2005 LEXUS ES300 Repair Manual

D25588
Stopper
Stopper
D26417
Disc Flange
Plate
D26421
Snap Ring
D26416
Disc Flange
Plate
Cushion
Plate
D26419
Snap Ring
- AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(g) Set the end gap of the snap ring in the piston shown in the
illustration.
NOTICE:
The end gap of the snap ring should not coincide with any
of the stoppers.
16. INSTALL OVERDRIVE DIRECT CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 plates, 4 discs and flange to the intermediate
shaft.
NOTICE:
Be careful about the order of discs, plates and flange as-
sembly.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.
17. INSTALL DIRECT MULTIPLE DISC CLUTCH CLUTCH
DISC
(a) Apply the 3 discs with ATF.
(b) Install the cushion plate, 3 plates, 3 discs and flange to the
intermediate shaft.
NOTICE:

Install the cushion plate with the mark on the white
surface facing to plate.

Be careful about the order of discs, plates and flange
assembly.
(c) Using a screwdriver, install the snap ring.
(d) Check that the end gap of the snap ring is not aligned with
one of the cutouts.
NOTICE:
The snap ring should be fixed certainly in the groove of the
drum.

D26426
D26427
D26428
40-90
- AUTOMATIC TRANSMISSION / TRANSDIRECT CLUTCH ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
18. INSPECT PACK CLEARANCE OF REVERSE CLUTCH
(a) Install the intermediate shaft on the transaxle rear cover.
(b) Using a dial indicator, measure the direct clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:0.60 - 0.82 mm (0.02362 - 0.03228 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the stroke is not within standard, select another flange.
HINT:
There are 6 flanges of different thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
13.0 (0.118)53.4 (0.134)
23.1 (0.122)63.5 (0.138)
33.2 (0.126)73.6 (0.142)
43.3 (0.130)--
19. INSPECT PACK CLEARANCE OF DIRECT CLUTCH &
OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch & over-
drive clutch pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Pack clearance:0.61 - 0.83 mm (0.02401 - 0.03268 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the stroke is not within standard, select another flange.
HINT:
There are 7 flanges in different thickness.
Flange thickness: mm (in.)
No.ThicknessNo.Thickness
02.5 (0.098)42.9 (0.114)
12.6 (0.102)53.0 (0.118)
22.7 (0.106)63.1 (0.122)
32.8 (0.110)--
(b) Check that the disc rotates when rotating the disc after in-
serting the rear planetary sun gear.
NOTICE:
Do not place the rear planetary sun gear in a vise.

4006I-03
D26703
SST
D26704
2nd Brake Piston
Return Spring
C89124
2nd Brake Piston
Return Spring
D26705
- AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
SECOND BRAKE PISTON ASSY (U151E/U151F)
OVERHAUL
1. REMOVE 2ND BRAKE PISTON RETURN SPRING
SUB-ASSY
(a) Place SST on the return spring and compress.
SST 09387-00060
(b) Using a screwdriver, remove the snap ring.
(c) Remove the 2nd brake piston return spring.
2. INSPECT 2ND BRAKE PISTON RETURN SPRING
SUB-ASSY
(a) Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 16.61 mm (0.6539 in.)
3. REMOVE 2ND BRAKE PISTON
(a) Hold the 2nd brake piston and apply compressed air (392
kPa, 4.0 kgf/cm
2, 57 psi) to the 2nd brake cylinder to re-
move the 2nd brake piston.

D26706
O-ring
O-ring
D26706
O-ring
O-ring
D26775
D26704
2nd Brake Piston
Return Spring
40-92
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
4. REMOVE 2ND BRAKE PISTON O-RING
(a) Remove the 2 O-rings from the 2nd brake piston.
5. INSTALL 2ND BRAKE PISTON O-RING
(a) Apply the 2 new O-rings with ATF, install them in the 2nd
brake piston.
NOTICE:
Assemble the O-ring carefully not to have a twist and a
pinching.
6. INSTALL 2ND BRAKE PISTON
(a) Apply the 2nd brake piston with ATF, and install it to the
2nd brake cylinder.
NOTICE:
Be careful not to damage the O-ring.
7. INSTALL 2ND BRAKE PISTON RETURN SPRING
SUB-ASSY
(a) Install the 2nd brake piston return spring.
NOTICE:
Installing the spring sub- assembly, check all of the
springs are fit in the piston correctly.

D26703
SST
- AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Place SST on the piston return spring, and compress the
piston return spring with a press.
SST 09387-00060
(c) Using a screwdriver, install the snap ring.
(d) Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.
NOTICE:

Stop the press when the spring sheet is lowered to the
place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring
groove.

This prevents the spring sheet from being deformed.

400H3-02
D26429
D03701
Snap Ring
D26430
Underdrive
Clutch Drum
40-94
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
UNDERDRIVE CLUTCH ASSY (U151E/U151F)
OVERHAUL
1. INSPECT UNDERDRIVE PACK CLEARANCE
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal rings.
(b) Install a dial indicator as shown in the illustration.
(c) Measure the underdrive clutch pack clearance while ap-
plying and releasing compressed air (392 kPa, 4.0 kgf/
cm
2, 57 psi).
Pack clearance: 1.51 - 1.71 mm (0.0594 - 0.0673 in.)
If the pack clearance is not within standard, inspect the discs,
plates and flange.
2. REMOVE UNDERDRIVE CLUTCH FLANGE NO.2
HOLE SNAP RING
(a) Using a screwdriver, remove the underdrive clutch flange
No.2 snap ring.
3. REMOVE UNDERDRIVE CLUTCH DISC NO.1
(a) Remove the flange, 4 discs and 4 plates from the under-
drive clutch drum.

D04077
D08129
D03703
SST
Snap Ring
C56359
Clutch
Balancer
Underdrive
Clutch Drum
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
4. INSPECT UNDERDRIVE CLUTCH DISC NO.1
(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 a
part of the groove is defaced, replace all discs.

Before assembling new discs, soak them in ATF for at
least 15 minutes.
5. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSY
(a) Using a dial indicator, measure the inside diameter of the
underdrive clutch drum bushing.
Standard drum bushing:
37.06 - 37.08 mm (1.4591 - 1.4598 in.)
Maximum drum bushing: 37.13 mm (1.4618 in.)
If the inside diameter is greater than the maximum, replace the
underdrive clutch drum.
6. REMOVE UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Place SST on the clutch balancer and compress the
spring with a press.
SST 09350-32014 (09351-32070)
(b) Using a snap ring expander, remove the snap ring.
NOTICE:

Stop the press when the spring sheet is lowered to the
place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring
groove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.
(c) Remove the clutch balancer from the underdrive clutch
drum.

C56360
D03824
D03705
D26465
O-ring
D26465
O-ring
40-96
- AUTOMATIC TRANSMISSION / TRANSUNDERDRIVE CLUTCH ASSY (U151E/U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Remove the return spring from the underdrive clutch
drum.
7. INSPECT UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a) Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 17.14 mm (0.6752 in.)
8. REMOVE UNDERDRIVE CLUTCH PISTON SET
(a) Install the underdrive clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b) Holding the underdrive clutch piston by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the transaxle
case to remove the underdrive clutch piston.
9. REMOVE UNDERDRIVE CLUTCH DRUM O-RING
(a) Using a screwdriver, remove the O-ring from the under-
drive clutch drum.
10. INSTALL UNDERDRIVE CLUTCH DRUM O-RING
(a) Apply the new O-ring with ATF, install it to the underdrive
clutch drum.
NOTICE:
Assemble the O-ring carefully not to have a twist and a
pinching.