2005 LEXUS ES300 brake

D26706
O-ring
O-ring
D26706
O-ring
O-ring
D26775
D26704
2nd Brake Piston
Return Spring
40-92
- AUTOMATIC TRANSMISSION / TRANSSECOND BRAKE PISTON ASSY (U151E/U151F)
11 6 Author
: Date
:
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)
40-93
11 7 Author
: Date
:
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.

4005R-08
D25120
Add if hotOK if hot
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE FLUID
40-1
2516 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
AUTOMATIC TRANSAXLE FLUID
ON-VEHICLE INSPECTION
1. CHECK THE FLUID LEVEL
HINT:
Drive the vehicle so that the engine and transaxle are at normal
operating temperature.
Fluid temperature: 70 - 80 °C (158 - 176 °F)
(a) Park the vehicle on a level surface and set the parking
brake.
(b) With the engine idling and the brake pedal depressed,
shift the shift lever into all positions from P to L position,
and return to P position.
(c) take out the dipstick and wipe it clean.
(d) Put it back fully into the pipe.
(e) take it out and check that the fluid level is in the HOT posi-
tion.
If there are leaks, it is necessary to repair or replace O-rings,
FIPGs, oil seals, plugs and/or other parts.

400FX-04
40-2
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSAXLE ASSY
2517 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
AUTOMATIC TRANSAXLE ASSY
PRECAUTION
1. The automatic transaxle is composed of highly precision-finished parts, if nequine careful in-
spection before reassembly therefore even a small nick may cause fluid leakage or may de-
grade the performance. The instructions here are organized so that you work on only one com-
ponent group at a time. This will help you to avoid confusion about similar-looking parts of
different sub-assemblies being on your workbench at the same time. The component groups
are inspected and repaired from the converter housing side. Inspectio, repair and reassembly
As much as possible, before proceeding to the next component group. If a defect is found in
a certain component group during reassembly, inspect and repair this group immediately. If a
component group cannot be assembled because parts are being ordered, be sure to keep all
parts of the group in a separate container while proceeding with disassembly, inspection, re-
pair and reassembly of other component groups.
Recommended ATF: T-IV
2. All disassembled parts should be washed clean and any fluid passages and holes should be
blown with compressed air.
3. Dry all parts with compressed airnever use shop rags.
4. When using compressed air, do not aim at yourself to prevent accidentally spraying ATF or ker-
osene on your face.
5. The recommended automatic transaxle fluid or kerosene should be used for cleaning.
6. After cleaning, the parts should be arranged in the correct order for efficient inspection, repairs,
and reassembly.
7. When disassembling a valve body, be sure to match each valve together with the correspond-
ing spring.
8. New discs for the brakes and clutches that are to be used for replacement must be soaked in
ATF for at least 15 minutes before reassembly.
9. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be
coated with ATF prior to reassembly.
10. All gaskets and rubber O-rings should be replaced.
11. Do not apply adhesive cements to gaskets and similar parts.
12. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed
in the groove correctly.
13. If a worn bushing is to be replaced, the sub-assembly containing the bushing must also be re-
placed.
14. Check thrust bearings and races for wear or damage. Replace if necessary.
15. Use petroleum jelly to keep parts in place.
16. When working with FIPG material, you must perform the following.
Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the
gasket surface.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non-residue solvent.
Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) ma-
terial must be removed and reapplied.

4010P-03
C99453
Groove
Neutral
Basic Line
- AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (U151E)
40-7
2522 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ADJUSTMENT
1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSY
(a) Apply the parking brake and turn the ignition switch to ON.
(b) Depress the brake pedal and check that the engine starts only when the shift lever is set in N or P posi-
tion.
(c) Check that the back-up light is lit and the reverse warning buzzer sounds only when the shift lever is
set in R position.
If a failure is found, check the continuity of the park/neutral position switch.
2. ADJUST PARK/NEUTRAL POSITION SWITCH ASSY
(a) Loosen the 2 bolts of park/neutral position switch and set
the shift lever to the N position.
(b) Align the groove with neutral basic line.
(c) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
(d) After adjustment, perform the inspection described in
step 1.

40067-09
C63995IG
E STP
- AUTOMATIC TRANSMISSION / TRANSSHIFT LOCK SYSTEM
40-31
2546 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
SHIFT LOCK SYSTEM
ON-VEHICLE INSPECTION
1. CHECK SHIFT LOCK OPERATION
(a) Shift the shift lever to P position.
(b) Turn the ignition switch to LOCK.
(c) Check that the shift lever cannot be shifted to any other positions other than P.
(d) Turn the ignition switch to ON, depress the brake pedal and check that the shift lever can be shifted
to any other positions.
2. CHECK SHIFT LOCK RELEASE BUTTON OPERATION
(a) Using a small screwdriver, remove the shift lock release cover.
(b) When operating the shift lever with the shift lock release button pressed, check that the lever can be
shifted to any position other than P.
3. CHECK KEY INTERLOCK OPERATION
(a) Turn the ignition switch to ON.
(b) Depress the brake pedal and shift the shift lever to any other position other than P.
(c) Check that the ignition key cannot be turned to LOCK.
(d) Shift the shift lever to P position, turn the ignition key to LOCK and check that the ignition key can be
removed.
4. INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY
(a) Using a voltmeter, measure the voltage at each terminal.
HINT:
Do not disconnect the shift lock control unit assembly connec-
tor.
TerminalMeasuring ConditionVoltage (V)
3 (STP) - 1 (E)Depress brake pedal10 - 14
3 (STP) - 1 (E)Release brake pedal0
5 (IG) - (E)Ignition switch ON10 - 14
5 (IG) - (E)Ignition switch OFF0

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.

32038-03
- BRAKEBRAKE SYSTEM
32-1
2435 Author
: Date
:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
BRAKE SYSTEM
PRECAUTION

Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard. Replace the parts with parts having the same part number
or equivalent.

It is very important to keep parts and the area clean when repairing the brake system.

If the vehicle is equipped with a mobile communication system, refer to the precaution in the
INTRODUCTION section.