2005 LEXUS ES300 Repair Manual

D26384
D26450
Differential Assy
D25215
90 - 100
C (194 - 230
F)
D26445
Mark
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151E)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)Mark ThicknessMark Thickness
72.35 (0.0925)G2.80 (0.1102)
82.40 (0.0945)H2.85 (0.1122)
(f) Remove the 16 bolts and the transaxle housing.
(g) Remove the differential assy.
16. INSTALL FRONT DIFFERENTIAL RING GEAR
(a) Using ATF and heater, heat the front differential ring gear
to 90 - 110
C (194.0 - 230.0
F).
NOTICE:
Do not overheat the ring gear to 110
C (230.0
F) or more.
(b) Clean the contact surface of the front differential case.
(c) Align the match-marks, install the front differential ring
gear case quickly.
NOTICE:
Do not install the bolts while the ring gear is hot.

D26446
D26451
SST
D25606
SST
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Tighten the 14 bolts.
Torque: 95.0 NVm (970 kgfVcm, 70 ftVlbf)
NOTICE:
Tighten the bolts a little at a time in diagonal order.
17. INSTALL TRANSAXLE HOUSING OIL SEAL
(a) Using SST and a hammer, install a new oil seal.
(b) Apply the rip of oil seal with a little MP grease.
SST 09223-15020, 09950-70010 (09951-07150)
Oil seal drive in depth: 0
0.5 mm (0
0.0197 in.)
18. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, drive into a new oil seal.
(b) Apply the lip of the oil seal with a little MP grease.
SST 09710-30050, 09950-70010 (09951-07150)
Oil seal drive in depth: 0
0.5 mm (0
0.0197 in.)

4006N-02
C50182
Match-marks
Front Differential Ring Gear
C50183
Front Differential
Ring Gear
C50184Front Differential Ring Gear
C50187
Differential
Case Assy
Differential
LH Case
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
FRONT DIFFERENTIAL ASSY (U151F)
OVERHAUL
1. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place the match-marks on the ring gear and differential
case.
(b) Remove the 16 bolts.
(c) Using a plastic hammer, tap on the ring gear to remove it
from the case.
2. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the differential LH case from the differential case
assy.

C50188
Differential
Case No.2
Differential
Case LH
C50189
Differential
Case LH
Center
Differential
Side Gear
Thrust Washer
No.2Conical Spring
Front
Differential
Side Gear
Thrust WasherFront
Differential
Side Gear
D25610
C50190
C50191
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(b) Remove the differential case No.2 from the differential
case LH.
(c) Remove the front differential side gear, front differential
side gear thrust washer, conical spring and center differ-
ential side gear thrust washer No.2 from the differential
case LH.
(d) Using a snap ring expander, remove the pinion shaft
spacer snap ring.
(e) Using a pin punch and a hammer, remove 3 straight pins.
(f) Remove the center differential pinion shaft and 2 differen-
tial pinion shafts.

C50943
D25597
SST
SST HoldTurn
D25598
SST
C50193
C50230
Differential
RH Case
Differential
Intermediate Case
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
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141 Author
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(g) Remove 4 front differential pinions, 4 front differential pin-
ion thrust washers, front differential pinion shaft holder,
front differential planetary ring gear and differential side
gear thrust washer No. 1.
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
(09951-00480)
(b) Using SST, remove the front differential case rear tapered
roller bearing outer race and differential case washer.
SST 09308-00010
4. REMOVE CENTER DIFFERENTIAL PINION
(a) Using torx socket (T50), remove the 15 bolts.
(b) Place the matchmarks on the differential intermediate
case and differential case.
(c) Remove the differential intermediate case from the differ-
ential case RH.

C50196
Differential Case RH
Center Differential
Side Gear
C50194
D25611
SSTSST Hold
Turn
D25596
SST
D25599
SST
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(d) Remove the center differential side gear, conical spring
washer and center differential side gear thrust washer No.
1 RH from the differential case RH.
(e) Remove the differential spider, 5 center differential pin-
ions and 5 center differential pinion thrust washers from
the differential intermediate case.
5. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING
(a) Using SST, remove the front differential case front ta-
pered roller bearing from the differential case.
SST 09950- 00020, 09950- 00030, 09950- 60010
(09951-00600)
(b) Using SST, remove the front differential case front ta-
pered roller bearing outer race and differential case wash-
er.
SST 09308-00010
6. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100), 09649-17010

D25600
SST
C50943
C50216
C50213
Differential
Case LH
Differential
Case No.2
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, remove the oil seal.
SST 09950-70010 (09951-07100), 09608-10010
8. INSTALL DIFFERENTIAL CASE SUB-ASSY NO.2
(a) Coat the front differential side gear thrust washer No.1,
front differential planetary ring gear, front differential pin-
ion No.2, front differential pinion thrust washer No.2, front
differential pinion shaft holder, front differential pinion
shaft and 2 differential pinion shafts with ATF, install them
to the differential case No.2.
(b) Using a dial indicator, measure the backlash of one pinion
gear while holding the front differential side gear toward
the case.
Standard backlash:
0.05 - 0.20 mm (0.0020 - 0.0079 in.)
NOTICE:
Do not mount the surface of front differential case which
contacts with bushing in a vise.
If the backlash is not within the specified value, refer to the table
below and select a thrust washer which will ensure that the
backlash is within the specified value.
Thrust washer thickness: mm (in.)
MarkThicknessMarkThickness
A0.95 (0.0373)F1.20 (0.0472)
B1.00 (0.0393)G1.25 (0.0492)
C1.05 (0.0413)H1.30 (0.0512)
D1.10 (0.0433)J1.35 (0.0532)
E1.15 (0.0453)K1.40 (0.0552)
(c) Engage the front differential side gear to the above men-
tioned front differential case.
(d) Install the differential case LH to the front differential case
and measure its center.
(e) After that, remove the differential case LH.

C50214
C50217
D25610
C51252
Differential Case RH
Center Differential
Side Gear
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- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL ASSY (U151F)
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U151E, U151F A/T REPAIR MANUAL (RM1021U)
(f) Using a straight edge and feeler gauge, measure the
clearance between the front differential case and the front
differential side gear.
t= Thrust washer thickness
L= Clearance
t= L-0.162 - 0.265 mm (0.0064 - 0.0104 in.)
If the clearance is not within the specified value, refer to the
table below and select a thrust washer which will ensure that the
clearance is within the specified value.
Thrust washer thickness: mm (in.)
MarkThicknessMarkThickness
A0.95 (0.0373)F1.20 (0.0472)
B1.00 (0.0393)G1.25 (0.0492)
C1.05 (0.0413)H1.30 (0.0512)
D1.10 (0.0433)J1.35 (0.0532)
E1.15 (0.0453)K1.40 (0.0552)
If the clearance is not within the specified value, parts may have
been assembled incorrectly, so check and reassemble it.
(g) Using a pin punch and a hammer, install 3 straight pins.
(h) Using a snap ring expander, install the pinion shaft spacer
snap ring.
9. INSTALL CTR DIFFERENTIAL PLANETARY GEAR
ASSY
(a) Install the center differential side gear, conical spring
washer and center differential side gear thrust washer
No.2 RH from the differential case RH.
HINT:
Ensure that the conical washers is installed correctly.