2005 LEXUS ES300 Repair Manual

030JK-02
V06821
Mark
Mark Class
Class
Hexagon head
bolt
Bolt
head No.4-
5-
6-
7-
8-
9-
10-
11 -4T
5T
6T
7T
8T
9T
10T
11 T
No mark
No mark Hexagon
flange bolt
w/ washer
hexagon bolt4T
4T
5T
6T
7T
8T Hexagon head
bolt
Hexagon
flange bolt
w/ washer
hexagon bolt
Hexagon head
bolt
Hexagon head
bolt2
Protruding
lines
2
Protruding
lines
3
Protruding
lines
4
Protruding
linesHexagon
flange bolt
w/ washer
hexagon bolt
Hexagon
flange bolt
w/ washer
hexagon bolt
Hexagon
flange bolt
w/ washer
hexagon bolt
Stud bolt
Welded bolt4
Protruding
lines
5
Protruding
lines
6
Protruding
lines
No mark
Grooved9T
10T
11 T
4T
6T
4T
- SERVICE SPECIFICATIONSSTANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL03-1
17 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
STANDARD BOLT FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
HOW TO DETERMINE BOLT STRENGTH

030JL-02
V00079
ClassDiameter
mmPitch
mmSpecified torque
Hexagon head bolt
Hexagon flange bolt
N´m kgf´cm
ft´lbf N´mkgf´cm
ft´lbf
in.´lbf
in.´lbf
in.´lbfin.´lbf
in.´lbf
in.´lbf 03-2
- SERVICE SPECIFICATIONSSTANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL
18 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
SPECIFIED TORQUE FOR STANDARD BOLTS

030JM-02
6N
8N
10N
11 N
12N
B06432
Nut Type
Present Standard
Hexagon Nut
Cold Forging Nut Cutting Processed NutClass
4N
5N (4T)
6N
7N (5T)
8N
10N (7T)
11 N
12N Old Standard Hexagon Nut
No Mark (w/ Washer)No Mark
*
No Mark (w/ Washer)
No Mark
No Mark
*: Nut with 1 or more marks on one side surface of the nut.
- SERVICE SPECIFICATIONSSTANDARD BOLT FOR AUTOMATIC TRANSAXLE
REPAIR MANUAL03-3
19 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
HOW TO DETERMINE NUT STRENGTH
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more

0305K-1 1
03-4
- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
20 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
AUTOMATIC TRANSMISSION / TRANSAXLE
SERVICE DATA
Oil pump
Body clearance STD
Max.0.10 - 0.17 mm (0.0039 - 0.0067 in.)
0.17 mm (0.0067 in.)
Tip clearance STD
Max.0.07 - 0.15 mm (0.0028 - 0.0059 in.)
0.15 mm (0.0059 in.)
Side clearance STD
Max.0.02 - 0.05 mm (0.0008 - 0.0020 in.)
0.05 mm (0.0020 in.)
Drive gear thickness Mark
A
B
C
D
E
11.690 - 11.699 mm (0.4602 - 0.4606 in.)
11.700 - 11.709 mm (0.4606 - 0.4610 in.)
11.710 - 11.720 mm (0.4610 - 0.4614 in.)
11.721 - 11.730 mm (0.4615 - 0.4618 in.)
11.731 - 11.740 mm (0.4619 - 0.4622 in.)
Driven gear thickness Mark
A
B
C
D
E
11.690 - 11.699 mm (0.4602 - 0.4606 in.)
11.700 - 11.709 mm (0.4606 - 0.4610 in.)
11.710 - 11.720 mm (0.4610 - 0.4614 in.)
11.721 - 11.730 mm (0.4615 - 0.4618 in.)
11.731 - 11.740 mm (0.4619 - 0.4622 in.)
Pump body bushing inside diameter STD
Max.38.113 - 38.138 mm (1.50050 - 1.50149 in.)
38.188 mm (1.50346 in.)
Stator shaft bushing inside diameter STD
Max.21.500 - 21.526 mm (0.84646 - 0.84748 in.)
21.57 mm (0.8492 in.)
Multiple disc clutch
Inside diameter STD
Max.23.025 - 23.045 mm (0.9065 - 0.9073 in.)
23.09 mm (0.9091 in.)
Forward clutch
Pack clearance1.00 - 1.25 mm (0.0394 - 0.4921 in.)
Return spring free length26.74 mm (1.0528 in.)
Flange thickness Mark
1
2
3
4
5
3.00 mm (0.1181 in.)
3.15 mm (0.1240 in.)
3.30 mm (0.1299 in.)
3.45 mm (0.1358 in.)
3.60 mm (0.1417 in.)
Reverse clutch
Pack clearance:0.60 - 0.82 mm (0.02362 - 0.03228 in.)
Flange thickness Mark
1
2
3
4
5
6
7
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)
3.2 mm (0.126 in.)
3.3 mm (0.130 in.)
3.4 mm (0.134 in.)
3.5 mm (0.138 in.)
3.6 mm (0.142 in.)

- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
03-5
21 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U) Direct clutch & O/D clutch
Pack clearance0.61 - 0.83 mm (0.02401 - 0.03268 in.)
Return spring free length25.91 mm (1.0201 in.)
Flange thickness Mark
0
1
2
3
4
5
6
2.5 mm (0.098 in.)
2.6 mm (0.102 in.)
2.7 mm (0.106 in.)
2.8 mm (0.110 in.)
2.9 mm (0.114 in.)
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)
2nd brake
Pack clearance0.62 - 0.91 mm (0.0244 - 0.0358 in.)
Return spring free length16.61 mm (0.6539 in.)
Flange thickness Mark
1
2
3
4
5
6
73.0 mm (0.118 in.)
3.1 mm (0.122 in.)
3.2 mm (0.126 in.)
3.3 mm (0.130 in.)
3.4 mm (0.134 in.)
3.5 mm (0.138 in.)
3.6 mm (0.142 in.)
U/D clutch
Pack clearance1.51 - 1.71 mm (0.0594 - 0.0673 in.)
U/D clutch drum bushing inside diameter STD
Max.37.06 - 37.08 mm (1.4591 - 1.4598 in.)
37.13 mm (1.4618 in.)
Return spring free length17.14 mm (0.6752 in.)
Flange thickness Mark
1
2
3
4
5
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)
3.2 mm (0.126 in.)
3.3 mm (0.130 in.)
3.4 mm (0.134 in.)
U/D brake
Pack clearance1.81 - 2.20 mm (0.0713 - 0.0866 in.)
Return spring free length14.04 mm (0.5528 in.)
Flange thickness Mark
1
2
3
3.0 mm (0.118 in.)
3.2 mm (0.126 in.)
3.4 mm (0.134 in.)
1st & reverse brake
Pack clearance1.16 - 1.35 mm (0.0457 - 0.0531in.)
Return spring free length15.53 mm (0.6114 in.)
Flange thickness Mark
1
2
3
4
5
6
7
8
1.8 mm (0.071 in.)
1.9 mm (0.075 in.)
2.0 mm (0.079 in.)
2.1 mm (0.083 in.)
2.2 mm (0.087 in.)
2.3 mm (0.091 in.)
2.4 mm (0.094 in.)
2.5 mm (0.098 in.)

03-6
- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
22 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U) U/D planetary gear
Preload (at 60 rpm)0.50 - 1.42 NVm (5.1 - 14.5 kgfVcm, 0.06 - 0.17 in.Vlbf)
Front planetary gear
Turning torque (at 60 rpm) New Bearing
Used Bearing0.51 - 1.02 NVm (5.1 - 10.0 kgfVcm, 4.4 - 8.7 in.Vlbf)
0.26 - 0.51 NVm (2.7 - 5.2 kgfVcm, 2.3 - 4.5 in.Vlbf)
Input shaft
End play0.262 - 1.249 mm (0.0103 - 0.0492 in.)
Transaxle rear cover
Bearing press fit depth20.55 - 21.25 mm (0.8091 - 0.8366 in.)
Transmission valve body
Valve body installation bolt length A
B
C41 mm (1.614 in.)
57 mm (2.244 in.)
25 mm (0.984 in.)
Accumulator
SpringFree length/Outer diameterColor
B3Inner
Outer62.00 (2.4409) / 15.50 (0.610)
74.23 (2.9224) / 16.50 (0.649)Purple
Purple
C260.96 (2.3999) / 14.10 (0.555)Yellow
C372.20 (2.8425) / 19.0 (0.748)Colorless
Front differential(U151E)
Backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thrust washer thickness Mark
-
-
-
1.625 mm (0.0640 in.)
1.725 mm (0.0679 in.)
1.825 mm (0.0719 in.)
Praload (at 60 rpm) New bearing
Used bearing0.20 - 0.69 NVm (2.0 - 7.0 kgfVcm, 1.8 - 6.1 in.Vlbf)
0.10 - 0.35 NVm (1.0 - 3.6 kgfVcm, 0.9 - 3.1 in.Vlbf)
Flange thickness Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.)
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)
Front differential (U151F)
Side gear backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)

- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
03-7
23 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U) Thrust washer thickness
= Clearance - 0.162 - 0.265 mm (0.0064 - 0.0104 in.)
Mark
A
B
C
D
E
F
G
H
J
K
0.95 mm (0.0373 in.)
1.00 mm (0.0393 in.)
1.05 mm (0.0413 in.)
1.10 mm (0.0433 in.)
1.15 mm (0.0453 in.)
1.20 mm (0.0472 in.)
1.25 mm (0.0492 in.)
1.30 mm (0.0512 in.)
1.35 mm (0.0532 in.)
1.40 mm (0.0552 in.)
Pinion's backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Thrust washer thickness Mark
MA
MB
MC
MD
ME
MF
MG
MH
MJ
MK
ML
MM
MN
0.80 mm (0.0313 in.)
0.85 mm (0.0333 in.)
0.90 mm (0.0353 in.)
0.95 mm (0.0373 in.)
1.00 mm (0.0393 in.)
1.05 mm (0.0413 in.)
1.10 mm (0.0433 in.)
1.15 mm (0.0453 in.)
1.20 mm (0.0472 in.)
1.25 mm (0.0492 in.)
1.30 mm (0.0512 in.)
1.35 mm (0.0532 in.)
1.40 mm (0.0552 in.)
Praload (at 60 rpm) New bearing
Used bearing0.20 - 0.69 NVm (2.0 - 7.0 kgfVcm, 1.8 - 6.1 in.Vlbf)
0.10 - 0.35 NVm (1.0 - 3.6 kgfVcm, 0.9 - 3.1 in.Vlbf)
Flange thickness Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.)
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)
Oil seal press in depth5.5 - 6.5 mm (0.217 - 0.256 in.)

0305L-1 1
03-8
- SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION / TRANSAXLE
24 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
TORQUE SPECIFICATION
Part TightenedNVmkgfVcmftVlbf
Differential gear lube apply tube x Transaxle housing9.810087 in.Vlbf
Front planetary gear lock nut210-3502141-3569155-258
Brake apply tube clamp x Transaxle case5.45548 in.Vlbf
Transaxle case No. 1 plug x Transaxle rear cover7.47565 in.Vlbf
Transaxle rear cover x Transaxle case Bolt A
Other bolt19
25190
25014
18
Pawl shaft clamp x Transaxle case9.810087 in.Vlbf
Oil pump assy x Transaxle case2222616
Transaxle housing x Transaxle case Bolt A
Bolt B
Bolt C
Bolt D25
33
29
22255
337
295
22618
24
21
16
Automatic transmission case plug x Transaxle housing7.47565 in.Vlbf
Automatic transmission case plug x Transaxle case7.47565 in.Vlbf
Parking lock pawl bracket x Transaxle case2020515
Manual detent spring x Transaxle case Bolt A
Bolt B20
12205
12015
9
Transmission wire x Transaxle housing5.45548 in.Vlbf
Transmission valve body x Transaxle case1111 08
ATF temperature sensor clamp x Transmission valve body6.66758 inVlbf
Valve body oil strainer assy x Transmission valve body1111 08
Automatic transaxle oil pan sub-assy x Transaxle case7.88069 in.Vlbf
Drain plug x Automatic transaxle oil pan sub-assy4950036
Speed sensor x Transaxle case1111 58
Oil cooler tube union x Transaxle case Union
Elbow27
27276
27620
20
Park/neutral start switch x nut6.97061 in.Vlbf
Park/neutral start switch x Bolt5.45548 in.Vlbf
Park/neutral start switch x Control shaft lever131309
Speedometer driven hole cover sub-assy x Transaxle case6.97061
Oil pump body x Stator shaft assy9.810087 in.Vlbf
Line pressure control solenoid assy x Transmission valve body assy6.66758 in.Vlbf
Shift solenoid valve SL1x Transmission valve body assy6.66758 in.Vlbf
Shift solenoid valve SL2x Transmission valve body assy10.811 08
Shift solenoid valve SL3x Transmission valve body assy6.66758 in.Vlbf
Shift solenoid valve S4x Transmission valve body assy10.811 08
Shift solenoid valve DSL x Transmission valve body assy10.811 08
Front differential case x Front differential ring gear95.197070