torque LEXUS ES300 2005 Manual PDF
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 184 of 969
D26384
C
C
C
CAB
A
D25604
SST
40-1 12
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
136 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Clean the matching surfaces of the transaxle case and
transaxle housing.
(c) Install the transaxle housing to the transaxle case and
tighten them with the 16 bolts.
Torque:
Bolt A: 25 NVm (255 kgfVcm, 18 ftVlbf)
Bolt B: 33 NVm (337 kgfVcm, 24 ftVlbf)
Bolt C: 29 NVm (295 kgfVcm, 21 ftVlbf)
Bolt D: 22 NVm (226 kgfVcm, 16.0 ftVlbf)
HINT:
Apply seal packing or equivalent to the A and D.
Seal packing:
THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
Bolt D: 72 mm (2.835 in.)
HINT:
Usually, bolt A is a non-reusable bolt. In this case, however, it
can be used after cleaning it.
(d) Using SST, turn the differential assy right and left 2
or 3
times to settle the bearing.
SST 09564-3201 1
(e) Using SST and a torque wrench, measure the turning
torque of the differential.
SST 09564-3201 1
Turning torque at 60 rpm:
New bearing
0.20 - 0.69 NVm (2.0 - 7.0 kgfVcm, 1.8 - 6.1 in.Vlbf)
Used bearing
0.10 - 0.35 NVm (1.0 - 3.6 kgfVcm, 0.9 - 3.1 in.Vlbf)
HINT:
If the turning torque is not within the specified value, refer to the
table below to select a thrust washer which turning torque is
within the specified value.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)
Page 186 of 969
D26446
D26451
SST
D25606
SST
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- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
138 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Tighten the 14 bolts.
Torque: 95.0 NVm (970 kgfVcm, 70 ftVlbf)
NOTICE:
Tighten the bolts a little at a time in diagonal order.
17. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
(b) Apply the rip of oil seal with a little MP grease.
SST 09223-15020, 09950-70010 (09951-07150)
Oil seal drive in depth: 0 0.5 mm (0 0.0197 in.)
18. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, drive into a new oil seal.
(b) Apply the lip of the oil seal with a little MP grease.
SST 09710-30050, 09950-70010 (09951-07150)
Oil seal drive in depth: 0 0.5 mm (0 0.0197 in.)
Page 195 of 969
C51469
C50188
Differential
Case No.2
Differential
Case LH
C50193
D25612
SST
D25603
SST
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40-123
147 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(j) Install the selected differential side gear thrust washer
No. 2 LH and center differential planetary gear to the dif-
ferential case LH.
(k) Install the differential case No. 2 to the differential case LH
again.
(l) Install the adjusted differential case RH to the intermedi-
ate case and tighten the 15 bolts using a torx socket
wrench (T50).
Torque: 63 NVm (642 kgfVcm, 46 ftVlbf)
NOTICE:
Align the matchmarks.
10. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing FR to the differential case.
SST 09950-70010 (09951-07100), 09649-17010
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.
(b) Using SST, install the outer race of the tapered roller bear-
ing FR.
SST 09527-1701 1, 09950-60020 (09951-01030)
NOTICE:
Clearance is not allowed between the plate washer and
transaxle housing.
Page 196 of 969
D25613
SST
D25601
SST
C50224
D03568
C
C
C
A
AB
C
40-124
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
148 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
11. INSTALL FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
tapered roller bearing RR to the differential case.
SST 09316-2001 1, 09214-76011
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.
(b) Install the front differential case shim RR to the transaxle
case.
If the bearing is new, check to select a front differential case
shim RR of proper thickness starting from the thinner ones.
If the bearing is reused, check to select a front differential case
shim RR starting from the same thickness as one installed be-
fore disassembly.
(c) Using SST, install the outer race of the front differential
case tapered roller bearing RR.
SST 09950- 60020 (09951- 00890), 09950- 70010
(09951-07100)
NOTICE:
Clearance is not allowed between the differential case
shim and transaxle case.
12. ADJUST TAPERED POLLER BEARING PRELOAD
(a) Install the intermediate case to the differential case LH
and fix them with 4 bolts.
(b) Install the differential assy to the transaxle case.
(c) Clean the matching surfaces of the transaxle case and
transaxle housing.
(d) Install the transaxle housing to the transaxle case and
tighten them with the 16 bolts.
Torque:
Bolt A: 25 NVm (255 kgfVcm, 18 ftVlbf)
Bolt B 33 NVm (337 kgfVcm, 24 ftVlbf)
Bolt C 29 NVm (295 kgfVcm, 21 ftVlbf)
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
HINT:
Usually, bolt A is a non-reusable bolt. In this case, however, it
can be used after cleaning it.
Page 197 of 969
SST
C50227
D25614
C50224
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
40-125
149 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(e) Using SST, turn the differential assy right and left 2or 3
times to allow the bearing settle.
SST 09564-3201 1
(f) Using SST and a torque wrench, measure the turning
torque of the differential case assy.
SST 09564-3201 1
Turning torque at 60 rpm:
New bearing
0.20 - 0.69 NVm (2.0 - 7.0 kgfVcm, 1.8 - 6.1 in.Vlbf)
Used bearing
0.10 - 0.35 NVm (1.0 - 3.6 kgfVcm, 0.9 - 3.1 in.Vlbf)
HINT:
If the turning torque is not within the specified value, refer to the
table below and select a thrust washer which turning torque is
within the specified value.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
(g) Remove the 16 bolts and the transaxle housing.
(h) Remove the differential assy.
Page 198 of 969
D25215
90 - 100 C (194 - 230 F)
C50186
Match-marks
C50232
C50233
D25605
SST 40-126
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
150 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
13. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring gear
to 90 - 110 C. (194.0 - 230.0 F)
NOTICE:
Do not overheat the ring gear to 110 C (230.0 F) or more.
(b) Clean the contact surface of the front differential case.
(c) Set the match-marks, install the front differential ring gear
case quickly.
NOTICE:
Do not install the bolts while the ring gear is hot.
(d) Temporarily install the 8 bolts as shown in the illustration.
(e) Remove the 4 bolts shown in the illustration.
(f) Temporarily install the remaining 8 set bolts.
(g) Fully tighten the set bolts.
Torque: 95.1 NVm (970 kgfVcm, 70 ftVlbf)
NOTICE:
Tighten the bolts a little at a time in diagonal order.
14. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
SST 09223-15020, 09950-70010 (09951-07100)
(b) Coat the rip of oil seal with a little MP grease.
Page 203 of 969
C99457
C87814
C99454
C99454Manual Valve Shaft
C99455
40-4
- AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (U151E)
2519 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) Pry out the lock plate.
(d) Remove the lock nut and lock plate.
(e) Remove the 2 bolts and pull out the park/neutral position
switch.
10. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY
(a) Install the park/neutral position switch to the manual valve
shaft.
(b) Temporarily install the 2 bolts.
(c) Place the lock plate and tighten the nut.
Torque: 6.9 NVm (70 kgfVcm, 61 in.Vlbf)
(d) Temporarily install the control shaft lever.
(e) Turn the lever counterclockwise until it stops, then turn it
clockwise 2 notches.
(f) Remove the control shaft lever.
Page 204 of 969
C99456
Neutral
Basic
Line
Groove
C99457
C99458
D30614
D25415
- AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (U151E)
40-5
2520 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(g) Align the groove with neutral basic line.
(h) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(i) Using a screwdriver, stake the nut with the lock plate.
(j) Install the control shaft lever, washer and nut.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
(k) Connect the park/neutral position switch connector.
11. CONNECT TRANSMISSION CONTROL CABLE ASSY
(a) Temporarily install the control cable to the control shaft le-
ver with the nut.
(b) Install the control cable and a new clip to the bracket.
Page 206 of 969
4010P-03
C99453
Groove
Neutral
Basic Line
- AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (U151E)
40-7
2522 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ADJUSTMENT
1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSY
(a) Apply the parking brake and turn the ignition switch to ON.
(b) Depress the brake pedal and check that the engine starts only when the shift lever is set in N or P posi-
tion.
(c) Check that the back-up light is lit and the reverse warning buzzer sounds only when the shift lever is
set in R position.
If a failure is found, check the continuity of the park/neutral position switch.
2. ADJUST PARK/NEUTRAL POSITION SWITCH ASSY
(a) Loosen the 2 bolts of park/neutral position switch and set
the shift lever to the N position.
(b) Align the groove with neutral basic line.
(c) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(d) After adjustment, perform the inspection described in
step 1.
Page 207 of 969
4010Q-02
D31337
Bearing Bracket Hole Snap Ring
32 (326, 24)
12 (122, 9)
64 (653, 47)
46 (470, 34)
Front Drive Shaft Assy RH
Transmission Control
Cable Bracket No.2
41 (418, 30)
12 (122, 9)
37 (377, 27)
5.5 (56, 49 in.Vlbf)
9.8 (100, 87 in.Vlbf)
Wire Harness
Automatic
Transmission Case
Cover
Front Drive
ShaftLH Hole
Snap Ring
Front Drive Shaft
Assy LH
Starter Assy
O-ring
Transimission Oil
Filler Tube Sub-assy
ATF Level
Gauge Oil Cooler
Outlet Tube No.1 Oil Cooler Inlet
Tube No.1Oil Cooler Tube ClampTransmission Control
Cable Bracket No.1 Flywheel Housing
Under CoverTorque Converter ClutchEngine
Mounting
Bracket FR
X6
N´m (kgf´cm, ft´lbf): Specified torque
Non-reusable partWire Harness Clamp
12 (122, 9)
12 (122, 9)
34 (350, 25)
8.4 (86, 74 in.Vlbf)
64 (653, 47)
5.4 (55, 48 in.Vlbf)
7.8 (80, 69 in.Vlbf)
13 (130, 9)
Exhaust Pipe Support Bracket
37 (377, 27)
34 (350, 25)
x 5 40-8
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E)
2523 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
AUTOMATIC TRANSAXLE ASSY (U151E)
COMPONENTS