2005 LEXUS ES300 Repair Manual

D09641
D09642
D09643
D09644
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Turn the lever counterclockwise until it stops, and then
turn it clockwise 2 notches.
(e) Remove the control shaft lever.
(f) Align the groove with neutral basic line.
(g) Tighten the 2 bolts.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(h) Using a screwdriver, stake the nut with the nut stopper.
(i) Install the control shaft lever, washer and nut.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
158. INSTALL SPEEDOMETER DRIVEN HOLE (ATM) COVER SUB-ASSY
(a) Coat a new O-ring with ATF and install it to the speedometer driven hole cover.
(b) Install the bolt and speedometer driven hole cover sub-assy to the transaxle assy.
Torque: 6.9 NVm (70 kgfVcm, 61 ftVlbf)

4006F-03
D09205
D03650
Clutch
Drum Oil
Seal Ring
D03651
D09207
Oil Pump Drive GearOil Pump
Driven Gear
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- AUTOMATIC TRANSMISSION / TRANSOIL PUMP ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
OIL PUMP ASSY (U151E/U151F)
OVERHAUL
1. INSPECT OIL PUMP ASSY
(a) Turn the drive gear with 2 screwdrivers and make sure it
rotates smoothly.
NOTICE:
Be careful not to damage the oil seal lip.
2. REMOVE CLUTCH DRUM OIL SEAL RING
(a) Remove the 2 clutch drum oil seal rings.
3. REMOVE STATOR SHAFT ASSY
(a) Using a torx socket (T30), remove the 11 bolts and stator
shaft.
(b) Keep the gears in assembling order.
4. INSPECT CLEARANCE OF OIL PUMP ASSEMBLY
(a) Push the driven gear to one side of the body.
(b) Using a feeler gauge, measure the clearance.
Standard body clearance:
0.10 - 0.17 mm (0.0039 - 0.0067 in.)
Side clearance: 0.02 - 0.05 mm (0.001 - 0.02 in.)
Maximum body clearance: 0.17 mm (0.0067 in.)
If the body clearance is greater than the maximum, replace the
oil pump body sub-assy.

D09208
D09209
D09206
D09206
- AUTOMATIC TRANSMISSION / TRANSOIL PUMP ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(c) Using a feeler gauge measure the tip clearance between
the driven gear teeth and drive gear teeth.
Standard tip clearance:
0.07 - 0.15 mm (0.0028 - 0.0059 in.)
Maximum tip clearance: 0.15 mm (0.0059 in.)
If the tip clearance is greater than the maximum, replace the oil
pump body sub-assy.
(d) Using a straight edge and feeler gauge, measure the side
clearance of both gears.
Standard side clearance:
0.02 - 0.05 mm (0.0008 - 0.0020 in.)
Maximum side clearance: 0.05 mm (0.0020 in.)
Drive gear thickness: mm (in.)
MarkThickness
A11.690 - 11.699 (0.4602 - 0.4606)
B11.700 - 11.709 (0.4606 - 0.4610)
C11.710 - 11.720 (0.4610 - 0.4614)
D11.721 - 11.730 (0.4615 - 0.4618)
E11.731 - 11.740 (0.4619 - 0.4622)
Driven gear thickness: mm (in.)
MarkThickness
A11.690 - 11.699 (0.4602 - 0.4606)
B11.700 - 11.709 (0.4606 - 0.4610)
C11.710 - 11.720 (0.4610 - 0.4614)
D11.721 - 11.730 (0.4615 - 0.4618)
E11.731 - 11.740 (0.4619 - 0.4622)
5. REMOVE FRONT OIL PUMP DRIVE GEAR
(a) Remove the front oil pump drive gear.
6. REMOVE FRONT OIL PUMP DRIVEN GEAR
(a) Remove the front oil pump driven gear.

D25586
O-ring
D03647
SST
D03648
D03653
D03654
SST
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- AUTOMATIC TRANSMISSION / TRANSOIL PUMP ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
7. REMOVE FRONT OIL PUMP BODY O-RING
(a) Using a screwdriver, remove the O-ring.
HINT:
Tape the screwdriver before use.
8. REMOVE FRONT OIL PUMP OIL SEAL
(a) Mount oil pump in a soft jaw vise.
(b) Using SST, remove the oil seal from the oil pump body.
SST 09308-00010
9. INSPECT FR OIL PUMP & GEAR BODY SUB-ASSY
(a) Using a dial indicator, measure the inside diameter of the
oil pump body bushing.
Standard inside diameter:
38.113 - 38.138 mm (1.50051 - 1.50149 in.)
Maximum inside diameter: 38.188 mm (1.50346 in.)
If the inside diameter is greater than the maximum, replace the
oil pump body sub-assy.
10. INSPECT STATOR SHAFT ASSY
(a) Using a dial indicator, measure the inside diameter of the
stator shaft.
Standard inside diameter:
21.500 - 21.526 mm (0.84646 - 0.84748 in.)
Maximum inside diameter: 21.57 mm (0.8492 in.)
If the indicator diameter is greater than maximum, replace the
stator shaft.
11. INSTALL FRONT OIL PUMP OIL SEAL
(a) Using SST and a hammer, install a new oil seal to the oil
pump body.
SST 09350-32014 (09351-32140)
HINT:
The seal end should be flat with the outer edge of the oil pump.
(b) Coat the lip of the oil seal with MP grease.

C55817
O-ring
D09206
MarkOil Pump
Driven
Gear
D09206
Mark
Oil
Pump
Drive
Gear
D03651
D26627
Clutch Drum
Oil Seal Ring
- AUTOMATIC TRANSMISSION / TRANSOIL PUMP ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
12. INSTALL FRONT OIL PUMP BODY O-RING
(a) Coat the new O-ring with ATF, install it to the oil pump
body.
NOTICE:
Assemble the O-ring carefully not to have a twist and a
pinching. Moreover, apply enough ATF to the O-ring prior
to assembling.
13. INSTALL FRONT OIL PUMP DRIVEN GEAR
(a) Coat the front oil pump driven gear with ATF, install it to
the oil pump body with the marked side up.
14. INSTALL FRONT OIL PUMP DRIVE GEAR
(a) Coat the front oil pump drive gear with ATF, install it to the
oil pump body with the marked side up.
15. INSTALL STATOR SHAFT ASSY
(a) Set the stator shaft aligned with each bolt hole.
(b) Using a torx socket (T30), install the 11 bolts.
Torque: 9.8 NVm (100 kgfVcm, 87 in.Vlbf)
16. INSTALL CLUTCH DRUM OIL SEAL RING
(a) Coat the 2 new clutch drum oil seal rings with ATF.
(b) Install the 2 new clutch drum oil seal rings.
NOTICE:
Do not expand the ring ends excessively.

D09205
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
17. INSPECT OIL PUMP ASSY
(a) Turn the drive gear with 2 screwdrivers and make sure it
rotates smoothly.
NOTICE:
Be careful not to damage the oil seal lip.

400H1-02
D26715
D26753
Snap Ring
D26754
- AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
FORWARD CLUTCH ASSY (U151E/U151F)
OVERHAUL
1. INSPECT PACK CLEARANCE OF FORWARD CLUTCH
(a) Install the forward clutch on the oil pump.
NOTICE:
Be careful not to damage the oil seal ring of oil pump.
(b) Using a dial indicator, measure the forward clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance: 1.00 - 1.25 mm (0.0394 - 0.4921 in.)
If the clearance is not within standard, inspect the discs, plates
and flange.
HINT:
As the opening is large, cover it with a shop rug to prevent the
compressed air from being released.
2. REMOVE FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Using a screwdriver, remove the snap ring.
(b) Remove the flange, 5 discs and 5 plates from the input
shaft assy.

D09189
D26418
SST
Snap Ring
D26709
Clutch
Balancer
Input Shaft
D26708
Forward Clutch
Return SpringInput Shaft
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- AUTOMATIC TRANSMISSION / TRANSFORWARD CLUTCH ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
3. INSPECT FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC
(a) Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
HINT:

If the lining of the disc comes off or discolors, or even if
replace all discs.

Before assembling new discs, soak them in ATF for at
least 15 minutes.
4. REMOVE FORWARD CLUTCH RETURN SPRING
SUB-ASSY
(a) Place SST on the spring retainer 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,
preventing the spring sheet from deforming.

Do not expand the snap ring excessively.
(c) Remove the clutch balancer from the input shaft.
(d) Remove the forward clutch return spring from the input
shaft.