LEXUS ES300 2005 Repair Manual
Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 191 of 969
D25600
SST
C50943
C50216
C50213
Differential
Case LH
Differential
Case No.2
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40-1 19
143 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100), 09608-10010
8. INSTALL DIFFERENTIAL CASE SUB-ASSY NO.2
(a) Coat the front differential side gear thrust washer No.1,
front differential planetary ring gear, front differential pin-
ion No.2, front differential pinion thrust washer No.2, front
differential pinion shaft holder, front differential pinion
shaft and 2 differential pinion shafts with ATF, install them
to the differential case No.2.
(b) Using a dial indicator, measure the backlash of one pinion
gear while holding the front differential side gear toward
the case.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
NOTICE:
Do not mount the surface of front differential case which
contacts with bushing in a vise.
If the backlash is not within the specified value, refer to the table
below and select a thrust washer which will ensure that the
backlash is within the specified value.
Thrust washer thickness: mm (in.)
MarkThicknessMarkThickness
A0.95 (0.0373)F1.20 (0.0472)
B1.00 (0.0393)G1.25 (0.0492)
C1.05 (0.0413)H1.30 (0.0512)
D1.10 (0.0433)J1.35 (0.0532)
E1.15 (0.0453)K1.40 (0.0552)
(c) Engage the front differential side gear to the above men-
tioned front differential case.
(d) Install the differential case LH to the front differential case
and measure its center.
(e) After that, remove the differential case LH.
Page 192 of 969
C50214
C50217
D25610
C51252
Differential Case RH
Center Differential
Side Gear
40-120
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
144 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(f) Using a straight edge and feeler gauge, measure the
clearance between the front differential case and the front
differential side gear.
t= Thrust washer thickness
L= Clearance
t= L-0.162 - 0.265 mm (0.0064 - 0.0104 in.)
If the clearance is not within the specified value, refer to the
table below and select a thrust washer which will ensure that the
clearance is within the specified value.
Thrust washer thickness: mm (in.)
MarkThicknessMarkThickness
A0.95 (0.0373)F1.20 (0.0472)
B1.00 (0.0393)G1.25 (0.0492)
C1.05 (0.0413)H1.30 (0.0512)
D1.10 (0.0433)J1.35 (0.0532)
E1.15 (0.0453)K1.40 (0.0552)
If the clearance is not within the specified value, parts may have
been assembled incorrectly, so check and reassemble it.
(g) Using a pin punch and a hammer, install 3 straight pins.
(h) Using a snap ring expander, install the pinion shaft spacer
snap ring.
9. INSTALL CTR DIFFERENTIAL PLANETARY GEAR
ASSY
(a) Install the center differential side gear, conical spring
washer and center differential side gear thrust washer
No.2 RH from the differential case RH.
HINT:
Ensure that the conical washers is installed correctly.
Page 193 of 969
C50950
C50205
C50206
C50207
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40-121
145 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Hold the differential case RH by vice. Install the center dif-
ferential pinion and pinion thrust washer to the differential
spider and install them to the differential case RH.
NOTICE:
When holding the differential case RH by vise, be sure to
place an aluminum sheet between them and use a mini-
mum force.
(c) Pressing and holding the differential spider toward the dif-
ferential case RH, measure the pinion's backlash with a
dial indicator as illustrated.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specified value, refer to the table
below and select a thrust washer which will ensure that the
backlash is within the specified value.
Thrust washer thickness: mm (in.)
MarkThicknessMarkThickness
MA0.80 (0.0313)MH1.15 (0.0453)
MB0.85 (0.0333)MJ1.20 (0.0472)
MC0.90 (0.0353)MK1.25 (0.0492)
MD0.95 (0.0373)ML1.30 (0.0512)
ME1.00 (0.0393)MM1.35 (0.0532)
MF1.05 (0.0413)MN1.40 (0.0552)
MG1.10 (0.0433)--
(d) Temporarily install the differential side gear thrust washer
No.2 LH, center differential side gear conical spring wash-
er and differential case No.2 to the differential case LH.
HINT:
Ensure that the conical washers is installed correctly.
(e) Install the differential intermediate case to the above and
fix them with 4 bolts.
Page 194 of 969
C50208
C50209
C50210
C51468
Differential
Case No.2
Differential
Case LH
40-122
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
146 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(f) Remove the differential spider, 5 center differential pin-
ions and 5 center differential pinion thrust washers from
the differential case RH. Put them in the differential inter-
mediate case and fix the case.
(g) Pressing and holding the differential spider toward the dif-
ferential intermediate case, measure the pinion's back-
lash with a dial indicator.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
If the backlash is not within the specified value, refer to the table
below and select a thrust washer which will ensure that the
backlash is within the specified value.
Thrust washer thickness: mm (in.)
MarkThicknessMarkThickness
MA0.80 (0.0313)MH1.15 (0.0453)
MB0.85 (0.0333)MJ1.20 (0.0472)
MC0.90 (0.0353)MK1.25 (0.0492)
MD0.95 (0.0373)ML1.30 (0.0512)
ME1.00 (0.0393)MM1.35 (0.0532)
MF1.05 (0.0413)MN1.40 (0.0552)
MG1.10 (0.0433)--
(h) Remove the 4 bolts and disconnect the differential case
LH from the differential intermediate case.
(i) Remove the differential case No.2 from the differential
case LH.
Page 195 of 969
C51469
C50188
Differential
Case No.2
Differential
Case LH
C50193
D25612
SST
D25603
SST
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40-123
147 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(j) Install the selected differential side gear thrust washer
No. 2 LH and center differential planetary gear to the dif-
ferential case LH.
(k) Install the differential case No. 2 to the differential case LH
again.
(l) Install the adjusted differential case RH to the intermedi-
ate case and tighten the 15 bolts using a torx socket
wrench (T50).
Torque: 63 NVm (642 kgfVcm, 46 ftVlbf)
NOTICE:
Align the matchmarks.
10. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing FR to the differential case.
SST 09950-70010 (09951-07100), 09649-17010
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.
(b) Using SST, install the outer race of the tapered roller bear-
ing FR.
SST 09527-1701 1, 09950-60020 (09951-01030)
NOTICE:
Clearance is not allowed between the plate washer and
transaxle housing.
Page 196 of 969
D25613
SST
D25601
SST
C50224
D03568
C
C
C
A
AB
C
40-124
- 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 197 of 969
SST
C50227
D25614
C50224
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40-125
149 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(e) Using SST, turn the differential assy right and left 2or 3
times to allow the bearing settle.
SST 09564-3201 1
(f) Using SST and a torque wrench, measure the turning
torque of the differential case assy.
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 and 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)
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
(g) Remove the 16 bolts and the transaxle housing.
(h) Remove the differential assy.
Page 198 of 969
D25215
90 - 100 C (194 - 230 F)
C50186
Match-marks
C50232
C50233
D25605
SST 40-126
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
150 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
13. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring gear
to 90 - 110 C. (194.0 - 230.0 F)
NOTICE:
Do not overheat the ring gear to 110 C (230.0 F) or more.
(b) Clean the contact surface of the front differential case.
(c) Set the match-marks, install the front differential ring gear
case quickly.
NOTICE:
Do not install the bolts while the ring gear is hot.
(d) Temporarily install the 8 bolts as shown in the illustration.
(e) Remove the 4 bolts shown in the illustration.
(f) Temporarily install the remaining 8 set bolts.
(g) Fully tighten the set bolts.
Torque: 95.1 NVm (970 kgfVcm, 70 ftVlbf)
NOTICE:
Tighten the bolts a little at a time in diagonal order.
14. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
SST 09223-15020, 09950-70010 (09951-07100)
(b) Coat the rip of oil seal with a little MP grease.
Page 199 of 969
D03809
Vinyl Tape
SST
D25615
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40-127
151 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
15. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Wind a vinyl tape around SST at the place 6.0 mm (0.236
in.) above from the bottom end until the thickness of the
wound tape is about 5.0 mm (0.197 in.).
SST 09950-60020 (09951-00730)
NOTICE:
Remove foreign matter such as grease on the SST before
winding the tape.
(b) Coat the rip of oil seal with a little MP grease.
(c) Using SST, install a new oil seal.
SST 09950- 60020 (09951- 00730), 09950- 70010
(09951-07150)
Standard press in depth:
5.5 - 6.5 mm (0.217 - 0.256 in.)
NOTICE:
Stop pressing when the would vinyl tape is contact with the
transaxle housing.
Page 200 of 969
4005R-08
D25120
Add if hotOK if hot
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE FLUID
40-1
2516 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
AUTOMATIC TRANSAXLE FLUID
ON-VEHICLE INSPECTION
1. CHECK THE FLUID LEVEL
HINT:
Drive the vehicle so that the engine and transaxle are at normal
operating temperature.
Fluid temperature: 70 - 80 °C (158 - 176 °F)
(a) Park the vehicle on a level surface and set the parking
brake.
(b) With the engine idling and the brake pedal depressed,
shift the shift lever into all positions from P to L position,
and return to P position.
(c) take out the dipstick and wipe it clean.
(d) Put it back fully into the pipe.
(e) take it out and check that the fluid level is in the HOT posi-
tion.
If there are leaks, it is necessary to repair or replace O-rings,
FIPGs, oil seals, plugs and/or other parts.