atf LEXUS ES300 2005 Repair Manual
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 63 of 969
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
Page 72 of 969
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
Page 92 of 969
C91925
C86316
Magnet
AT0103
Magnet
C91927
Temperature
Sensor
D03547
Transmission Wire
40-20
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
44 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
9. REMOVE AUTOMATIC TRANSAXLE OIL PAN
SUB-ASSY
(a) Remove the 18 bolts, oil pan and gasket.
(b) Remove the 2 magnets from the oil pan.
10. INSPECT TRANSMISSION OIL CLEANER MAGNET
(a) Remove the magnets and use them to collect any steel
chips. Examine the chips and particles in the pan and on
the magnet to determine what type of wear has occurred
in the transaxle:
Steel (magnetic).... bearing, gear and plate wear
Brass (non-magnetic).... bushing wear
11. DISCONNECT TRANSMISSION WIRE
(a) Remove the 7 connectors from the shift solenoid valves.
(b) Remove the bolt, lock plate and ATF temperature sensor.
12. REMOVE TRANSMISSION WIRE
(a) Remove the bolt and transmission wire from the transaxle
case.
Page 94 of 969
C83129
D03554
Check Ball
D03555
D03556
D03902
O-ring
C-3 Accumulator Piston 40-22
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
46 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
17. REMOVE BRAKE DRUM GASKET
(a) Remove the brake drum gasket from the transaxle case.
18. REMOVE CHECK BALL BODY
(a) Remove the check ball body and spring from the trans-
axle case.
19. REMOVE C-3 ACCUMULATOR PISTON
(a) Remove the spring from the C-3 accumulator piston.
(b) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil hole and remove the C-3 accumulator piston.
NOTICE:
Blowing off the air may cause the piston to jump-out.
When removing the piston, hold it by your hand using
a waste cloth.
Take care not to splash ATF when air-blowing.
(c) Remove the O-ring from the C-3 accumulator piston.
Page 95 of 969
D26401
D26402
O-ring
O-ring Reverse clutch Accumulator Piston
D03558
D03904
O-ring
B-3 Accumulator Piston
D03559
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40-23
47 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
20. REMOVE REVERSE CLUTCH ACCUMULATOR
PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil hole and remove the reverse accumulator piston and
spring.
NOTICE:
Blowing off the air may cause the piston to jump-out.
When removing the piston, hold it by your hand using
a waste cloth.
Take care not to splash ATF when air-blowing.
(b) Remove the 2 O-rings from the reverse clutch accumula-
tor piston.
21. REMOVE B-3 ACCUMULATOR PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil hole and remove the B-3 accumulator piston and 2
springs.
NOTICE:
Blowing off the air may cause the piston to jump-out.
When removing the piston, hold it by your hand using
a waste cloth.
Take care not to splash ATF when air-blowing.
(b) Remove the O-ring from the B-3 accumulator piston.
22. REMOVE MANUAL VALVE LEVER SHAFT RETAINER
SPRING
(a) Using a needle-nose pliers, remove the manual valve le-
ver shaft retainer spring.
Page 102 of 969
D03907
Outer Race
Retainer
D26466
Snap
Ring
D26385
Flange
D09196
D26387
40-30
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
54 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Remove the outer race retainer from the 1-way clutch.
43. REMOVE UNDERDRIVE CLUTCH DISC NO.2
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 4 discs and 4 plates from the trans-
axle case.
44. INSPECT UNDERDRIVE CLUTCH DISC NO.2
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
If the lining of the disc comes off or discolors, or even
if a part of the groove is defaced, replace all discs.
Before assembling new discs, soak them in ATF for
at least 15 minutes.
45. REMOVE TRANSAXLE REAR COVER SUB-ASSY
(a) Remove the 11 bolts.
(b) Tap in the circumference of the rear cover with a plastic
hammer to remove the transaxle rear cover from the
transaxle case.
Page 106 of 969
D26394
Planetary Carrier
Thrust Washer No.1
D26395
Snap Ring
D26717
D08058
Snap Ring
D26396
Second Brake
Piston Assy
40-34
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
58 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
57. REMOVE PLANETARY CARRIER THRUST WASHER
NO.1
(a) Remove the planetary carrier thrust washer No.1 from the
planetary gear assy.
58. REMOVE 2ND BRAKE CLUTCH DISC
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 4 discs and 4 plates from the trans-
axle case.
59. INSPECT 2ND BRAKE CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
If the lining of the disc comes off or discolors, or even
if a part of the groove is defaced, replace all discs.
Before assembling new discs, soak them in ATF for
at least 15 minutes.
60. REMOVE SECOND BRAKE PISTON ASSY
(a) Using a screwdriver, remove the snap ring.
(b) Remove the second brake piston assy from the transaxle
case.
Page 107 of 969
D03616
Snap Ring
D26591
Rear Planetary
Gear Assy
D03873
Thrust Bearing
Race No.2
Thrust Needle Roller BearingInput
Sun
Gear
D26397
D09189
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40-35
59 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
61. REMOVE REAR PLANETARY GEAR ASSY
(a) Using a screwdriver, remove the snap ring.
(b) Remove the rear planetary gear assy from the transaxle
case.
62. REMOVE INPUT SUN GEAR
(a) Remove the 2 thrust needle roller bearings, thrust bearing
race No.2 and input sun gear from the transaxle case.
63. REMOVE 1ST & REVERSE BRAKE CLUTCH DISC
(a) Remove the flange, 6 discs and 6 plates from the trans-
axle case.
64. INSPECT 1ST & REVERSE BRAKE CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
If the lining of the disc comes off or discolors, or even
if a part of the groove is defaced, replace all discs.
Before assembling new discs, soak them in ATF for
at least 15 minutes.
Page 109 of 969
D03600
SST
C89128
D26405
1st & Reverse Brake Piston
D26713
O-ringO-ring
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40-37
61 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
67. REMOVE 1ST & REVERSE BRAKE RETURN SPRING
SUB-ASSY
(a) Place SST on the return spring, and compress the return
spring with a press.
SST 09387-00070
(b) Using a snap ring expander, remove the snap ring.
NOTICE:
Stop the press when the spring sheet is lowered 1 -
2 mm (0.039 - 0.078 in.) from the snap ring groove, to
prevent the spring sheet from deforming.
Do not expand the snap ring excessively.
68. INSPECT 1ST & REVERSE BRAKE RETURN SPRING
SUB-ASSY
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 17.61 mm (0.6933 in.)
69. REMOVE 1ST & REVERSE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
transaxle case to remove 1st & reverse brake piston.
NOTICE:
Blowing off the air may cause the piston to jump-out.
When removing the piston, hold it by your hand using
a waste cloth.
Take care not to splash ATF when air-blowing.
(b) Remove the 2 O-rings from the 1st & reverse brake pis-
ton.
Page 116 of 969
D26400
Transaxle Apply
Tube Clamp
Differential Gear Lube Apply Tube
D26383
Underdrive
Output Shaft
Oil Seal Ring
D03915
AT F
D03807
SST
D03914
Underdrive
Clutch Drum
Oil Seal Ring
AT F 40-44
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
68 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
83. INSTALL DIFFERENTIAL GEAR LUBE APPLY TUBE
(a) Install the differential gear lube apply tube and transaxle
apply tube clamp with the bolt to the transaxle housing.
Torque: 9.8 NVm (100 kgfVcm, 87 in.Vlbf)
NOTICE:
Make sure to insert the pipe to the stopper.
84. INSTALL TRANSAXLE CASE NO.1 PLUG
(a) Install the 2 new O-rings to the 2 transaxle case No.1
plugs.
(b) Install the 2 transaxle case No.1 plugs to the transaxle
rear cover.
Torque: 7.4 NVm (75 kgfVcm, 65 in.Vlbf)
85. INSTALL UNDERDRIVE OUTPUT SHAFT OIL SEAL
RING
(a) Coat the new oil seal ring with ATF and install it to the
transaxle housing.
86. INSTALL UNDERDRIVE CYLINDRICAL ROLLER
BEARING
(a) Coat the underdrive cylindrical roller bearing with ATF.
(b) Using SST and a press, install the underdrive cylindrical
roller bearing.
SST 09950- 60020 (09951- 00810), 09950- 70010
(09951-07100)
NOTICE:
Do not apply excessive pressure to it.
87. INSTALL UNDERDRIVE CLUTCH DRUM OIL SEAL
RING
(a) Coat the 2 new oil seal rings with ATF, install them to the
transaxle rear cover.
NOTICE:
Do not expand the gap of the oil seal ring too much.
Fix the hooks certainly. Confirm the smooth rotation.