) Coat the 2 new clutch drum oil seal rings with ATF.
(b) Install the 2 new clutch drum oil seal rings.
NOTICE:
Do not expand the ring ends excessively.
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D09205
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17. INSPECT OIL PUMP ASSY
(a) Turn the drive gear with 2 screwdrivers and make sure it
rotates smoothly.
NOTICE:
Be careful not to damage the oil seal lip.