length 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 142 of 969
D03547
Transmission Wire
C91927
GFE
A
B
C
D
C91933
A
CB
B
A
C
C91932
O-ring
40-70
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
94 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(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 153 of 969
D09211
Forward Clutch Re-
turn Spring
D03664
C56374
D25587
A
D26707Forward Clutch Piston
- AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
40-81
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 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 163 of 969
4006I-03
D26703
SST
D26704
2nd Brake Piston
Return Spring
C89124
2nd Brake Piston
Return Spring
D26705
- AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U151E/U151F)
40-91
11 5 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
SECOND BRAKE PISTON ASSY (U151E/U151F)
OVERHAUL
1. REMOVE 2ND BRAKE PISTON RETURN SPRING
SUB-ASSY
(a) Place SST on the return spring and compress.
SST 09387-00060
(b) Using a screwdriver, remove the snap ring.
(c) Remove the 2nd brake piston return spring.
2. INSPECT 2ND BRAKE PISTON RETURN SPRING
SUB-ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 16.61 mm (0.6539 in.)
3. REMOVE 2ND BRAKE PISTON
(a) Hold the 2nd brake piston and apply compressed air (392
kPa, 4.0 kgf/cm
2, 57 psi) to the 2nd brake cylinder to re-
move the 2nd brake piston.
Page 168 of 969
C56360
D03824
D03705
D26465
O-ring
D26465
O-ring
40-96
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
120 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Remove the return spring from the underdrive clutch
drum.
7. INSPECT UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 17.14 mm (0.6752 in.)
8. REMOVE UNDERDRIVE CLUTCH PISTON SET
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b) Holding the underdrive clutch piston by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the transaxle
case to remove the underdrive clutch piston.
9. REMOVE UNDERDRIVE CLUTCH DRUM O-RING
(a) Using a screwdriver, remove the O-ring from the under-
drive clutch drum.
10. INSTALL UNDERDRIVE CLUTCH DRUM O-RING
(a) Apply the new O-ring with ATF, install it to the underdrive
clutch drum.
NOTICE:
Assemble the O-ring carefully not to have a twist and a
pinching.
Page 171 of 969
4006K-03
D25593
SST Underdrive
Planetary Gear
D25594
SST
D03686
SST
D03687
Underdrive
Planetary Gear
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)40-99
123 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
UNDERDRIVE PLANETARY GEAR ASSY (U151E/U151F)
OVERHAUL
1. INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a) Using SST, fix the underdrive planetary gear assy.
SST 09387-00050
(b) Using SST and a torque wrench, measure the turning
torque of underdrive planetary gear assy while rotating
the torque wrench at 60 rpm.
SST 09387-00050
Turning torque at 60 rpm.:
0.50 - 1.42 NVm (5.1 - 14.5 kgfVcm, 0.06 - 0.17 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
2. REMOVE FRONT PLANETARY GEAR NUT
(a) Using SST, loosen the staked part of the lock nut.
SST 09930- 00010 (09931- 00010, 09931- 00020),
09387-00050
(b) Clamp the underdrive planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
Page 175 of 969
D26434
SST
Differential
Drive Pinion
D26432
SST
D25609
Underdrive
Planetary Gear
D25594
SST Underdrive
Planetary Gear
C56809
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR
ASSY (U151E/U151F)40-103
127 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
8. INSTALL DIFFERENTIAL DRIVE PINION
(a) Using a press, press the differential drive pinion.
SST 09726- 40010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100)
NOTICE:
Press the counter driven gear while rotating it.
9. INSTALL CYLINDRICAL ROLLER BEARING RACE
INNER
(a) Using a press, press the cylindrical roller bearing race in-
ner.
SST 09506- 35010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100)
NOTICE:
Press the counter driven gear while rotating it.
10. INSTALL FRONT PLANETARY GEAR NUT
(a) Clamp the underdrive planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
(b) Using a socket wrench, install a new lock nut.
Torque: 280 NVm (2,855 kgfVcm, 207 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 750 mm (29.53
in.).
11. INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a) Using SST and a torque wrench, measure the turning
torque of underdrive planetary gear assy while rotating
the torque wrench at 60 rpm.
SST 09387-00050
Turning torque at 60 rpm.:
0.5 - 1.42 NVm (5.1 - 14.5 kgfVcm, 0.06 - 0.17 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).
(b) Using a pin punch and hammer, stake the lock nut.
NOTICE:
Make sure that there are no cracks on the nut.
Page 184 of 969
D26384
C
C
C
CAB
A
D25604
SST
40-1 12
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
136 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Clean the matching surfaces of the transaxle case and
transaxle housing.
(c) Install the transaxle housing to the transaxle case and
tighten them with the 16 bolts.
Torque:
Bolt A: 25 NVm (255 kgfVcm, 18 ftVlbf)
Bolt B: 33 NVm (337 kgfVcm, 24 ftVlbf)
Bolt C: 29 NVm (295 kgfVcm, 21 ftVlbf)
Bolt D: 22 NVm (226 kgfVcm, 16.0 ftVlbf)
HINT:
Apply seal packing or equivalent to the A and D.
Seal packing:
THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
Bolt D: 72 mm (2.835 in.)
HINT:
Usually, bolt A is a non-reusable bolt. In this case, however, it
can be used after cleaning it.
(d) Using SST, turn the differential assy right and left 2
or 3
times to settle the bearing.
SST 09564-3201 1
(e) Using SST and a torque wrench, measure the turning
torque of the differential.
SST 09564-3201 1
Turning torque at 60 rpm:
New bearing
0.20 - 0.69 NVm (2.0 - 7.0 kgfVcm, 1.8 - 6.1 in.Vlbf)
Used bearing
0.10 - 0.35 NVm (1.0 - 3.6 kgfVcm, 0.9 - 3.1 in.Vlbf)
HINT:
If the turning torque is not within the specified value, refer to the
table below to select a thrust washer which turning torque is
within the specified value.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)
Page 196 of 969
D25613
SST
D25601
SST
C50224
D03568
C
C
C
A
AB
C
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- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
148 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
11. INSTALL FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing RR to the differential case.
SST 09316-2001 1, 09214-76011
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.
(b) Install the front differential case shim RR to the transaxle
case.
If the bearing is new, check to select a front differential case
shim RR of proper thickness starting from the thinner ones.
If the bearing is reused, check to select a front differential case
shim RR starting from the same thickness as one installed be-
fore disassembly.
(c) Using SST, install the outer race of the front differential
case tapered roller bearing RR.
SST 09950- 60020 (09951- 00890), 09950- 70010
(09951-07100)
NOTICE:
Clearance is not allowed between the differential case
shim and transaxle case.
12. ADJUST TAPERED POLLER BEARING PRELOAD
(a) Install the intermediate case to the differential case LH
and fix them with 4 bolts.
(b) Install the differential assy to the transaxle case.
(c) Clean the matching surfaces of the transaxle case and
transaxle housing.
(d) Install the transaxle housing to the transaxle case and
tighten them with the 16 bolts.
Torque:
Bolt A: 25 NVm (255 kgfVcm, 18 ftVlbf)
Bolt B 33 NVm (337 kgfVcm, 24 ftVlbf)
Bolt C 29 NVm (295 kgfVcm, 21 ftVlbf)
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
HINT:
Usually, bolt A is a non-reusable bolt. In this case, however, it
can be used after cleaning it.
Page 217 of 969
C11090
D25368
OK NG
The Bottom is
Damaged
C81014
40-18
- AUTOMATIC TRANSMISSION / TRANSTORQUE CONVERTER CLUTCH AND DRIVE PLATE
2533 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Clean and check the oil cooler and oil pipe line.
(1) If the torque converter clutch is inspected or the ATF
is exchanged, clean the oil cooler and oil pipe line.
HINT:
Spray compressed air of 196 kPa (2 kgf/cm2, 28 psi) from
the inlet hose.
If plenty of fine powders are identified in the ATF, add new
ATF using a bucket pump and clean it again.
(2) If the ATF is cloudy, inspect the oil cooler (radiator).
(e) Prevent deformation of the torque converter clutch and
damage to the oil pump gear.
(1) When any marks due to interference are found on
the end of the bolt for the torque converter clutch
and on the bottom of the bolt hole, replace the bolt
and the torque converter clutch.
(2) All of the bolts must be have the same length.
(3) No missing spring washer.
2. INSPECT DRIVE PLATE & RING GEAR SUB-ASSY
(a) Set up a dial indicator and measure the drive plate runout.
(b) Check the damage of the ring gear.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification or ring gear is dam-
aged, replace the drive plate.