lock LEXUS ES300 2005 Owner's Manual
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 101 of 969
D03579
Underdrive
Planetary
Gear Assy
D26386
D03580
Thrust Bearing
Bearing Race
D03581Snap Ring
D03627
Underdrive
1-W ay
Clutch
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(d) Remove the underdrive planetary gear assy from the
transaxle case.
NOTICE:
Be careful so that the underdrive planetary gear assy will
not fall out.
40. REMOVE PARKING LOCK PAWL
(a) Remove the spring, pawl pin and parking lock pawl.
41. REMOVE UNDERDRIVE CLUTCH ASSY
(a) Remove the underdrive clutch assy, thrust bearing and
bearing race from the transaxle case.
42. REMOVE UNDERDRIVE 1 WAY CLUTCH ASSY
(a) Using a screwdriver, remove the snap ring from the trans-
axle case.
(b) Remove the underdrive 1-way clutch from the transaxle
case.
Page 108 of 969
D03595
Lock Washer
D03596
SST
D26398
SST
D26763
Front Planetary
Gear Assy
Brake Hub
D03615
Front Planetary Ring Gear
Brake Hub
Snap Ring
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65. REMOVE FRONT PLANETARY GEAR ASSY
(a) Using a chisel and hammer, unstake the lock washer.
NOTICE:
Push down all claws of the washer. Otherwise SST cannot
be fully pressed against the nut, and cannot loosen the nut.
(b) Using SST, remove the nut.
SST 09387-00030, 09387-00080
(c) Using SST and a press, remove the front planetary gear
assy from the counter drive gear.
SST 09950- 60010 (09951- 00450), 09950- 70010
(09951-07100)
(d) Remove the front planetary gear assy from the brake hub.
66. REMOVE FRONT PLANETARY RING GEAR
(a) Using a screwdriver, remove the snap ring and front plan-
etary ring gear from the brake hub.
Page 122 of 969
D03918
SST
D08074
Lock Washer
C89123
C
BA
Input Sun Gear
D
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(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 125 of 969
D03909
1-W ay Clutch
Inner Race
D09638
Free
D03588
Thrust Needle
Roller Bearing
1-W ay Clutch Assy
D26394
Planetary Carrier
Thrust Washer No.1
D26393
Planetary Carrier Thrust Washer No.2
Rear Planetary Sun Gear
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104. INSTALL 1 WAY CLUTCH ASSY
(a) Install the 1-way clutch inner race to the 1-way clutch.
NOTICE:
Check the direction of the inner race.
Confirm that the discrimination mark can be seen by
the worker.
(b) Check the rotating direction of 1-way clutch for the lock
or free operation, as shown in the illustration.
(c) Install the 1-way clutch and thrust needle roller bearing
to the 1-way clutch sleeve outer.
Bearing diameter: mm (in.)
InsideOutside
Bearing53.6 (2.110)69.4 (2.732)
NOTICE:
Install the thrust bearing properly so that no-colored race
will be visible.
105. INSTALL PLANETARY CARRIER THRUST WASHER
NO.1
(a) Coat the planetary carrier thrust washer No. 1 with yellow
petrolatum, install it onto the planetary sun gear assy.
NOTICE:
After assembling, confirm that the projection should be
fixed surely in the hole of the planetary sun gear assembly.
106. INSTALL REAR PLANETARY SUN GEAR ASSY
(a) Coat the planetary carrier thrust washer No. 2 with yellow
petrolatum, install it onto the rear planetary sun gear.
Page 131 of 969
D03925
Free
Free
D03907
Outer Race
Retainer
D03627
Mark
Mark
D03581Snap Ring
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119. INSPECT UNDERDRIVE 1 WAY CLUTCH ASSY
(a) Install the underdrive clutch assy to the 1-way clutch.
(b) Rotate the underdrive clutch assy to check the rotating
direction for the lock or free operation.
120. INSTALL UNDERDRIVE 1 WAY CLUTCH ASSY
(a) Install the outer race retainer to the 1-way clutch.
NOTICE:
Fix the outer race retainer to the external tooth of the one
way clutch surely.
(b) Install the 1-way clutch to the transaxle case.
NOTICE:
Make sure that the mark on the 1-way clutch outer race is
visible.
(c) Using a screwdriver, install the snap ring to the transaxle
case.
NOTICE:
The snap ring should be fixed certainly in the groove of the
transaxle case as the gap exists except in the lock of teeth.
Page 132 of 969
D03580
D09691
Parking Lock Pawl
Spring
Pawl Pin
D26386
D03579
Underdrive
Planetary
Gear Assy
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121. INSTALL UNDERDRIVE CLUTCH ASSY
(a) Coat the bearing and bearing race with petroleum jelly,
install them onto the underdrive clutch.
Bearing and bearing race diameter: mm (in.)
InsideOutside
Bearing37.73 (1.4854)58.0 (2.2835)
Race29.9 (1.1772)55.5 (2.185)
(b) Install the underdrive clutch assy to the transaxle case.
NOTICE:
Installing the underdrive clutch drum sub-assy, be sure
not to damage the oil seal ring.
122. INSTALL PARKING LOCK PAWL
(a) Install the pawl pin and spring to the parking lock pawl.
(b) Temporarily install the parking lock pawl, shaft and spring
to the transaxle case, as shown in the illustration.
123. INSTALL UNDERDRIVE PLANETARY GEAR ASSY
(a) Install the underdrive planetary gear assy to the transaxle
case.
NOTICE:
Engage all the discs of underdrive clutch and hub splines
of the underdrive planetary gear assy firmly and assemble
them securely.
Page 133 of 969
D09693
D03576Pawl Shaft Clamp
D03875
E
D25511
Dimension (1)
Dimension (2)
D08087
Thrust Bearing Race No.1
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(b) Install the parking lock pawl shaft.
(c) Install the pawl shaft clamp with the bolt.
Torque: 9.8 NVm (100 kgfVcm, 87 in.Vlbf)
(d) Using a straight edge and vernier calipers as shown in the
illustration, measure the gap between the top of the differ-
ential drive pinion in the underdrive planetary gear and
contact surface of the transaxle case and housing (Di-
mension E).
NOTICE:
Note down the dimension E as it is necessary for the follow-
ing process.
(e) As shown in the illustration, measure the 2 places of the
transaxle housing, calculate the dimension F using the
formula.
NOTICE:
Note down the dimension F as it is necessary for the follow-
ing process.
HINT:
Dimension F = Dimension (1) - Dimension (2)
124. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB
(a) Install the thrust bearing race No.1 to the transaxle case
while checking its direction.
Bearing race diameter: mm (in.)
InsideOutside
Bearing race39.5 (1.555)45.8 (1.803)
Page 138 of 969
D26382
Parking Lock Rod Sub-assy
D03565
Spacer
D03564
D26765
D03559
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135. INSTALL PARKING LOCK ROD SUB-ASSY
(a) Install the parking lock rod to the manual valve lever.
136. INSTALL MANUAL VALVE LEVER SUB-ASSY
(a) Install a new spacer and manual valve lever shaft to the
transaxle case.
NOTICE:
Do not damage on the oil seal during assembling the shaft
to the transaxle case.
(b) Using a pin punch and hammer, drive in a new pin.
(c) Turn the spacer and the lever shaft to align the small hole
for locating the staking position in the spacer with the
staking position mark on the lever shaft.
(d) Using a pin punch, stake the spacer through the small
hole.
(e) Check that the spacer does not turn.
137. INSTALL MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using needle-nose pliers, install the retainer spring.
NOTICE:
Hang the spring on the shaft certainly.
Page 139 of 969
D03561
D03560
B
A
D03904
O-ring
B-3 Accumulator Piston
D25512
AT F
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138. INSTALL PARKING LOCK PAWL BRACKET
(a) Install the parking lock pawl bracket with the 2 bolts.
Torque: 20 NVm (205 kgfVcm, 15 ftVlbf)
Bolt length: 25 mm (0.984 in.)
NOTICE:
Be sure the parking rod is placed between the parking pawl
and the guide of the parking bracket when the parking
bracket is assembled.
139. INSTALL MANUAL DETENT SPRING SUB-ASSY
(a) Install the manual detent spring with the 2 bolts.
NOTICE:
Make sure to install the manual detent spring and cover in
this order.
HINT:
Tighten them in the order, A and B.
Torque:
Bolt A: 20 NVm (205 kgfVcm, 15 ftVlbf)
Bolt B: 12 NVm (120 kgfVcm, 9 ftVlbf)
Bolt length:
Bolt A: 27 mm (1.063 in.)
Bolt B: 16 mm (0.630 in.)
140. INSTALL B-3 ACCUMULATOR PISTON
(a) Coat a new O-ring with ATF, install it to the B-3 accumula-
tor piston.
NOTICE:
Install the O-ring to the accumulator piston and the accu-
mulator sleeve not to have a twist and a protrusion. More-
over, apply enough ATF prior to assembling. Be sure to the
installed position.
(b) Coat the piston with ATF, install it to the transaxle case.
NOTICE:
Install the springs to each accumulator piston with check-
ing of the identification color or each spring.
Accumulator spring:
Free length
Outer diameter mm (in.)Color
Inner 62.00 (2.4409) /
15.50 (0.610)Purple
Outer 74.23 (2.9224) /
21.70 (0.854)Purple
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.