Page 227 of 969
D30865
C91925
40-28
- AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U151E)
2543 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
10. I N S TA L L A U TO M AT I C T R A N S A X L E O I L PA N
SUB-ASSY
(a) Install the 2 magnets in the oil pan.
(b) Apply seal packing to 18 bolts.
Seal packing:
THREE BOND 2430 or equivalent
(c) Install a new gasket, oil pan and 18 bolts to the transaxle
case.
Torque: 7.8 NVm (80 kgfVcm, 69 in.Vlbf)
NOTICE:
Since the bolts should be seal bolts, apply seal packing to
the bolts and tighten them within 10 minutes after applying.
11. ADD AUTOMATIC TRANSAXLE FLUID
12. INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-1)
13. INSTALL ENGINE UNDER COVER NO.1
14. RESET MEMORY (SEE PAGE 05-604)
Page 228 of 969
4010X-04
D25831
SST
D25832
SST
D25833
SST
- AUTOMATIC TRANSMISSION / TRANSFRONT DIFFERENTIAL OIL SEAL (U151E)
40-29
2544 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
FRONT DIFFERENTIAL OIL SEAL (U151E)
REPLACEMENT
1. REMOVE FRONT WHEELS
2. REMOVE ENGINE UNDER COVER NO.1
3. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) Remove the drain plug, gasket and drain ATF.
(b) Install a new gasket and drain plug.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
4. REMOVE FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-8)
5. REMOVE FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-8)
6. REMOVE TRANSAXLE HOUSING OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09308-00010
7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST, pull out the oil seal.
SST 09308-00010
8. INSTALL DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL
(a) Using SST and a hammer, drive in a new oil seal.
SST 09316-6001 1 (09316-00011)
Oil seal drive in depth:
0 0.5 mm (0 0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
SST 09316-6001 1 (09316-00011)
Page 239 of 969
400H6-03
D25118
D25119
40-40
- AUTOMATIC TRANSMISSION / TRANSFLOOR SHIFT ASSY
2555 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ADJUSTMENT
1. INSPECT SHIFT LEVER POSITION
(a) When shifting from P to R position only with ignition switch ON and brake pedal, make sure that the
shifting lever moves smoothly and can be moderately operated.
(b) When starting engine, make sure that the vehicle moves forward when shifting from N to D position
and moves rearward when shifting to R position.
2. ADJUST SHIFT LEVER POSITION
(a) Loosen the nut on the control shaft lever.
(b) Push the control shaft fully downward.
(c) Return the control shaft lever 2 notches to N position.
(d) Set the shift lever to N position.
(e) While holding the shift lever lightly toward the R position
side, tighten the shift lever nut.
Torque: 14.7 N´m (150 kgf´cm, 10 ft´lbf)
(f) Start the engine and make sure that the vehicle moves
forward when shifting the lever from N to D position and
moves rearward when shifting it to R position.
Page 250 of 969
G23361DLC3
Hand-held Tester
C80826
- BRAKEBRAKE FLUID
32-5
2439 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(f) Repeat the above procedure to bleed the air out of the
brake line for each wheel.
4. BLEED BRAKE ACTUATOR ASSY (W/ VSC)
NOTICE:
After performing the usual air bleeding in the brake system,
if the height or feel of the brake pedal cannot be obtained,
perform air bleeding in the brake actuator assy with a
hand-held tester by following procedures below.
(a) Depress the brake pedal more than 20 times with the en-
gine off.
(b) Connect the hand-held tester to the DLC3, then turn the
ignition switch to the ON position.
NOTICE:
Do not start the engine.
(c) Select ºAIR BLEEDINGº on the hand-held tester.
HINT:
Please refer to the Hand-Held Tester Operator's Manual for fur-
ther details.
(d) Bleed the air out of the regular brake line in ºStep1: In-
creaseº on the hand-held tester display.
NOTICE:
Perform the air bleeding by following the steps dis-
played on the hand-held tester.
Make sure that the brake fluid in the master cylinder
reservoir tank does not become empty.
(1) Connect the vinyl tube to either one of the bleeder
plugs.
(2) Depress the brake pedal several times, then loosen
the bleeder plug of one of the above wheels with the
pedal depressed.
(3) When fluid stops coming out, tighten the bleeder
plug, then release the brake pedal.
(4) Repeat (2) and (3) until all air in the fluid is complete-
ly bled out.
(5) Tighten the bleeder plug certainly.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
(6) Repeat the above procedure to bleed the air out of
the brake line for each wheel.
(e) Bleed the air out of the suction line in ºStep2: Inhalationº
on the hand-held tester display.
NOTICE:
Perform the air bleeding by following the steps dis-
played on the hand-held tester.
Make sure that the brake fluid in the master cylinder
reservoir tank does not become empty.
Page 254 of 969
F41698
Pedal Free play
R00934
Pedal Reserve
Distance
- BRAKEBRAKE PEDAL SUPPORT ASSY
32-9
2443 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
2. CHECK PEDAL FREE PLAY
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal until the beginning of the resistance is
felt. Measure the distance, as shown.
Pedal free play: 1 - 6 mm (0.04 - 0.24 in.)
If incorrect, check the stop lamp switch clearance.
If the clearance is OK, then troubleshoot the brake system.
Stop lamp switch clearance:
0.5 - 2.5 mm (0.020 - 0.098 in.)
3. CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake pedal.
With engine running, depress the pedal and measure the
pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf): More than 70 mm (2.76 in.)
If incorrect, troubleshoot the brake system.
Page 258 of 969
F42718
Pedal Free Play
R00934
Pedal Reserve
Distance
- BRAKEACCELERATOR & BRAKE PEDAL ASSY (From August,
2002)32-13
2447 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
2. CHECK PEDAL FREE PLAY
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal until the beginning of the resistance is
felt. Measure the distance, as shown.
Pedal free play: 1 - 6 mm (0.04 - 0.24 in.)
If incorrect, check the stop lamp switch assy clearance.
If the clearance is OK, then troubleshoot the brake system.
Stop lamp switch clearance:
0.5 - 2.5 mm (0.020 - 0.098 in.)
3. CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake pedal.
With engine running, depress the pedal and measure the
pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf): More than 63 mm (2.48 in.)
If incorrect, troubleshoot the brake system.
Page 271 of 969
3203F-08
BR2238
GOOD NO GOOD
2nd3rd
1st
BR2237
C16481
Ventilation
No Ventilation 32-26
- BRAKEBRAKE BOOSTER ASSY
2460 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE BOOSTER ASSY (From July, 2003)
ON-VEHICLE INSPECTION
1. INSPECT BRAKE BOOSTER
(a) Air tightness check.
(1) Start the engine and stop it after 1 or 2 minutes. De-
press the brake pedal several times slowly.
HINT:
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(2) Depress the brake pedal while the engine is run-
ning, and stop the engine with the pedal depressed.
HINT:
If there is no change in the pedal reserve distance after holding
the pedal for 30 seconds, the booster is air tight.
(b) Operating check.
(1) Depress the brake pedal several times with the igni-
tion switch OFF and check that there is no change
in the pedal reserve distance.
(2) Depress the brake pedal and start the engine.
HINT:
If the pedal goes down slightly, operation is normal.
2. INSPECT VACUUM CHECK VALVE
(a) Check vacuum check valve.
(1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check that there is ventilation from the booster to
engine, and no ventilation from the engine to the
booster.
(4) If any fault is found, replace the vacuum check
valve.
Page 292 of 969
320E1-02
- BRAKEBRAKE ACTUATOR ASSY (W/O VSC)
32-47
2481 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE ACTUATOR ASSY (W/O VSC)
ON-VEHICLE INSPECTION
1. CONNECT HAND-HELD TESTER:
(a) Connect the hand-held tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the hand-held tester.
HINT:
Please refer to the hand-held tester operator's manual for further details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay ON, check the actuator motor operation noise.
(b) Turn the motor relay OFF.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be de-
pressed.
(d) With the motor relay ON, check that the pedal does not pulsate.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn ON the solenoid which is not described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid ON simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep solenoid ON for more than 10 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid OFF simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay ON, and check that the pedal returns.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously,
set the interval of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) As in the same procedure, check the solenoids of other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR
