atf LEXUS ES300 2005 Workshop Manual
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 213 of 969
D31340
D25420
C88135
D31339
Breather Hose
C88278
40-14
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E)
2529 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 NVm (80 kgfVcm, 69 in.Vlbf)
21. INSTALL ENGINE MOUNTING BRACKET FR
(a) Install the engine mounting bracket FR with the 3 bolts to
the automatic transaxle.
Torque: 64 NVm (653 kgfVcm, 47 ftVlbf)
22. INSTALL TRANSMISSION OIL FILLER TUBE
SUB-ASSY
(a) Coat a new O-ring with ATF, and install it to the oil filler
tube.
(b) Install the oil filler tube with the bolt to the automatic trans-
axle.
Torque: 5.5 NVm (56 kgfVcm, 49 in.Vlbf)
(c) Install the ATF level gauge.
(d) Connect the breather hose to the wire harness bracket.
23. INSTALL TRANSMISSION CONTROL CABLE
BRACKET NO.1
(a) Install the control cable bracket No.1 with the 2 bolts.
Torque: 12 NVm (122 kgfVcm, 9 ftVlbf)
24. INSTALL OIL COOLER INLET TUBE NO.1
(a) Temporarily install the oil cooler outlet tube No.1.
(b) Temporarily install the oil cooler inlet tube No.1.
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 218 of 969
40060-08
C90569
C90570
C90570
C90569
- AUTOMATIC TRANSMISSION / TRANSSPEED SENSOR
40-19
2534 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
SPEED SENSOR
REPLACEMENT
1. REMOVE BATTERY
2. REMOVE AIR CLEANER ASSY
3. REMOVE AIR CLEANER HOSE NO.1
4. REMOVE SPEED SENSOR (NT SENSOR)
(a) Disconnect the speed sensor connector.
(b) Remove the bolt and speed sensor.
5. REMOVE SPEED SENSOR (NC SENSOR)
(a) Disconnect the speed sensor connector.
(b) Remove the bolt and speed sensor.
6. INSTALL SPEED SENSOR (NC SENSOR)
(a) Coat O-ring with ATF.
(b) Install the speed sensor with the bolt.
Torque: 11.3 NVm (115 kgfVcm, 8 ftVlbf)
HINT:
Make sure of the manufacturer's name.
(c) Connect the speed sensor connector.
7. INSTALL SPEED SENSOR (NT SENSOR)
(a) Coat O-ring with ATF.
(b) Install the speed sensor with the bolt.
Torque: 11.3 NVm (115 kgfVcm, 8 ftVlbf)
HINT:
Make sure of the manufacturer's name.
(c) Connect the speed sensor connector.
Page 220 of 969
4010V-04
C91925
D30865
AT0103
C91927
- AUTOMATIC TRANSMISSION / TRANSTRANSMISSION WIRE (U151E)
40-21
2536 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
TRANSMISSION WIRE (U151E)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER NO.1
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket, and drain ATF.
(b) Install a new gasket and drain plug.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
3. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB-ASSY
(a) Remove the 18 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Remove all the pan
bolts, and carefully remove the oil pan assembly.
(b) Remove the 2 magnets from the oil pan.
(c) Examine particles in pan.
(1) Use the removed magnets to collect steel chips.
Look carefully at the chips and particles in the pan
and the magnet to anticipate the type of wear you
will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non-magnetic): bearing wear
4. DISCONNECT TRANSMISSION WIRE
(a) Disconnect the 7 shift solenoid valve connectors.
(b) Remove the bolt and lock plate, and disconnect the ATF
temperature sensor.
Page 221 of 969
D03547
D03547
C91927
D30865
C91925
40-22
- AUTOMATIC TRANSMISSION / TRANSTRANSMISSION WIRE (U151E)
2537 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
5. REMOVE TRANSMISSION WIRE
(a) Disconnect the transmission wire connectors.
(b) Remove the bolt and transmission wire.
6. INSTALL TRANSMISSION WIRE
(a) Coat a O-ring of the transmission wire connector with
AT F.
(b) Install the transmission wire with the bolt.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
7. 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 shift solenoid valve connectors.
8. 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 the 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.
Page 223 of 969
4010W-04
C91925
D30865
AT0103
C91927
40-24
- AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E)
2539 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
TRANSMISSION VALVE BODY ASSY (U151E)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER NO.1
2. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket, and drain ATF.
(b) Install a new gasket and drain plug.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
3. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB-ASSY
(a) Remove the 18 bolts, oil pan and gasket.
NOTICE:
Some fluid will remain in the oil pan. Remove all the pan
bolts, and carefully remove the oil pan assembly.
(b) Remove the 2 magnets from the oil pan.
(c) Examine particles in pan.
(1) Use the removed magnets to collect steel chips.
Look carefully at the chips and particles in the pan
and the magnet to anticipate the type of wear you
will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non-magnetic): bearing wear
4. DISCONNECT TRANSMISSION WIRE
(a) Disconnect the 7 shift solenoid valve connectors.
(b) Remove the bolt and lock plate, and disconnect the ATF
temperature sensor.
Page 226 of 969
C91933
A
B
CB
B
B
A
CCC
C
B
C91932
C91931
C91927
- AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E)
40-27
2542 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Align the groove of the manual valve with the pin of lever.
(d) Install the 17 bolts.
Torque: 11 NVm (110 kgfVcm, 8 ftVlbf)
NOTICE:
Push the valve body against the accumulator piston
spring and the check ball body to install it.
Temporarily tighten those bolts marked by in the il-
lustration first because they are positioning bolts.
Bolt length:
Bolt A: 25 mm (0.984 in.)
Bolt B: 57 mm (2.244 in.)
Bolt C: 41 mm (1.614 in.)
8. INSTALL VALVE BODY OIL STRAINER ASSY
(a) Coat a new O-ring with ATF.
(b) Install the O-ring to the oil strainer.
(c) Install the oil strainer with the 3 bolts.
Torque: 11 NVm (110 kgfVcm, 8 ftVlbf)
9. INSTALL TRANSMISSION WIRE
(a) Coat a O-ring 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 shift solenoid valve connectors.
Page 228 of 969
4010X-04
D25831
SST
D25832
SST
D25833
SST
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL OIL SEAL (U151E)
40-29
2544 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT DIFFERENTIAL OIL SEAL (U151E)
REPLACEMENT
1. REMOVE FRONT WHEELS
2. REMOVE ENGINE UNDER COVER NO.1
3. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket and drain ATF.
(b) Install a new gasket and drain plug.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
4. REMOVE FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-8)
5. REMOVE FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-8)
6. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09308-00010
7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09308-00010
8. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09316-6001 1 (09316-00011)
Oil seal drive in depth:
0 0.5 mm (0 0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
SST 09316-6001 1 (09316-00011)
Page 361 of 969
F07391
C91598
R00764
C83851
30-16
- DRIVE SHAFT / PROPELLER SHAFTFRONT DRIVE SHAFT (From July, 2003)
2419 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Claw Engagement type
(1) Using pliers, install the front axle inboard joint boot
LH clamp and front axle inboard joint boot LH No.2
clamp, as shown in the illustration.
35. INSPECT FRONT DRIVE SHAFT
NOTICE:
Move the drive shaft assy keeping it level.
(a) Check that there is no remarkable play in the radial direc-
tion of the outboard joint.
(b) Check that the inboard joint slides smoothly in the thrust
direction.
(c) Check that there is no remarkable play in the radial direc-
tion of the inboard joint.
(d) Check the boots for damage.
(e) Make sure that the 2 boots are on the shaft groove.
(f) Make sure that the 2 boots are not stretched or contracted
when the drive shaft is at standard length.
Drive shaft standard length: mm (in.)
LH576.9 2.0 (22.713 0.079)
RH896.4 2.0 (35.291 0.079)
36. INSTALL FRONT DRIVE SHAFT ASSY LH
(a) Install a new front drive shaft LH hole snap ring.
(b) Coat the spline of the inboard joint shaft assy with ATF.
(c) Align the shaft splines and install the drive shaft assy with
a brass bar and hammer.
NOTICE:
Set the snap ring with the opening side facing down-
ward.
Be careful not to damage the oil seal, boot and dust
cover.
Move the drive shaft assy while keeping it level.