automatic transmission LEXUS ES300 2005 Repair Manual

01-8- INTRODUCTIONTERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
8 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U) ISC
Idle Speed Control-
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure-
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Light
MSTManifold Surface temperature-
MVZManifold Vacuum Zone-
NVRAMNon-V olatile Random Access Memory-
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn-Board DiagnosticOn-Board Diagnostic (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Converter (OC), CC0
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module-
PNPPark/Neutral Position-
PROMProgrammable Read Only Memory-
PSPPower Steering Pressure-
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module-
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger Bypass-
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter-
SRIService Reminder Indicator-
SRTSystem Readiness Test-
STScan Tool-
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter
TCMTransmission Control ModuleTransmission ECU (Electronic Control Unit)
TPThrottle PositionThrottle Position
TRTransmission Range-
TVVThermal Vacuum ValveBimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
TWCThree-W ay Catalytic ConverterThree-W ay Catalytic (TWC)
CC
RO
TWC+OCThree-W ay + Oxidation Catalytic ConverterCCR + CCO
VA FVolume Air FlowAir Flow Meter
VRVoltage RegulatorVoltage Regulator
VSSVehicle Speed SensorVehicle Speed Sensor (Read Switch Type)
WOTWide Open ThrottleFull Throttle

022FX-01
- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02-1
10 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
AUTOMATIC TRANSMISSION / TRANS
PREPARATION
SST
09214-7601 1Crankshaft Pulley ReplacerFRONT DIFFERENTIAL
ASSY(U151F)
09215-00013Crankshaft Bearing Remover &
Replacer Set BFRONT DIFFERENTIAL
ASSY(U151E)
(09215-00471)Camshaft Bearing Remover &
ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
09223-15020Oil Seal & Bearing ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)
09223-15030Oil Seal & Bearing ReplacerAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09308-00010Oil Seal PullerFRONT DIFFERENTIAL
ASSY(U151E)
OIL PUMP ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09316-12010Transfer Bearing ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
09316-2001 1Transfer Bearing ReplacerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09350-32014TOYOTA Automatic Transmission
Tool SetOIL PUMP ASSY(U151E/U151F)
UNDERDRIVE CLUTCH
ASSY(U151E/U151F)
(09351-32070)No.2 Piston Spring CompressorUNDERDRIVE CLUTCH
ASSY(U151E/U151F)
(09351-32140)Oil Seal ReplacerOIL PUMP ASSY(U151E/U151F)
09387-00020Direct Clutch WrenchAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FORWARD CLUTCH
ASSY(U151E/U151F)
DIRECT CLUTCH
ASSY(U151E/U151F)

02-2
- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
11 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
09387-00030Counter Drive Gear Holding ToolAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09387-00041Bearing Puller AssemblyAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01010)Claw No.1AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01021)Claw No.2AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01030)PinAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01040)Bearing Puller BodyAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09387-00050Under Drive Gear PullerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09387-00060Second Brake WrenchSECOND BRAKE PISTON
ASSY(U151E/U151F)
09387-00070First & Reverse Brake WrenchAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09387-00080Counter Drive Gear Nut WrenchAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09502-12010Differential Bearing ReplacerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09506-35010Differential Drive Pinion Rear
Bearing ReplacerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09514-3501 1Rear Wheel Bearing PullerAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)

- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02-3
12 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
09527-1701 1Rear Axle Shaft Bearing RemoverAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09550-60010Differential Side Bearing
ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
(09951-00490)Replacer 49FRONT DIFFERENTIAL
ASSY(U151E)
09564-3201 1Differential Preload AdaptorFRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)
09608-10010Steering Knuckle Oil Seal
ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
FRONT DIFFERENTIAL
ASSY(U151F)
09649-17010Steering Knuckle ToolAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09710-30050Suspension Arm Bushing ReplacerFRONT DIFFERENTIAL
ASSY(U151E)
09726-40010Lower Control Shaft Bearing
ReplacerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09930-00010Drive Shaft Nut ChiselUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
(09931-00010)HandleUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
(09931-00020)Nut ChiselUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09950-00020Bearing RemoverFRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

02-4
- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
13 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
09950-00030Bearing Remover AttachmentFRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09950-4001 1Puller B SetFRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
(09957-04010)AttachmentFRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09950-60010Replacer SetFRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
(09951-00230)Replacer 23AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09951-00260)Replacer 26UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
(09951-00320)Replacer 32AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
(09951-00450)Replacer 45AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09951-00480)Replacer 48FRONT DIFFERENTIAL
ASSY(U151F)
(09951-00490)Replacer 49FRONT DIFFERENTIAL
ASSY(U151E)
(09951-00500)Replacer 50AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)

- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02-5
14 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(09951-00590)Replacer 59AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09951-00600)Replacer 60FRONT DIFFERENTIAL
ASSY(U151F)
(09952-06010)AdapterAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09950-60020Replacer Set No.2FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
(09951-00730)Replacer 73FRONT DIFFERENTIAL
ASSY(U151F)
(09951-00750)Replacer 75AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09951-00810)Replacer 81AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09951-00890)Replacer 89FRONT DIFFERENTIAL
ASSY(U151E)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
(09951-00910)Replacer 91FRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09951-01030)Replacer 103AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)
09950-70010Handle SetFRONT DIFFERENTIAL
ASSY(U151E)
AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
UNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
FRONT DIFFERENTIAL
ASSY(U151F)

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

- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
02-7
16 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
SSM (Special Service Materials)
08826-00090Seal Packing 1281,
THREE BOND 1281 or equivalent
(FIPG)
08833-00080Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalent

0305K-1 1
03-4
- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
20 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
AUTOMATIC TRANSMISSION / TRANSAXLE
SERVICE DATA
Oil pump
Body clearance STD
Max.0.10 - 0.17 mm (0.0039 - 0.0067 in.)
0.17 mm (0.0067 in.)
Tip clearance STD
Max.0.07 - 0.15 mm (0.0028 - 0.0059 in.)
0.15 mm (0.0059 in.)
Side clearance STD
Max.0.02 - 0.05 mm (0.0008 - 0.0020 in.)
0.05 mm (0.0020 in.)
Drive gear thickness Mark
A
B
C
D
E
11.690 - 11.699 mm (0.4602 - 0.4606 in.)
11.700 - 11.709 mm (0.4606 - 0.4610 in.)
11.710 - 11.720 mm (0.4610 - 0.4614 in.)
11.721 - 11.730 mm (0.4615 - 0.4618 in.)
11.731 - 11.740 mm (0.4619 - 0.4622 in.)
Driven gear thickness Mark
A
B
C
D
E
11.690 - 11.699 mm (0.4602 - 0.4606 in.)
11.700 - 11.709 mm (0.4606 - 0.4610 in.)
11.710 - 11.720 mm (0.4610 - 0.4614 in.)
11.721 - 11.730 mm (0.4615 - 0.4618 in.)
11.731 - 11.740 mm (0.4619 - 0.4622 in.)
Pump body bushing inside diameter STD
Max.38.113 - 38.138 mm (1.50050 - 1.50149 in.)
38.188 mm (1.50346 in.)
Stator shaft bushing inside diameter STD
Max.21.500 - 21.526 mm (0.84646 - 0.84748 in.)
21.57 mm (0.8492 in.)
Multiple disc clutch
Inside diameter STD
Max.23.025 - 23.045 mm (0.9065 - 0.9073 in.)
23.09 mm (0.9091 in.)
Forward clutch
Pack clearance1.00 - 1.25 mm (0.0394 - 0.4921 in.)
Return spring free length26.74 mm (1.0528 in.)
Flange thickness Mark
1
2
3
4
5
3.00 mm (0.1181 in.)
3.15 mm (0.1240 in.)
3.30 mm (0.1299 in.)
3.45 mm (0.1358 in.)
3.60 mm (0.1417 in.)
Reverse clutch
Pack clearance:0.60 - 0.82 mm (0.02362 - 0.03228 in.)
Flange thickness Mark
1
2
3
4
5
6
7
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)
3.2 mm (0.126 in.)
3.3 mm (0.130 in.)
3.4 mm (0.134 in.)
3.5 mm (0.138 in.)
3.6 mm (0.142 in.)

- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
03-5
21 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U) Direct clutch & O/D clutch
Pack clearance0.61 - 0.83 mm (0.02401 - 0.03268 in.)
Return spring free length25.91 mm (1.0201 in.)
Flange thickness Mark
0
1
2
3
4
5
6
2.5 mm (0.098 in.)
2.6 mm (0.102 in.)
2.7 mm (0.106 in.)
2.8 mm (0.110 in.)
2.9 mm (0.114 in.)
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)
2nd brake
Pack clearance0.62 - 0.91 mm (0.0244 - 0.0358 in.)
Return spring free length16.61 mm (0.6539 in.)
Flange thickness Mark
1
2
3
4
5
6
73.0 mm (0.118 in.)
3.1 mm (0.122 in.)
3.2 mm (0.126 in.)
3.3 mm (0.130 in.)
3.4 mm (0.134 in.)
3.5 mm (0.138 in.)
3.6 mm (0.142 in.)
U/D clutch
Pack clearance1.51 - 1.71 mm (0.0594 - 0.0673 in.)
U/D clutch drum bushing inside diameter STD
Max.37.06 - 37.08 mm (1.4591 - 1.4598 in.)
37.13 mm (1.4618 in.)
Return spring free length17.14 mm (0.6752 in.)
Flange thickness Mark
1
2
3
4
5
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)
3.2 mm (0.126 in.)
3.3 mm (0.130 in.)
3.4 mm (0.134 in.)
U/D brake
Pack clearance1.81 - 2.20 mm (0.0713 - 0.0866 in.)
Return spring free length14.04 mm (0.5528 in.)
Flange thickness Mark
1
2
3
3.0 mm (0.118 in.)
3.2 mm (0.126 in.)
3.4 mm (0.134 in.)
1st & reverse brake
Pack clearance1.16 - 1.35 mm (0.0457 - 0.0531in.)
Return spring free length15.53 mm (0.6114 in.)
Flange thickness Mark
1
2
3
4
5
6
7
8
1.8 mm (0.071 in.)
1.9 mm (0.075 in.)
2.0 mm (0.079 in.)
2.1 mm (0.083 in.)
2.2 mm (0.087 in.)
2.3 mm (0.091 in.)
2.4 mm (0.094 in.)
2.5 mm (0.098 in.)