torque spec LEXUS ES300 2005 Service Manual
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 211 of 969
D30511D30668
C88136
C88136
40-12
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E)
2527 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Remove the 8 bolts.
(d) Separate and remove the automatic transaxle.
15. REMOVE TORQUE CONVERTER CLUTCH ASSY
16. REMOVE TRANSAXLE CASE COVER UPPER
(a) Remove the 3 bolts and transmission case cover.
17. INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE PAGE 40-17)
SST 09350-32014 (09351-32010, 09351-32020)
18. INSTALL TRANSAXLE CASE COVER UPPER
(a) Install the transmission case cover with the 3 bolts.
Torque: 12 NVm (122 kgfVcm, 9 ftVlbf)
Page 216 of 969
40063-10
AT0953
SST
AT3306
Hold
TurnLock
Free
D25367
Sample showing minimum amount of
powders in ATF
Actual Size
- AUTOMATIC TRANSMISSION / TRANSTORQUE CONVERTER CLUTCH AND DRIVE PLATE
40-17
2532 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
TORQUE CONVERTER CLUTCH AND DRIVE PLATE
INSPECTION
1. INSPECT TORQUE CONVERTER CLUTCH ASSY
(a) Inspect the one-way clutch.
(1) Set SST into the inner race of the one-way clutch.
SST 09350-32014 (09351-32010)
(2) Install SST so that it fits in the notch of the converter
hub and outer race of the one-way clutch.
SST 09350-32014 (09351-32020)
(3) With the torque converter clutch setting up on its
side, check that the one-way clutch locks when it is
turned counterclockwise, and rotates clockwise
smoothly.
If necessary, clean the converter and retest the one- way
clutch.
Replace the converter if the one-way clutch still fails the test.
(b) Determine the condition of the torque converter clutch
assy.
(1) If the inspection result of the torque converter clutch
assy meets the following item, replace the torque
converter clutch.
Malfunction item:
Any metallic sound is heard from the torque convert-
er clutch during stall test or when the shift lever is in
neutral position.
One-way clutch is free or locked in both directions.
Fine powders exceeding the sample limit is identified
in ATF. (See the sample.)
HINT:
The sample shows the auto fluid of approx. 0.25 liters (0.26 US
qts, 0.22 Imp. qts) that is taken out from the removed torque
converter clutch
(c) Replace the ATF in the torque converter clutch.
(1) If the ATF is discolored and/or has a foul odor, com-
pletely stir the ATF in the torque converter clutch
and drain it with the face for installation facing up.
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.
Page 227 of 969
D30865
C91925
40-28
- AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E)
2543 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10. I N S TA L L A U TO M AT I C T R A N S A X L E O I L PA N
SUB-ASSY
(a) Install the 2 magnets in the oil pan.
(b) Apply seal packing to 18 bolts.
Seal packing:
THREE BOND 2430 or equivalent
(c) Install a new gasket, oil pan and 18 bolts to the transaxle
case.
Torque: 7.8 NVm (80 kgfVcm, 69 in.Vlbf)
NOTICE:
Since the bolts should be seal bolts, apply seal packing to
the bolts and tighten them within 10 minutes after applying.
11. ADD AUTOMATIC TRANSAXLE FLUID
12. INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-1)
13. INSTALL ENGINE UNDER COVER NO.1
14. RESET MEMORY (SEE PAGE 05-604)
Page 239 of 969
400H6-03
D25118
D25119
40-40
- AUTOMATIC TRANSMISSION / TRANSFLOOR SHIFT ASSY
2555 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ADJUSTMENT
1. INSPECT SHIFT LEVER POSITION
(a) When shifting from P to R position only with ignition switch ON and brake pedal, make sure that the
shifting lever moves smoothly and can be moderately operated.
(b) When starting engine, make sure that the vehicle moves forward when shifting from N to D position
and moves rearward when shifting to R position.
2. ADJUST SHIFT LEVER POSITION
(a) Loosen the nut on the control shaft lever.
(b) Push the control shaft fully downward.
(c) Return the control shaft lever 2 notches to N position.
(d) Set the shift lever to N position.
(e) While holding the shift lever lightly toward the R position
side, tighten the shift lever nut.
Torque: 14.7 N´m (150 kgf´cm, 10 ft´lbf)
(f) Start the engine and make sure that the vehicle moves
forward when shifting the lever from N to D position and
moves rearward when shifting it to R position.
Page 245 of 969
C90581
C93327
D25414
D25415
40-46
- AUTOMATIC TRANSMISSION / TRANSTRANSMISSION CONTROL CABLE ASSY
2561 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Install the shift cable grommet retainer No.2 with the 2
bolts.
Torque: 4.9 NVm (50 kgfVcm, 43 in.Vlbf)
(e) Connect the control cable to the control cable clamp.
(f) Temporarily install the control cable to the control shaft le-
ver with nuts.
(g) Install the control cable and a new clip to the bracket.
10. INSTALL INTAKE AIR RESONATOR SUB-ASSY
11. INSTALL AIR CLEANER HOSE NO.1
12. INSTALL AIR CLEANER ASSY
13. INSTALL AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-55)
14. INSTALL AIR CONDITIONING RADIATOR ASSY (SEE PAGE 55-17)
15. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (SEE PAGE 71-1 1)
16. INSTALL BATTERY
17. ADJUST SHIFT LEVER POSITION (SEE PAGE40-40)
18. INSPECT SHIFT LEVER POSITION (SEE PAGE40-40)
Page 249 of 969
3211W-03
F41694
F41695
F41696
C80826
32-4
- BRAKEBRAKE FLUID
2438 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE FLUID (From July, 2003)
BLEEDING
HINT:
If any work is done on the brake system or if air in the brake lines is suspected, bleed the air from the system.
NOTICE:
Wash off the brake fluied immediately if it comes into contact with a painted surface.
1. FILL RESERVOIR WITH BRAKE FLUID
Fluid: SAE J1703 or FMVSS No. 116 DOT3
2. BLEED MASTER CYLINDER
HINT:
If the master cylinder has been disassembled or if the reservoir
becomes empty, bleed the air from the master cylinder.
(a) Remove the air cleaner assembly with hose.
(b) Disconnect the brake lines from the master cylinder.
SST 09023-00101
(c) Slowly depress the brake pedal and hold it.
(d) Block off the outer holes with your fingers, and release the
brake pedal.
(e) Repeat (c) and (d) 3 or 4 times.
(f) Install the air cleaner assembly with hose.
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the brake caliper.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
(c) At the point when fluid stops coming out, tighten the
bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
(e) Tighten the bleeder plug certainly.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
Page 253 of 969
320DV-02
F41697
Stop Lamp
Switch
Push Rod
Pedal Height
32-8
- BRAKEBRAKE PEDAL SUPPORT ASSY
2442 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE PEDAL SUPPORT ASSY
ADJUSTMENT
1. CHECK AND ADJUST BRAKE PEDAL HEIGHT
(a) Inspect brake pedal height.
Pedal height from asphalt sheet:
144.1 - 154.1 mm (5.673 - 6.067 in.)
(b) Adjust brake pedal height.
(1) Remove the instrument panel finish panel sub-
assy lower and instrument panel insert sub-assy
lower LH.
(2) Disconnect the connector from the stop lamp
switch.
(3) Loosen the stop lamp switch lock nut and remove
the stop lamp switch.
(4) Loosen the clevis lock nut.
(5) Adjust the pedal height by turning the pedal push
rod.
(6) Tighten the push rod lock nut.
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
(7) Install the stop lamp switch.
(8) Connect the connector to the stop lamp switch.
(9) Push the brake pedal in 5 - 10 mm (0.20 - 0.39 in.),
turn the stop lamp switch to lock the nut in the posi-
tion where the stop lamp goes off.
(10) After installation, push the brake pedal in 5 - 10 mm
(0.20 - 0.39 in.), check that stop lamp lights up.
(11) Install the instrument panel insert sub-assy lower
LH and instrument panel finish panel sub-assy low-
er.
Page 255 of 969
320DW-02
F42132
Brake Pedal Support
Stop Lamp
Switch Assy
Lock Nut
Brake Pedal Bush
Brake Pedal Bush Stop Light Switch Cushion
Brake Pedal
Push Rod Pin Brake Pedal Return Spring
Clip
Brake Pedal Pad
Non-reusable part
NVm (kgfVcm, ftVlbf) : Specified torque
Lithium soap base glycol grease
26 (265, 19)
37 (375, 27)
13 (130, 9)
13 (130, 9)
20 (204, 15)
32-10
- BRAKEBRAKE PEDAL SUPPORT ASSY
2444 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COMPONENTS
Page 257 of 969
320OF-03
F42717
Stop Lamp
Switch Assy
Push Rod
Pedal Height
32-12- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
2446 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)
ADJUSTMENT
1. CHECK AND ADJUST BRAKE PEDAL HEIGHT
(a) Inspect brake pedal height.
Pedal height from asphalt sheet:
144.1 - 154.1 mm (5.673 - 6.067 in.)
(b) Adjust brake pedal height.
(1) Remove the instrument panel finish panel sub-
assy lower and instrument panel insert sub-assy
lower LH.
(2) Disconnect the connector from the stop lamp switch
assy.
(3) Loosen the stop lamp switch lock nut and remove
the stop lamp switch assy.
(4) Loosen the clevis lock nut.
(5) Adjust the pedal height by turning the pedal push
rod.
(6) Tighten the push rod lock nut.
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
(7) Install the stop lamp switch assy.
(8) Connect the connector to the stop lamp switch assy.
(9) Push the brake pedal in 5 - 10 mm (0.20 - 0.39 in.),
turn the stop lamp switch assy to lock the nut in the
position where the stop lamp goes off.
(10) After installation, push the brake pedal in 5 - 10 mm
(0.20 - 0.39 in.), check that stop lamp lights up.
(11) Install the instrument panel insert sub-assy lower
LH and instrument panel finish panel sub-assy low-
er.