2005 LEXUS ES300 Repair Manual

D03707
 Oil Seal
Bearing Race
Differential RH Case
Center Differential
Side Gear Thrust
Washer No.1
Conical Spring
Center Differential
Side Gear
Center Differential
Pinion Spider
Center Differential
Pinion Thrust Washer
Center Differential Pinion
x16
Differential
Intermediate
Case63 (642, 46)
x15
Front Differential
Side Gear Thrust
Washer
Front Differential
Side Gear
Front Differential
Case No.2Pin
Front Differential
Pinion Shaft
Front Differential
Pinion Thrust Washer
Pinion Shaft
Spacer Snap
Ring
Front Differential
Pinion Shaft
 Oil Seal
Front Differential
Side Gear Thrust
Washer
Center Differential
Side Gear Thrust
Washer No.2
Differential Ring Gear
Front Differential
Side GearConical
Spring
N´m (kgf´cm, ft´lbf) : Specified torque
 Non-reusable part
Differential
LH Case
Tapered Roller Bearing
Bearing RacePlate Washer
Front Differential
Pinion Front Differential
Pinion Shaft Holder
U151F:
95.1 (970, 70)
Tapered Roller
Bearing
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)40-17
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U151E, U151F A/T REPAIR MANUAL (RM1021U)

4010K-01
D09644
Control Shaft Lever
D09643
Lock Nut
Nut Stopper
D09639
Park/neutral Position Switch
40-18
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
AUTOMATIC TRANSAXLE ASSY (U151E/U151F)
OVERHAUL
1. REMOVE SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSY
(a) Remove the bolt and speedometer driven hole cover sub-assy from the transaxle assy.
(b) Remove the O-ring from the speedometer driven hole cover.
2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSY
(a) Remove the nut, washer and control shaft lever.
(b) Using a screwdriver, unstake the nut stopper, and re-
move the lock nut and nut stopper.
(c) Remove the 2 bolts and pull out the park/neutral position
switch.
3. REMOVE BREATHER PLUG HOSE
(a) Remove the breather plug hose from the transaxle case.

C83143
Union
O-ring
C83144
Elbow
O-ring
D03900D30672
Speed Sensor
D26716
D09176
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
4. REMOVE OIL COOLER TUBE UNION (INLET OIL
COOLER UNION)
(a) Remove the union.
(b) Remove the O-ring from the union.
5. REMOVE OIL COOLER TUBE UNION (OUTLET OIL
COOLER UNION)
(a) Remove the elbow.
(b) Remove the O-ring from the elbow.
6. REMOVE SPEED SENSOR
(a) Remove the 2 bolts and the 2 speed sensors from the
transaxle assy.
7. REMOVE TRANSAXLE CASE NO.1 PLUG
(a) Remove the 4 transaxle case No. 1 plugs from the trans-
axle case.
(b) Remove the 4 O-rings from the 4 transaxle case No.1
plugs.
8. FIX AUTOMATIC TRANSAXLE ASSY
(a) Fix the transaxle assy.

C91925
C86316
Magnet
AT0103
Magnet
C91927
Temperature
Sensor
D03547
Transmission Wire
40-20
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
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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.

C91931
Valve Body Oil
Strainer Assy
C91932
O-ring
C91933
C83127
C83128
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
13. REMOVE VALVE BODY OIL STRAINER ASSY
(a) Remove the 3 bolts and oil strainer.
(b) Remove the O-ring from the oil strainer.
14. REMOVE TRANSMISSION VALVE BODY ASSY
(a) Support the valve body assy and remove the 17 bolts and
valve body assy.
15. REMOVE GOVERNOR APPLY GASKET NO.1
(a) Remove the governor apply gasket No.1 from the trans-
axle case.
16. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET
(a) Remove the transaxle case 2nd brake gasket from the
transaxle case.

C83129
D03554
Check Ball
D03555
D03556
D03902
O-ring
C-3 Accumulator Piston 40-22
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
46 Author
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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.

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)
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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.

D03560
C56727
D03563
D03564
D03565
40-24
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
23. REMOVE MANUAL DETENT SPRING SUB-ASSY
(a) Remove the 2 bolts, the manual detent spring sub-assy
and cover.
24. REMOVE PARKING LOCK PAWL BRACKET
(a) Remove the 2 bolts and parking lock pawl bracket.
25. REMOVE MANUAL VALVE LEVER SUB-ASSY
(a) Using a chisel and hammer, cut off and remove the
spacer.
(b) Using a pin punch (f35 mm) and hammer, drive out the
pin.
HINT:
Slowly drive out the pin so that it will not fall into the transaxle
case.
(c) Remove the manual valve lever shaft and manual valve
lever.