LEXUS ES300 2005 Repair Manual
Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 151 of 969
400H1-02
D26715
D26753
Snap Ring
D26754
- AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
40-79
103 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
FORWARD CLUTCH ASSY (U151E/U151F)
OVERHAUL
1. INSPECT PACK CLEARANCE OF FORWARD CLUTCH
(a) Install the forward clutch on the oil pump.
NOTICE:
Be careful not to damage the oil seal ring of oil pump.
(b) Using a dial indicator, measure the forward clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance: 1.00 - 1.25 mm (0.0394 - 0.4921 in.)
If the clearance is not within standard, inspect the discs, plates
and flange.
HINT:
As the opening is large, cover it with a shop rug to prevent the
compressed air from being released.
2. REMOVE FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 5 discs and 5 plates from the input
shaft assy.
Page 152 of 969
D09189
D26418
SST
Snap Ring
D26709
Clutch
Balancer
Input Shaft
D26708
Forward Clutch
Return SpringInput Shaft
40-80
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
3. INSPECT FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:
If the lining of the disc comes off or discolors, or even if
replace all discs.
Before assembling new discs, soak them in ATF for at
least 15 minutes.
4. REMOVE FORWARD CLUTCH RETURN SPRING
SUB-ASSY
(a) Place SST on the spring retainer and compress the return
spring with a press.
SST 09387-00020
(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,
preventing the spring sheet from deforming.
Do not expand the snap ring excessively.
(c) Remove the clutch balancer from the input shaft.
(d) Remove the forward clutch return spring from the input
shaft.
Page 153 of 969
D09211
Forward Clutch Re-
turn Spring
D03664
C56374
D25587
A
D26707Forward Clutch Piston
- AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
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105 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
5. INSPECT FORWARD CLUTCH RETURN SPRING
SUB-ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 26.74 mm (1.0528 in.)
6. REMOVE FORWARD CLUTCH PISTON SUB-ASSY
(a) Place the forward clutch drum onto the oil pump.
(b) Holding the forward clutch piston by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the oil pump
to remove the forward clutch piston.
HINT:
When the piston cannot be removed as it is slanted, either blow
the air again with the protruding side pushed, or remove the pis-
ton using the needle nose plier with vinyl tape on the tip.
7. REMOVE INPUT SHAFT OIL SEAL RING
(a) Remove the input shaft oil seal ring to the input shaft.
8. INSTALL INPUT SHAFT OIL SEAL RING
(a) Compress the new input shaft oil seal ring from both sides
to reduce dimension A.
Dimension A: 5 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the input
shaft.
NOTICE:
Do not expand the gap of the oil seal ring too much. Fix the
hooks certainly.
9. INSTALL FORWARD CLUTCH PISTON SUB-ASSY
(a) Coat the forward clutch piston with ATF, and install it to the
input shaft.
NOTICE:
Be careful not to damage the lip seal of the forward clutch
piston.
Page 154 of 969
D26708
Forward Clutch
Return SpringInput Shaft
D26709
Clutch BalancerInput Shaft
D26418
SST
Snap Ring
D26788
Stopper
Stopper
40-82
- AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
106 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
10. INSTALL FORWARD CLUTCH RETURN SPRING
SUB-ASSY
(a) Install the return spring to the input shaft.
NOTICE:
Installing the spring sub- assembly, check all of the
springs are fit in the piston correctly.
(b) Coat the clutch balancer with ATF.
(c) Install the clutch balancer to the input shaft.
NOTICE:
Be careful not to damage the lip seal of the forward
clutch balancer.
Install the clutch balancer carefully not to have a
pinching and any other defects at the sealing lip.
Apply enough ATF to the sealing lip prior to assem-
bling.
(d) Place SST on the clutch balancer, and compress the
clutch balancer with a press.
SST 09387-00020
(e) Install the snap ring with a snap ring expander.
(f) Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.
NOTICE:
Stop the press when the spring sheet is lowered to the
place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring
groove.
This prevents the spring sheet from being deformed.
Do not expand the snap ring excessively.
(g) Set the end gap of the snap ring in the piston shown in the
illustration.
NOTICE:
The end gap of the snap ring should not coincide with any
of the stoppers.
Page 155 of 969
D26415
Flange
Plate Disc
D26753
Snap Ring
D26715
D03672
- AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
40-83
107 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
11. INSTALL FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Coat the 5 discs with ATF.
(b) Install the 5 plates, 5 discs and flange input shaft.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
12. INSPECT PACK CLEARANCE OF FORWARD CLUTCH
(a) Using a dial indicator, measure the forward clutch pack
clearance while applying and releasing compressed air
(392 kgfVcm
2, 4.0 kPa, 57 psi).
Pack clearance: 1.00 - 1.25 mm (0.0394 - 0.4921 in.)
If the piston stroke is less than the minimum, parts may have
been assembled incorrectly. Check and reassemble again.
If the clearance is not standard, select another flange.
HINT:
There are 5 different flanges in thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
13.00 (0.1181)43.45 (0.1358)
23.15 (0.1240)53.60 (0.1417)
33.30 (0.1299)--
13. INSPECT FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Check if the disc lightly rotates when rotating the forward
clutch assy after inserting the multiple disc clutch into it.
NOTICE:
Do not place the forward clutch assy in a vise.
Page 156 of 969
400H2-02
D26426
D26427
40-84
- AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
108 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
DIRECT CLUTCH ASSY (U151E/U151F)
OVERHAUL
1. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the intermediate shaft and needle roller bearing on
the transaxle rear cover .
(b) Using a dial indicator, measure the reverse clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:0.60 - 0.82 mm (0.02362 - 0.03228 in.)
If the pack clearance is not within standard, inspect the discs,
plates and flange.
2. INSPECT PACK CLEARANCE OF DIRECT CLUTCH &
OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch & over-
drive clutch pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:0.61 - 0.83 mm (0.02401 - 0.03268 in.)
If the pack clearance is not within standard, inspect the discs,
plates and flange.
Page 157 of 969
D26419
Snap Ring
D26420
D26718
D26422
D26719
- AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
40-85
109 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
3. REMOVE DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Using a screwdriver, remove the snap ring from the inter-
mediate shaft.
(b) Remove the flange, 3 discs,, 3 plates and cushion plate
from the intermediate shaft.
4. INSPECT DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:
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.
5. REMOVE OVERDRIVE DIRECT CLUTCH DISC
(a) Using a screwdriver, remove the snap ring from the inter-
mediate shaft.
(b) Remove the flange, 4 discs and 4 plates from the inter-
mediate shaft.
6. INSPECT OVERDRIVE DIRECT CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:
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 158 of 969
D03677
SST
D26424
Clutch
Balancer
Direct Clutch
Drum
D26423
Direct Clutch
Drum
Overdrive
Clutch Return
Spring
D09211
Overdrive Clutch
Return Spring
40-86
- AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
11 0 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
7. REMOVE OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Place SST on the clutch balancer and compress the
spring with a press.
SST 09387-00020
(b) Using a snap ring expander, remove the snap ring from
the direct clutch drum.
NOTICE:
Stop the press when the spring sheet is lowered to the
place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring
groove.
This prevents the spring sheet from being deformed.
Do not expand the snap ring excessively.
(c) Remove the clutch balancer from the direct clutch drum.
(d) Remove the overdrive clutch return spring from the direct
clutch drum.
8. INSPECT OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 25.91 mm (1.0201 in.)
Page 159 of 969
D26463
D26425
D26464
O-ring
D26464
O-ring
D26462
Intermediate
ShaftDirect Clutch
Drum
- AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
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111 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
9. REMOVE OVERDRIVE DIRECT CLUTCH PISTON
(a) Install intermediate shaft on the transaxle rear cover.
(b) Holding the direct clutch piston with your hand, apply
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
transaxle rear cover to remove the direct clutch piston.
10. REMOVE OVERDRIVE DIRECT CLUTCH DRUM
SUB-ASSY
(a) Holding the direct clutch drum by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the transaxle
rear cover to remove the direct clutch drum.
11. REMOVE OVERDRIVE DIRECT CLUCH O-RING
(a) Using a screwdriver, remove the O-ring from the direct
clutch drum.
12. INSTALL OVERDRIVE DIRECT CLUCH O-RING
(a) Coat a O-ring with ATF, and install it to the direct clutch
drum.
NOTICE:
Assemble the O-ring carefully not to have a twist and a
pinching.
13. INSTALL OVERDRIVE DIRECT CLUTCH DRUM
SUB-ASSY
(a) Coat the direct clutch drum with ATF, and install it to the
intermediate shaft.
NOTICE:
Be careful not to damage the O-ring.
Be careful not to damage the lip seal of the direct
clutch drum.
Page 160 of 969
D26461
Overdrive Direct
Clutch Piston
D26423
Overdrive
Clutch Return
Spring
D26424
Clutch
BalancerDirect Clutch
Drum
D03677
SST
40-88
- AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
11 2 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
14. INSTALL OVERDRIVE DIRECT CLUTCH PISTON
(a) Apply the overdrive direct clutch piston with ATF, and
install it to the direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the direct clutch pis-
ton.
15. INSTALL OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Install the piston return spring to the direct clutch drum.
NOTICE:
Installing the spring sub- assembly, check all of the
springs are fit in the piston correctly.
(b) Coat the clutch balancer with ATF.
(c) Install the clutch balancer to the direct clutch drum.
NOTICE:
Be careful not to damage the lip seal of the direct
clutch balancer.
Install the clutch balancer carefully not to have a
pinching and any other defects at the sealing lip.
Apply enough ATF to the sealing lip prior to assem-
bling.
(d) Place SST on the clutch balancer and compress the pis-
ton return spring with a press.
SST 09387-00020
(e) Using a snap ring expander, install the snap ring to the di-
rect clutch drum.
(f) Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.
NOTICE:
Stop the press when the spring sheet is lowered to the
place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring
grove.
This prevents the spring sheet from being deformed.
Do not expand the snap ring excessively.