atf LEXUS ES300 2005 User Guide
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 117 of 969
D03809
Vinyl Tape
SST
D03810
SST
D03794
O-ringO-ring
D26764
Underdrive
Brake Piston
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
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88. INSTALL NEEDLE ROLLER BEARING
(a) Wind a vinyl tape around SST at the place 4.0 mm (0.157
in.) above from the bottom end until the thickness of the
wound tape is about 5.0 mm (0.197 in.).
NOTICE:
Clean SST to remove deposited oil, before winding a vinyl
tape.
(b) Coat the needle roller bearing with ATF.
(c) Using SST and a press, install the needle-roller bearing
to the transaxle case.
SST 09950- 60010 (09951- 00320), 09950- 70010
(09951-07100)
NOTICE:
When the wound vinyl tape contacts the transaxle case,
stop press-fitting.
89. INSTALL UNDERDRIVE BRAKE PISTON
(a) Coat the 2 new O-rings with ATF, install them to the un-
derdrive brake piston.
NOTICE:
Assemble the O-ring carefully not to have a twist and
a pinching.
Apply enough ATF to the O-ring prior to assembling.
(b) Coat the underdrive brake piston with ATF.
(c) Install the underdrive brake piston to the transaxle case.
NOTICE:
Be careful not to damage the O-ring.
Page 118 of 969
D26407
SST
Snap Ring
C89126
SST
D26467
Snap Ring
D26410
SST
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90. INSTALL UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Place SST on the return spring and compress the return
spring with a press.
SST 09387-00020
(b) Using a snap ring expander, install the snap ring to the
transaxle case.
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.
Installing the spring sub-assembly, check all of the
springs are fit in the piston correctly.
The snap ring should be fixed surely in the groove of
the transaxle case.
91. INSTALL BREATHER PLUG NO.2 (ATM)
92. INSTALL COUNTER DRIVE GEAR BEARING
(a) Coat the counterdrive gear bearing with ATF.
(b) Using SST and a press, install the bearing outer race.
SST 09950- 60020 (09951- 01030), 09950- 70010
(09951-07150), 09649-17010
NOTICE:
Do not apply excessive pressure to it.
Press-fit the bearing outer race until it contacts the
transaxle case.
(c) Using a snap ring expander, install the snap ring.
NOTICE:
Face the white mark side of the snap ring up.
93. INSTALL COUNTER DRIVE GEAR
(a) Coat the couterdrive gear with ATF.
(b) Using SST and a press, install the tapered roller bearing
to the counter drive gear.
SST 09950-70010 (09951-07150), 09649-17010
NOTICE:
Do not apply excessive pressure to it.
Page 119 of 969
C89122
SST
SST
Counter Drive
GearBearing
D26713
O-ringO-ring
D26593
1st & Reverse
Brake Piston
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(c) Using SST and a press, install the counter drive gear and
bearing to the transaxle case.
SST 09223- 15030, 09527- 17011, 09950- 60020
(09951-00750), 09950-70010 (09951-07150)
NOTICE:
Do not apply excessive pressure to it.
94. INSTALL 1ST & REVERSE BRAKE PISTON
(a) Coat the 2 new O-rings with ATF.
(b) Install the 2 O-rings to the 1st & reverse brake piston.
NOTICE:
Assemble the O-ring carefully not to have a twist and
a pinching.
Apply enough ATF to the O-ring prior to assembling.
(c) Coat a 1st & reverse brake piston with ATF, install it to the
transaxle case.
NOTICE:
Be careful not to damage the O-ring.
Page 122 of 969
D03918
SST
D08074
Lock Washer
C89123
C
BA
Input Sun Gear
D
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(e) Using SST and a torque wrench, measure the turning
torque of the bearing while rotating SST at 60 rpm. When
the measured value is not within the specified value,
gradually tighten the nut until it reaches the specified val-
ue.
SST 09387-00080
Turning torque at 60 rpm:
New Bearing
0.51 - 1.02 NVm (5.1 - 10.0 kgfVcm, 4.4 - 8.7 in.Vlbf)
Used Bearing
0.26 - 0.51 NVm (2.7 - 5.2 kgfVcm, 2.3 - 4.5 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
(f) Tighten the nut gradually until the specified rotation
torque of tapered roller bearing is measured.
Torque: 350 NVm (3,569 kgfVcm, 258 ftVlbf) (a limit)
(g) Using a chisel and hammer, stake the front lock washer.
98. INSTALL INPUT SUN GEAR
(a) Coat the 2 thrust bearings with ATF.
(b) Install the 2 thrust bearings, the bearing race and the front
planetary sun gear to the front planetary gear assy.
NOTICE:
Install the bearing race on the side of the front plane-
tary carrier. Be careful about the orientation of the
race.
Installing thrust bearing and front sun gears, be care-
ful about the orientation of the parts.
Install the bearing race on the side of the front sun
gear. Be careful about the orientation of the race.
Install the thrust bearing and the race after holding
the parts on the rear planetary carrier by applying
grease. Be sure the assembling order.
Page 123 of 969
D26591Rear Planetary Gear Assy
D03616
Snap Ring
D26413
Disc
Plate
D26452
A
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
Thrust bearing and bearing race diameter: mm (in.)
insideoutside
Thrust Bearing, A32.5 (1.28)56.5 (2.224)
Bearing Race, B40.2 (1.583)59.3 (2.335)
Thrust Bearing, C38.6 (1.520)59.7 (2.35)
Bearing Race, D38.6 (1.520)59.3 (2.335)
99. INSTALL REAR PLANETARY GEAR ASSY
(a) Install the rear planetary gear assy to the rear planetary
ring gear.
(b) Using a screwdriver, install the snap ring.
NOTICE:
Confirm the snap ring is fixed in the groove of the 1st & re-
verse brake hub correctly.
100. INSTALL 1ST & REVERSE BRAKE CLUTCH DISC
(a) Coat the 6 discs with ATF.
(b) Install the 6 plates and 6 discs.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
101. INSPECT PACK CLEARANCE OF FIRST & REVERSE
BRAKE
(a) Using vernier calipers, measure the distance between the
disc surface and the contact surface of the 2nd brake cyl-
inder and transaxle case(Dimension A).
(b) Select an appropriate flange so that the pack clearance
will meet the specified value.
Pack clearance: 1.16 - 1.35 mm (0.0457 - 0.0531 in.)
HINT:
Piston stroke = Dimension A -Flange thickness
Page 126 of 969
D26404
BA
D26714Rear Planetary Sun Gear Assy
D26412
Plate Disc
D26453
B 40-54
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(b) Coat the bearing with yellow petrolatum, install it onto the
rear planetary sun gear.
Bearing diameter: mm (in.)
InsideOutside
Race, A33.0 (1.299)45.4 (1.787)
Bearing, B31.85 (1.254)45.2 (1.78)
(c) Install the rear planetary sun gear assy to the rear plane-
tary gear.
NOTICE:
Installing the rear planetary sun gear assembly, confirm
that the B1 discs engage.
107. INSTALL 2ND BRAKE CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs and 4 plates to the transaxle case.
(c) Temporarily install the snap ring.
108. INSPECT PACK CLEARANCE OF SECOND BRAKE
(a) Using a vernier calipers, measure the distance between
the disc surface and snap ring surface (Dimension B).
(b) Select an appropriate flange so that the pack clearance
will meet the specified value.
Pack clearance: 0.62 - 0.91 mm (0.0244 - 0.0358 in.)
HINT:
Piston stroke = Dimension B - Flange thickness - Snap ring
thickness 1.6 mm (0.063 in.)
Flange thickness: mm (in.)
MarkThicknessMarkThickness
13.0 (0.118)53.4 (0.134)
23.1 (0.122)63.5 (0.138)
33.2 (0.126)73.6 (0.142)
43.3 (0.130)8-
Page 127 of 969
D03623
Snap Ring
D26392
BA
Overdrive Direct
Clutch Hub
D26403
Thrust Bearing
Direct Clutch Assy
D26469
C
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Temporarily remove the snap ring, attach the selected
flange and restore the snap ring.
NOTICE:
Secure the snap ring so that its gap is visible through the
groove of the transaxle case.
109. I N S TA L L O V E R D R E V E D I R E C T C L U T C H H U B
SUB-ASSY
(a) Install the direct clutch hub to the planetary gear assy.
NOTICE:
Be careful not to damage the bush inside of the overdrive
clutch hub during instaling.
(b) Coat the thrust bearing with ATF.
(c) Install the bearing race and the thrust bearing to the direct
clutch hub.
NOTICE:
Installing the bearing, hold the part on the side of the over-
drive clutch hub.
Bearing and race diameter: mm (in.)
InsideOutside
Bearing, A24.7 (0.972)39.5 (1.555)
Race, B23.6 (0.929)38.0 (1.496)
110. INSTALL DIRECT CLUTCH ASSY
(a) Coat the thrust bearing with ATF.
(b) Install the direct clutch assy and thrust bearing to the rear
planetary sun gear assy.
NOTICE:
The disc in the direct clutch should completely match with
the hub attached outside the rear planetary sun gear.
Otherwise, the rear cover can not be installed.
(c) Clean the connecter part of the transaxle case and the
rear cover.
(d) As shown in the illustration, place a straight edge on the
direct clutch drum and measure the distance between
transaxle case and the straight edge using vernier cali-
pers (Dimension C).
Page 129 of 969
D26766
SST
D26389
Rear Clutch
Oil Seal
Ring Outer
D26388
D26454
FIPG
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113. INSTALL NEEDLE ROLLER BEARING
(a) Using SST and a press, install the needle roller bearing
to the transaxle rear cover.
SST 09950-60010 (09951-00230, 09952-06010)
Press fit depth: 20.55 - 21.25 mm (0.8091 - 0.8366 in.)
NOTICE:
Face the inscribed mark side of the bearing race up.
Repeat the press fit until the specified value is ob-
tained.
(b) Coat a needle roller bearing with ATF.
114. INSTALL REAR CLUTCH OIL SEAL RING OUTER
(a) Coat the 3 new rear clutch oil seal rings with ATF, install
them to the transaxle rear cover.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
115. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Install the 4 new O-ring to the 4 transaxle case No. 1
plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle
rear cover.
Torque: 7.4 NVm (75 kgfVcm, 65 in.Vlbf)
116. INSTALL TRANSAXLE REAR COVER SUB-ASSY
(a) Remove any packing material and be careful not to get oil
on the contacting surfaces of the transaxle rear cover or
the transaxle case.
(b) Apply FIPG to the cover.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equiva-
lent.
NOTICE:
Concerning about the amount of the FIPG application, the
amount should be controlled to from even sealing film on
entire flange surface and have slight protrusion of the FIPG
all around of the connecting area. The FIPG shall be ap-
plied continuously on the flange. (Reference value of the
section diameter: f1.2)
Page 130 of 969
D26387AA
D26414
Flange
Plate Disc
D26466
Snap Ring
D08082
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(c) Apply liquid sealer to the ºAº bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent.
(d) Install the 11 bolts.
Torque:
Bolt A: 19.0 NVm (190 kgfVcm, 14 ftVlbf)
Other bolt: 25.0 NVm (250 kgfVcm, 18 ftVlbf)
117. INSTALL UNDERDRIVE CLUTCH DISC NO.2
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs, 4 plates and flange to the transaxle
case.
NOTICE:
Be careful about the order of discs, plate and flange assem-
bly.
(c) Using a screwdriver, install the snap ring.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
118. INSPECT PACK CLEARANCE OF UNDERDRIVE
BRAKE
(a) Using a dial indicator, measure the underdrive brake pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance: 1.81 - 2.20 mm (0.0713 - 0.0866 in.)
HINT:
Select an appropriate flange from the table below so that it will
meet the specified value.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
13.0 (0.118)43.1 (0.122)
23.2 (0.126)53.3 (0.130)
33.4 (0.134)--
(b) Temporally remove the snap ring and attach to the flange.
(c) Restore the snap ring.
Page 134 of 969
D26710
Thrust Needle
Roller BearingMultiple Disc
Clutch Clutch
Hub
D26711
Thrust Needle
Roller BearingMultiple Disc
Clutch Clutch
Hub
D03820
Thrust Needle
Roller Bearing
D03574
Forward Clutch Assy
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(b) Coat the thrust needle roller bearing and race with yellow
petrolatum, install them onto the multiple disc clutch hub.
Thrust bearing and race diameter: mm (in.)
InsideOutside
Thrust Bearing36.4 (1.433)52.2 (2.055)
(c) Coat the needle roller bearing with ATF.
(d) Install the needle roller bearing to the multiple clutch hub.
Bearing diameter: mm (in.)
InsideOutside
Bearing23.6 (0.929)44 (1.732)
(e) Install the multiple clutch hub to the transaxle case.
125. INSTALL FORWARD CLUTCH ASSY
(a) Coat the thrust needle roller bearing with ATF.
(b) Install the thrust needle roller bearing to the forward
clutch.
Thrust bearing diameter: mm (in.)
InsideOutside
Thrust Bearing33.58 (1.3220)51.9 (2.043)
NOTICE:
Install the thrust bearing properly so that the no colored
race or blue ink jet race will be visible.
(c) Install the forward clutch to the forward clutch assy.
NOTICE:
Align the splines of all discs in the forward clutch with
those of multiple clutch hub to assemble them se-
curely.
Be careful not to damage the bush inside of the for-
ward clutch hub during installing.