torque LEXUS ES300 2005 Owner's Manual

- INTRODUCTIONHOW TO USE THIS AUTOMATIC TRANSAXLE REPAIR
MANUAL01-3
3 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
7. SI UNIT
(a) The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys-
tem of Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque:
30 NVm (310 kgfVcm, 22 ftVlbf)

0103B-07
Z11554
Seal Lock Adhesive 01-4
- INTRODUCTIONREPAIR INSTRUCTION FOR AUTOMATIC
TRANSAXLE REPAIR MANUAL
4 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
REPAIR INSTRUCTION FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL
PRECAUTION
1. BASIC REPAIR HINT
(a) PRECOATED PARTS
(1) Precoated parts are bolts, nuts, etc. that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(3) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.
NOTICE:
Do the torque checking with the lower limit value of the torque tolerance.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) GASKETS
When necessary, use a sealer on gaskets to prevent leaks.
(c) BOLTS, NUTS AND SCREWS
Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.

L1 L2L1 L2
D02612
L2 L1L2 L1
D01201
L2 L1L2 L1
D01202
- INTRODUCTIONREPAIR INSTRUCTION FOR AUTOMATIC
TRANSAXLE REPAIR MANUAL01-5
5 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) TORQUE WHEN USING EXTENSION TOOL WITH
TORQUE WRENCH
(1) In case of tightening by extending the entire length
of the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the read-
ing of the torque wrench by the formula.
(3) Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench {NVm (kgfVcm, ftVlbf)}
TTorque {NVm (kgfVcm, ftVlbf)}
L1Length of SST or tool (cm)
L2Length of torque wrench (cm)

01-8- INTRODUCTIONTERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
8 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U) ISC
Idle Speed Control-
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure-
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Light
MSTManifold Surface temperature-
MVZManifold Vacuum Zone-
NVRAMNon-V olatile Random Access Memory-
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn-Board DiagnosticOn-Board Diagnostic (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Converter (OC), CC0
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module-
PNPPark/Neutral Position-
PROMProgrammable Read Only Memory-
PSPPower Steering Pressure-
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module-
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger Bypass-
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter-
SRIService Reminder Indicator-
SRTSystem Readiness Test-
STScan Tool-
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter
TCMTransmission Control ModuleTransmission ECU (Electronic Control Unit)
TPThrottle PositionThrottle Position
TRTransmission Range-
TVVThermal Vacuum ValveBimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
TWCThree-W ay Catalytic ConverterThree-W ay Catalytic (TWC)
CC
RO
TWC+OCThree-W ay + Oxidation Catalytic ConverterCCR + CCO
VA FVolume Air FlowAir Flow Meter
VRVoltage RegulatorVoltage Regulator
VSSVehicle Speed SensorVehicle Speed Sensor (Read Switch Type)
WOTWide Open ThrottleFull Throttle

02-6
- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
15 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(09951-07100)Handle 100FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
(09951-07150)Handle 150FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
Recomended Tools
09031-00030Pin PunchAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09031-00040Pin Punch .FRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)
09905-00012Snap Ring No.1 ExpanderAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FORWARD CLUTCH
ASSY(U151E/U151F)
DIRECT CLUTCH
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09905-00013Snap Ring PliersUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
Equipment
Dial indicator with magnetic base
Feeler gauge
Vernier calipers
Torque wrench
Plastic hammer
Straight edge
Press
Seal packing 2403, THREE BOND 2403 or equivalent
Seal packing 2430, THREE BOND 2430 or equivalent
Lubricant
item
U151E / U151F
Automatic transaxle fluid
Dry fill
Drain and refill
6.8 liter (7.2 USqts, 6.0 lmp.qts)
2.9 liter (3.1 USqts, 2.6 lmp.qts)ATF type T-IV

030JL-02
V00079
ClassDiameter
mmPitch
mmSpecified torque
Hexagon head bolt
Hexagon flange bolt
N´m kgf´cm
ft´lbf N´mkgf´cm
ft´lbf
in.´lbf
in.´lbf
in.´lbfin.´lbf
in.´lbf
in.´lbf 03-2
- SERVICE SPECIFICATIONSSTANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL
18 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
SPECIFIED TORQUE FOR STANDARD BOLTS

03-6
- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
22 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U) U/D planetary gear
Preload (at 60 rpm)0.50 - 1.42 NVm (5.1 - 14.5 kgfVcm, 0.06 - 0.17 in.Vlbf)
Front planetary gear
Turning torque (at 60 rpm) New Bearing
Used Bearing0.51 - 1.02 NVm (5.1 - 10.0 kgfVcm, 4.4 - 8.7 in.Vlbf)
0.26 - 0.51 NVm (2.7 - 5.2 kgfVcm, 2.3 - 4.5 in.Vlbf)
Input shaft
End play0.262 - 1.249 mm (0.0103 - 0.0492 in.)
Transaxle rear cover
Bearing press fit depth20.55 - 21.25 mm (0.8091 - 0.8366 in.)
Transmission valve body
Valve body installation bolt length A
B
C41 mm (1.614 in.)
57 mm (2.244 in.)
25 mm (0.984 in.)
Accumulator
SpringFree length/Outer diameterColor
B3Inner
Outer62.00 (2.4409) / 15.50 (0.610)
74.23 (2.9224) / 16.50 (0.649)Purple
Purple
C260.96 (2.3999) / 14.10 (0.555)Yellow
C372.20 (2.8425) / 19.0 (0.748)Colorless
Front differential(U151E)
Backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thrust washer thickness Mark
-
-
-
1.625 mm (0.0640 in.)
1.725 mm (0.0679 in.)
1.825 mm (0.0719 in.)
Praload (at 60 rpm) New bearing
Used bearing0.20 - 0.69 NVm (2.0 - 7.0 kgfVcm, 1.8 - 6.1 in.Vlbf)
0.10 - 0.35 NVm (1.0 - 3.6 kgfVcm, 0.9 - 3.1 in.Vlbf)
Flange thickness Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.)
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)
Front differential (U151F)
Side gear backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)

0305L-1 1
03-8
- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
24 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
TORQUE SPECIFICATION
Part TightenedNVmkgfVcmftVlbf
Differential gear lube apply tube x Transaxle housing9.810087 in.Vlbf
Front planetary gear lock nut210-3502141-3569155-258
Brake apply tube clamp x Transaxle case5.45548 in.Vlbf
Transaxle case No. 1 plug x Transaxle rear cover7.47565 in.Vlbf
Transaxle rear cover x Transaxle case Bolt A
Other bolt19
25190
25014
18
Pawl shaft clamp x Transaxle case9.810087 in.Vlbf
Oil pump assy x Transaxle case2222616
Transaxle housing x Transaxle case Bolt A
Bolt B
Bolt C
Bolt D25
33
29
22255
337
295
22618
24
21
16
Automatic transmission case plug x Transaxle housing7.47565 in.Vlbf
Automatic transmission case plug x Transaxle case7.47565 in.Vlbf
Parking lock pawl bracket x Transaxle case2020515
Manual detent spring x Transaxle case Bolt A
Bolt B20
12205
12015
9
Transmission wire x Transaxle housing5.45548 in.Vlbf
Transmission valve body x Transaxle case1111 08
ATF temperature sensor clamp x Transmission valve body6.66758 inVlbf
Valve body oil strainer assy x Transmission valve body1111 08
Automatic transaxle oil pan sub-assy x Transaxle case7.88069 in.Vlbf
Drain plug x Automatic transaxle oil pan sub-assy4950036
Speed sensor x Transaxle case1111 58
Oil cooler tube union x Transaxle case Union
Elbow27
27276
27620
20
Park/neutral start switch x nut6.97061 in.Vlbf
Park/neutral start switch x Bolt5.45548 in.Vlbf
Park/neutral start switch x Control shaft lever131309
Speedometer driven hole cover sub-assy x Transaxle case6.97061
Oil pump body x Stator shaft assy9.810087 in.Vlbf
Line pressure control solenoid assy x Transmission valve body assy6.66758 in.Vlbf
Shift solenoid valve SL1x Transmission valve body assy6.66758 in.Vlbf
Shift solenoid valve SL2x Transmission valve body assy10.811 08
Shift solenoid valve SL3x Transmission valve body assy6.66758 in.Vlbf
Shift solenoid valve S4x Transmission valve body assy10.811 08
Shift solenoid valve DSL x Transmission valve body assy10.811 08
Front differential case x Front differential ring gear95.197070

4010I-01
C86320
N´m (kgf´cm, ft´lbf): Specified torque
 Non-reusable partElbow
27 (276, 20)
Drain Plug Drain Plug Gasket Automatic Transmission
Case PlugO-Ring Automatic Transmission
Case Plug Speed Sensor
Automatic Transmission
Case Plug
47 (479, 34)
Speed Sensor
7.4 (75, 65 in.Vlbf)

O-Ring  O-Ring 
O-Ring 
O-Ring 
O-Ring 
7.4 (75, 65 in.Vlbf)
7.4 (75, 65 in.Vlbf)
11.3 (158, 8)
11.3 (158, 8)
5.4 (55, 48 in.Vlbf)
U151E:
Transmission Wire
Union
25 (255, 18)
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)40-1
25 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
AUTOMATIC TRANSMISSION / TRANSAXLE (U151E/U151F)
COMPONENTS

C89119
N´m (kgf´cm, ft´lbf): Specified torque
 Non-reusable partO-Ring 
 Precoated partx 18
Automatic Transaxle
Oil Pan Sub-assyAutomatic Transaxle
Oil Pan Gasket Valve Body
Oil Strainer AssyOil Cleaner
Magnet
 
Oil Strainer Gasket
11 (110, 8 )
x 17 Transmission Valve Body Assy
Parking Lock
Rod Sub-assy
Parking Lock
Pawl Bracket
Manual Detent
Spring Sub-assy11 (110, 8)
20 (205, 15)
20 (205, 15)
C-3 Accumulator
Piston
O-Ring 
Compression
Spring
O-Ring O-Ring 
B-3 Accumulator
Piston Compression Spring
Reverse Clutch
Accumulator PistonCompression Spring
Washer Control Shaft Lever
Nut Stopper Park/ Neutral
Position SwitchManual Valve Lever Shaft Oil Seal Manual Valve Lever Shaft Sloted Spring Pin Retainer Spring Spacer
13 (130, 9)
6.9 (70, 61 in.Vlbf)
5.4 (55, 48 in.Vlbf)
x 5 O-Ring x 8O-Ring  Transaxle Apply Tube ClampAutomatic Transaxle
Case Sub-assyTransaxle Rear Cover
x 11
Governor Apply Gasket
Transaxle Case
2nd Brake Gasket Differential Gear
Lube Apply Tube
Brake Drum Gasket
7.4 (75, 65 in.Vlbf)
29 (295, 21)
9.8 (100, 87 in.Vlbf)
25 (255, 18)
Case Plug
Spring
Check Ball
Body
Bolt A: 18.6 (190, 14)
Other bolt: 24.5 (250, 18)
U151E:
x 3
33 (337, 24)
11.8 (120, 9)
7.8 (80, 69 in.Vlbf)
40-2- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
26 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)