2005 LEXUS ES300 Repair Manual

C89113
C89115
C89115
C89112
- AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E/U151F)
40-105
129 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
6. REMOVE SHIFT SOLENOID VALVE SL2
(a) Remove the bolt and shift solenoid valve SL2 from the
valve body assy.
7. REMOVE SHIFT SOLENOID VALVE SL1
(a) Remove the bolt and shift solenoid valve SL1 from the
valve body assy.
8. REMOVE MANUAL VALVE
(a) Remove the manual valve from the valve body assy.
9. INSTALL MANUAL VALVE
(a) Install the manual valve to the valve body assy.
10. INSTALL SHIFT SOLENOID VALVE SL1
(a) Install the shift solenoid valve SL1 to the valve body assy
with the bolt.
Torque: 6.6 NVm (67 kgfVcm, 58 in.Vlbf)
11. INSTALL LINE PRESSURE CONTROL SOLENOID
ASSY
(a) Install the shift solenoid valve SLT to the valve body assy
with the bolt.
Torque: 6.6 NVm (67 kgfVcm, 58 in.Vlbf)
12. INSTALL SHIFT SOLENOID VALVE SL3
(a) Install the shift solenoid valve SL3 to the valve body assy
with the bolt.
Torque: 6.6 NVm (67 kgfVcm, 58 in.Vlbf)

C89113
D26443
D26438
D26442
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- AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E/U151F)
130 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
13. INSTALL SHIFT SOLENOID VALVE SL2
(a) Install the shift solenoid valve SL2 to the valve body assy
with the bolt.
Torque: 10.8 NVm (110 kgfVcm, 8 ftVlbf)
14. INSTALL SHIFT SOLENOID VALVE DSL
(a) Install the shift solenoid valve DSL to the valve body assy
with the bolt.
Torque: 10.8 NVm (110 kgfVcm, 8 ftVlbf)
15. INSTALL SHIFT SOLENOID VALVE SR
(a) Install the shift solenoid valve SR to the valve body assy.
16. INSTALL SHIFT SOLENOID VALVE S4
(a) Install the shift solenoid valve S4 to the valve body assy
with the bolt.
Torque: 10.8 NVm (110 kgfVcm, 8 ftVlbf)

4006M-03
D26445
Mark
Front
Differential
Ring Gear
D26446
Front
Differential
Ring Gear
C50237Front Differential Ring Gear
D25595
HoldTurn
SST
SST
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
40-107
131 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
FRONT DIFFERENTIAL ASSY (U151E)
OVERHAUL
1. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place the match-marks on the front differential ring gear
and differential case.
(b) Remove the 14 bolts.
(c) Using a plastic hammer, tap on the front differential ring
gear to remove it from the case.
2. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case front differ-
ential tapered roller bearing from the differential case.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00490), 09950-40011 (09957-04010)

D25596
SST
D25597
HoldTurn
SST
SST
D25598
SST
C50240
C50241
Differential Case
Front Differential Pinion Shaft No.1
40-108
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
132 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Using SST, remove the front differential case front ta-
pered roller bearing outer race.
SST 09308-00010
3. REMOVE FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case rear tapered
roller bearing from the differential case.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00490), 09950-40011 (09957-04010)
(b) Using SST, remove the front differential case rear tapered
roller bearing outer race.
SST 09308-00010
4. REMOVE FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch and hammer, install the straight pin.
NOTICE:
Before removing the straight pin, unstake it with a pin
punch.
5. REMOVE FRONT DIFFERENTIAL PINION SHAFT
NO.1
(a) Remove the front differential pinion shaft No.1 from the
differential case.

C50242
Front Differential
Side Gear
Front
Differential
Side Gear
D25599
SST
D25600
SST
C50242
Front Differential
Side Gear
Front
Differential
Side Gear
C50241
Differential Case
Front Differential Pinion Shaft No.1
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
40-109
133 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the 2 front differential pinions, 2 pinion thrust
washers, 2 front differential side gears and 2 side gear
thrust washers from the differential case.
7. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950- 70010 (09951- 07100), 09215- 00013
(09215-00471)
8. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100), 09608-10010
9. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Apply the 2 front differential side gears, 2 side gear thrust
washers, 2 front differential pinions and 2 pinion thrust
washers with ATF and install them to the differential case.
10. INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1
(a) Apply the front differential pinion shaft No.1 with ATF,
install it to the differential case.

C50252
C50253
C50254
D26447
SST
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- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
134 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
11. INSPECT BACKLASH
(a) Using a dial indicator, inspect the backlash of the side
gear.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thrust washer thickness
MarkThickness
-1.625 mm (0.0640 in.)
-1.725 mm (0.0679 in.)
-1.825 mm (0.0719 in.)
12. INSTALL FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using a pin punch and hammer, install the pinion shaft
straight pin.
(b) Using a chisel and hammer, stake the differential case.
NOTICE:
Stake it after adjusting the backlash.
13. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
rear tapered roller bearing to the differential case.
SST 09316- 12010, 09550- 60010 (09951- 00490),
09950-70010 (09951-07100)
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.

C83736
D26448
SST
D26449
SST
D26450
Differential Assy
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
40-1 11
135 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Using SST and a hammer, install the front differential
case tapered roller bearing front outer race to the trans-
axle housing.
SST 09550- 60010 (09951- 00490), 09950- 60020
(09951-00910)
14. INSTALL FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING
(a) Using SST and a press, install the front differential case
front tapered roller bearing to the differential case.
SST 09316- 12010, 09550- 60010 (09951- 00490),
09950-70010 (09951-07100)
NOTICE:
Do not make a damage on the bearing cage during the bear-
ing inner race installation.
(b) Using SST and a hammer, install the front differential
case tapered roller bearing front outer race to the trans-
axle housing.
SST 09950- 70010 (09951- 07150), 09950- 60020
(09951-00890)
NOTICE:
Clearance is not allowed between the bearing and trans-
axle housing.
15. ADJUST DIFFERENTIAL SIDE BEARING RRELOAD
(a) Install the differential assy to the transaxle case.

D26384
C
C
C
CAB
A
D25604
SST
40-1 12
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
136 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Clean the matching surfaces of the transaxle case and
transaxle housing.
(c) Install the transaxle housing to the transaxle case and
tighten them with the 16 bolts.
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 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.)
HINT:
Usually, bolt A is a non-reusable bolt. In this case, however, it
can be used after cleaning it.
(d) Using SST, turn the differential assy right and left 2
or 3
times to settle the bearing.
SST 09564-3201 1
(e) Using SST and a torque wrench, measure the turning
torque of the differential.
SST 09564-3201 1
Turning torque at 60 rpm:
New bearing
0.20 - 0.69 NVm (2.0 - 7.0 kgfVcm, 1.8 - 6.1 in.Vlbf)
Used bearing
0.10 - 0.35 NVm (1.0 - 3.6 kgfVcm, 0.9 - 3.1 in.Vlbf)
HINT:
If the turning torque is not within the specified value, refer to the
table below to select a thrust washer which turning torque is
within the specified value.
Flange thickness: mm (in.)
MarkThicknessMarkThickness
02.00 (0.0787)92.45 (0.0965)
12.05 (0.0807)A2.50 (0.0984)
22.10 (0.0827)B2.55 (0.1004)
32.15 (0.0846)C2.60 (0.1024)
42.20 (0.0866)D2.65 (0.1043)
52.25 (0.0886)E2.70 (0.1063)
62.30 (0.0906)F2.75 (0.1083)