torque 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 139 of 969
D03561
D03560
B
A
D03904
O-ring
B-3 Accumulator Piston
D25512
AT F
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
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
40-70
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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.
Page 143 of 969
C91931
Valve Body Oil
Strainer Assy.
C86316
Magnet
C91925
D26716
D03900D30672
Speed Sensor
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(b) Install the oil strainer and 3 bolts to the valve body.
Torque: 11 NVm (110 kgfVcm, 8 ftVlbf)
NOTICE:
Apply ATF to the bolts.
151. 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 or equivalent to new 18 bolts.
Seal packing:
THREE BOND 2430 or equivalent
(c) Install the new oil pan gasket with the 18 bolts to the trans-
axle case.
Torque: 7.8 NVm (80 kgfVcm, 69 in.Vlbf)
NOTICE:
Because the bolts should be seal bolts, apply seal
packing to new bolts and tighten them within 10 min-
utes after application.
Remove any oil or grease from the contacting surface
of the transaxle case and the oil pan with the gasket
completely before the oil pan to the case.
152. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Coat the 4 new O-rings with ATF, install them to the 4
transaxle case No. 1 plugs.
(b) Install the 4 transaxle case No. 1 plugs to the transaxle
case.
Torque: 7.4 NVm (75 kgfVcm, 65 in.Vlbf)
153. INSTALL SPEED SENSOR
(a) Install them to the 2 sensors.
(b) Install the 2 sensors to the transaxle case with the 2 bolts.
Torque: 11.0 NVm (115 kgfVcm, 8 ftVlbf)
Page 144 of 969
C83144
Elbow
O-ring
C83143
Union
O-ring
D09639
D09640Control Shaft Lever
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154. INSTALL OIL COOLER TUBE UNION (OUTLET OIL
COOLER UNION)
(a) Coat a new O-ring with ATF, install it to the elbow.
(b) Install the elbow to the transaxle case.
Torque: 27 NVm (276 kgfVcm, 20 ftVlbf)
155. INS TALL OIL CO O LE R TUBE UNIO N (INLE T OIL
COOLER UNION)
(a) Coat a new O-ring with ATF, install it to the union.
(b) Install the union to the transaxle case.
Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)
156. INSTALL BREATHER PLUG HOSE
(a) Install the breather plug hose into the transaxle case certainly.
157. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY
(a) Install the park/neutral position switch onto the manual
valve lever shaft and temporarily install the 2 adjusting
bolts.
(b) Install a new nut stopper and nut.
Torque: 6.9 NVm (70 kgfVcm, 61 in.Vlbf)
(c) Temporarily install control shaft lever.
Page 145 of 969
D09641
D09642
D09643
D09644
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(d) Turn the lever counterclockwise until it stops, and then
turn it clockwise 2 notches.
(e) Remove the control shaft lever.
(f) Align the groove with neutral basic line.
(g) Tighten the 2 bolts.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(h) Using a screwdriver, stake the nut with the nut stopper.
(i) Install the control shaft lever, washer and nut.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
158. INSTALL SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSY
(a) Coat a new O-ring with ATF and install it to the speedometer driven hole cover.
(b) Install the bolt and speedometer driven hole cover sub-assy to the transaxle assy.
Torque: 6.9 NVm (70 kgfVcm, 61 ftVlbf)
Page 149 of 969
C55817
O-ring
D09206
MarkOil Pump
Driven
Gear
D09206
Mark
Oil
Pump
Drive
Gear
D03651
D26627
Clutch Drum
Oil Seal Ring
- AUTOMATIC TRANSMISSION / TRANSOIL PUMP ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
12. INSTALL FRONT OIL PUMP BODY O-RING
(a) Coat the new O-ring with ATF, install it to the oil pump
body.
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.
13. INSTALL FRONT OIL PUMP DRIVEN GEAR
(a) Coat the front oil pump driven gear with ATF, install it to
the oil pump body with the marked side up.
14. INSTALL FRONT OIL PUMP DRIVE GEAR
(a) Coat the front oil pump drive gear with ATF, install it to the
oil pump body with the marked side up.
15. INSTALL STATOR SHAFT ASSY
(a) Set the stator shaft aligned with each bolt hole.
(b) Using a torx socket (T30), install the 11 bolts.
Torque: 9.8 NVm (100 kgfVcm, 87 in.Vlbf)
16. INSTALL CLUTCH DRUM OIL SEAL RING
(a) Coat the 2 new clutch drum oil seal rings with ATF.
(b) Install the 2 new clutch drum oil seal rings.
NOTICE:
Do not expand the ring ends excessively.
Page 171 of 969
4006K-03
D25593
SST Underdrive
Planetary Gear
D25594
SST
D03686
SST
D03687
Underdrive
Planetary Gear
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE PLANETARY GEAR
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
UNDERDRIVE PLANETARY GEAR ASSY (U151E/U151F)
OVERHAUL
1. INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a) Using SST, fix the underdrive planetary gear assy.
SST 09387-00050
(b) Using SST and a torque wrench, measure the turning
torque of underdrive planetary gear assy while rotating
the torque wrench at 60 rpm.
SST 09387-00050
Turning torque at 60 rpm.:
0.50 - 1.42 NVm (5.1 - 14.5 kgfVcm, 0.06 - 0.17 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
2. REMOVE FRONT PLANETARY GEAR NUT
(a) Using SST, loosen the staked part of the lock nut.
SST 09930- 00010 (09931- 00010, 09931- 00020),
09387-00050
(b) Clamp the underdrive planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
Page 175 of 969
D26434
SST
Differential
Drive Pinion
D26432
SST
D25609
Underdrive
Planetary Gear
D25594
SST Underdrive
Planetary Gear
C56809
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ASSY (U151E/U151F)40-103
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8. INSTALL DIFFERENTIAL DRIVE PINION
(a) Using a press, press the differential drive pinion.
SST 09726- 40010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100)
NOTICE:
Press the counter driven gear while rotating it.
9. INSTALL CYLINDRICAL ROLLER BEARING RACE
INNER
(a) Using a press, press the cylindrical roller bearing race in-
ner.
SST 09506- 35010, 09950- 60010 (09951- 00260),
09950-70010 (09951-07100)
NOTICE:
Press the counter driven gear while rotating it.
10. INSTALL FRONT PLANETARY GEAR NUT
(a) Clamp the underdrive planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
(b) Using a socket wrench, install a new lock nut.
Torque: 280 NVm (2,855 kgfVcm, 207 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 750 mm (29.53
in.).
11. INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a) Using SST and a torque wrench, measure the turning
torque of underdrive planetary gear assy while rotating
the torque wrench at 60 rpm.
SST 09387-00050
Turning torque at 60 rpm.:
0.5 - 1.42 NVm (5.1 - 14.5 kgfVcm, 0.06 - 0.17 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).
(b) Using a pin punch and hammer, stake the lock nut.
NOTICE:
Make sure that there are no cracks on the nut.
Page 177 of 969
C89113
C89115
C89115
C89112
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6. REMOVE SHIFT SOLENOID VALVE SL2
(a) Remove the bolt and shift solenoid valve SL2 from the
valve body assy.
7. REMOVE SHIFT SOLENOID VALVE SL1
(a) Remove the bolt and shift solenoid valve SL1 from the
valve body assy.
8. REMOVE MANUAL VALVE
(a) Remove the manual valve from the valve body assy.
9. INSTALL MANUAL VALVE
(a) Install the manual valve to the valve body assy.
10. INSTALL SHIFT SOLENOID VALVE SL1
(a) Install the shift solenoid valve SL1 to the valve body assy
with the bolt.
Torque: 6.6 NVm (67 kgfVcm, 58 in.Vlbf)
11. INSTALL LINE PRESSURE CONTROL SOLENOID
ASSY
(a) Install the shift solenoid valve SLT to the valve body assy
with the bolt.
Torque: 6.6 NVm (67 kgfVcm, 58 in.Vlbf)
12. INSTALL SHIFT SOLENOID VALVE SL3
(a) Install the shift solenoid valve SL3 to the valve body assy
with the bolt.
Torque: 6.6 NVm (67 kgfVcm, 58 in.Vlbf)
Page 178 of 969
C89113
D26443
D26438
D26442
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13. INSTALL SHIFT SOLENOID VALVE SL2
(a) Install the shift solenoid valve SL2 to the valve body assy
with the bolt.
Torque: 10.8 NVm (110 kgfVcm, 8 ftVlbf)
14. INSTALL SHIFT SOLENOID VALVE DSL
(a) Install the shift solenoid valve DSL to the valve body assy
with the bolt.
Torque: 10.8 NVm (110 kgfVcm, 8 ftVlbf)
15. INSTALL SHIFT SOLENOID VALVE SR
(a) Install the shift solenoid valve SR to the valve body assy.
16. INSTALL SHIFT SOLENOID VALVE S4
(a) Install the shift solenoid valve S4 to the valve body assy
with the bolt.
Torque: 10.8 NVm (110 kgfVcm, 8 ftVlbf)