length 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 53 of 969
L1 L2L1 L2
D02612
L2 L1L2 L1
D01201
L2 L1L2 L1
D01202
- INTRODUCTIONREPAIR INSTRUCTION FOR AUTOMATIC
TRANSAXLE REPAIR MANUAL01-5
5 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) TORQUE WHEN USING EXTENSION TOOL WITH
TORQUE WRENCH
(1) In case of tightening by extending the entire length
of the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the read-
ing of the torque wrench by the formula.
(3) Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench {NVm (kgfVcm, ftVlbf)}
TTorque {NVm (kgfVcm, ftVlbf)}
L1Length of SST or tool (cm)
L2Length of torque wrench (cm)
Page 68 of 969
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.)
Page 69 of 969
- 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.)
Page 70 of 969
03-6
- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
22 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U) U/D planetary gear
Preload (at 60 rpm)0.50 - 1.42 NVm (5.1 - 14.5 kgfVcm, 0.06 - 0.17 in.Vlbf)
Front planetary gear
Turning torque (at 60 rpm) New Bearing
Used Bearing0.51 - 1.02 NVm (5.1 - 10.0 kgfVcm, 4.4 - 8.7 in.Vlbf)
0.26 - 0.51 NVm (2.7 - 5.2 kgfVcm, 2.3 - 4.5 in.Vlbf)
Input shaft
End play0.262 - 1.249 mm (0.0103 - 0.0492 in.)
Transaxle rear cover
Bearing press fit depth20.55 - 21.25 mm (0.8091 - 0.8366 in.)
Transmission valve body
Valve body installation bolt length A
B
C41 mm (1.614 in.)
57 mm (2.244 in.)
25 mm (0.984 in.)
Accumulator
SpringFree length/Outer diameterColor
B3Inner
Outer62.00 (2.4409) / 15.50 (0.610)
74.23 (2.9224) / 16.50 (0.649)Purple
Purple
C260.96 (2.3999) / 14.10 (0.555)Yellow
C372.20 (2.8425) / 19.0 (0.748)Colorless
Front differential(U151E)
Backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thrust washer thickness Mark
-
-
-
1.625 mm (0.0640 in.)
1.725 mm (0.0679 in.)
1.825 mm (0.0719 in.)
Praload (at 60 rpm) New bearing
Used bearing0.20 - 0.69 NVm (2.0 - 7.0 kgfVcm, 1.8 - 6.1 in.Vlbf)
0.10 - 0.35 NVm (1.0 - 3.6 kgfVcm, 0.9 - 3.1 in.Vlbf)
Flange thickness Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.)
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)
Front differential (U151F)
Side gear backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)
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 111 of 969
D26407
SST
Snap Ring
D03806D30852
Underdrive
Brake Return
Spring
D26406
Underdrive Brake Piston
D03794
O-ringO-ring
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40-39
63 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
72. REMOVE BREATHER PLUG NO.2 (ATM)
73. REMOVE UNDERDRIVE BRAKE RETURN SPRING
SUB-ASSY
(a) Place SST on the return spring, and compress the return
spring with a press.
SST 09387-00020
(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.
74. INSPECT UNDERDRIVE 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: 13.24 mm (0.5213 in.)
75. REMOVE UNDERDRIVE BRAKE PISTON
(a) Apply compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
transaxle case to remove the underdrive brake piston.
(b) Remove the 2 O-rings from the underdrive brake piston.
Page 122 of 969
D03918
SST
D08074
Lock Washer
C89123
C
BA
Input Sun Gear
D
40-50
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
74 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(e) Using SST and a torque wrench, measure the turning
torque of the bearing while rotating SST at 60 rpm. When
the measured value is not within the specified value,
gradually tighten the nut until it reaches the specified val-
ue.
SST 09387-00080
Turning torque at 60 rpm:
New Bearing
0.51 - 1.02 NVm (5.1 - 10.0 kgfVcm, 4.4 - 8.7 in.Vlbf)
Used Bearing
0.26 - 0.51 NVm (2.7 - 5.2 kgfVcm, 2.3 - 4.5 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
(f) Tighten the nut gradually until the specified rotation
torque of tapered roller bearing is measured.
Torque: 350 NVm (3,569 kgfVcm, 258 ftVlbf) (a limit)
(g) Using a chisel and hammer, stake the front lock washer.
98. INSTALL INPUT SUN GEAR
(a) Coat the 2 thrust bearings with ATF.
(b) Install the 2 thrust bearings, the bearing race and the front
planetary sun gear to the front planetary gear assy.
NOTICE:
Install the bearing race on the side of the front plane-
tary carrier. Be careful about the orientation of the
race.
Installing thrust bearing and front sun gears, be care-
ful about the orientation of the parts.
Install the bearing race on the side of the front sun
gear. Be careful about the orientation of the race.
Install the thrust bearing and the race after holding
the parts on the rear planetary carrier by applying
grease. Be sure the assembling order.
Page 137 of 969
D25608
C
C
CAB2WD:
4WD:
B
D
C CC
CB
B
A
A
D08091
D03631
D26468
SST
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40-65
89 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Install the transaxle housing and 16 bolts to the transaxle
case.
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 bolt 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.)
NOTICE:
Because the bolt A is a seal bolt, apply the seal packing to
new bolts and tighten them within 10 minutes after applica-
tion.
132. INSPECT INPUT SHAFT ENDPLAY
(a) Using a dial indicator, measure the input shaft end play.
End play: 0.262 - 1.249 mm (0.0100 - 0.0494 in.)
133. FIX AUTOMATIC TRANSAXLE ASSY
(a) Fix the transaxle assy.
134. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Coat a new oil seal with MP grease.
(b) Install the oil seal to the transaxle case.
SST 09950- 60010 (09951- 00230), 09950- 70010
(09951-07100)
Oil seal drive in depth: 0 0.5 mm (0 0.0197 in.)
Page 139 of 969
D03561
D03560
B
A
D03904
O-ring
B-3 Accumulator Piston
D25512
AT F
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
40-67
91 Author: Date:
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 140 of 969
D26402
O-ring
O-ring Reverse clutch Accumulator Piston
C92978
AT F
D03902
O-ring
C-3 Accumulator Piston
C83146
D03555
40-68
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
92 Author: Date:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
141. I N S TA L L REVERSE CLUTCH ACCUMULATOR
PISTON
(a) Coat the 2 new O-rings with ATF, install them to the re-
verse accumulator 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
60.96 (2.3999) /
14.10 (0.555)Yellow
142. INSTALL C-3 ACCUMULATOR PISTON
(a) Coat a new O-ring with ATF, install it to the C-3 accumu-
lator 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
72.20 (2.8425) /
19.0 (0.748)Colorless
(c) Install the spring from the C-3 accumulator piston.
NOTICE:
Install the springs to each accumulator piston with check-
ing of the identification color or each spring.