2005 LEXUS ES300 brake

0103C-05
01-6- INTRODUCTIONTERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL
6 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ASSYAssembly
AT FAutomatic Transaxle Fluid
B3U/D Brake
C2Reverse Clutch
C3U/D Clutch
FIPGFormed In Place Gasket
O/DOverdrive
SSMSpecial Service Materials
SSTSpecial Service Tools
U/DUnderdrive
w/With
w/oWithout
1stFirst
2ndSecond

02-2
- PREPARATIONAUTOMATIC TRANSMISSION / TRANS
11 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)
09387-00030Counter Drive Gear Holding ToolAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09387-00041Bearing Puller AssemblyAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01010)Claw No.1AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01021)Claw No.2AUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01030)PinAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
(09387-01040)Bearing Puller BodyAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09387-00050Under Drive Gear PullerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09387-00060Second Brake WrenchSECOND BRAKE PISTON
ASSY(U151E/U151F)
09387-00070First & Reverse Brake WrenchAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09387-00080Counter Drive Gear Nut WrenchAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)
09502-12010Differential Bearing ReplacerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09506-35010Differential Drive Pinion Rear
Bearing ReplacerUNDERDRIVE PLANETARY GEAR
ASSY(U151E/U151F)
09514-3501 1Rear Wheel Bearing PullerAUTOMATIC TRANSAXLE
ASSY(U151E/U151F)

- 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.)

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

C89119
N´m (kgf´cm, ft´lbf): Specified torque
 Non-reusable partO-Ring 
 Precoated partx 18
Automatic Transaxle
Oil Pan Sub-assyAutomatic Transaxle
Oil Pan Gasket Valve Body
Oil Strainer AssyOil Cleaner
Magnet
 
Oil Strainer Gasket
11 (110, 8 )
x 17 Transmission Valve Body Assy
Parking Lock
Rod Sub-assy
Parking Lock
Pawl Bracket
Manual Detent
Spring Sub-assy11 (110, 8)
20 (205, 15)
20 (205, 15)
C-3 Accumulator
Piston
O-Ring 
Compression
Spring
O-Ring O-Ring 
B-3 Accumulator
Piston Compression Spring
Reverse Clutch
Accumulator PistonCompression Spring
Washer Control Shaft Lever
Nut Stopper Park/ Neutral
Position SwitchManual Valve Lever Shaft Oil Seal Manual Valve Lever Shaft Sloted Spring Pin Retainer Spring Spacer
13 (130, 9)
6.9 (70, 61 in.Vlbf)
5.4 (55, 48 in.Vlbf)
x 5 O-Ring x 8O-Ring  Transaxle Apply Tube ClampAutomatic Transaxle
Case Sub-assyTransaxle Rear Cover
x 11
Governor Apply Gasket
Transaxle Case
2nd Brake Gasket Differential Gear
Lube Apply Tube
Brake Drum Gasket
7.4 (75, 65 in.Vlbf)
29 (295, 21)
9.8 (100, 87 in.Vlbf)
25 (255, 18)
Case Plug
Spring
Check Ball
Body
Bolt A: 18.6 (190, 14)
Other bolt: 24.5 (250, 18)
U151E:
x 3
33 (337, 24)
11.8 (120, 9)
7.8 (80, 69 in.Vlbf)
40-2- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
26 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)

D26457
N´m (kgf´cm, ft´lbf): Specified torque
 Non-reusable part
x 7 Oil Pump AssyThrust Needle
Roller Bearing
Forward Clutch AssyThrust Needle
Roller Bearing
22 (226, 16)
O/D Brake gasket
Counter Drive
Gear Bearing Counter
Drive Gear
Washer
Thrust Bearing
Race No. 1
Thrust Needle
Roller Bearing
Multiple
Disc Clutch
Clutch Hub
1st & Reverse
Brake Piston
O-Ring
Snap RingSnap RingPlateFlange
Disc
1st & Reverse Brake
Return Spring
Counter Drive
Gear Bearing
Planetary Carrier
Thrust Washer No. 1Front Planetary
Gear Assy
Brake Hub
Snap Ring
Flange
Plate
Disc
Snap Ring
Second Brake Piston AssyFront Planetary
Ring GearThrust Bearing Race
Thrust Needle
Roller Bearing
Planetary Carrier
Thrust Washer No. 2
Thrust Needle
Roller Bearing
1-W ay Clutch
Inner Race1-W ay Clutch Assy
1-W ay Clutch Sleeve Outer
Rear Planetary
Gear Assy
Thrust Bearing
Race No. 2
Thrust Needle
Roller Bearing
Input Sun Gear
Thrust Needle
Roller BearingSnap Ring
Thrust BearingTransaxle Rear Cover
Needle Roller Bearing
Outer Rear Clutch Oil Seal Ring
Direct Clutch Assy
Thrust Bearing Race
O/D Direct
Clutch Hub Sub-assyThrust Bearing
Rear Planetary
Sun Gear Assy
U151E:
Nut
210 (2,141, 155) - 350 (3,569, 258)
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)40-3
27 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)

D26594
O-Ring 
N´m (kgf´cm, ft´lbf): Specified torque
 Non-reusable part Thrust Needle
Roller Bearing Thrust Bearing
Underdrive Race No. 2Underdrive
Planetary
Gear AssyUnderdrive Clutch Assy
Snap RingFlangePlate
Disc
Underdrive 1-Way
Clutch Assy
Bearing Race
Snap Ring
Underdrive Brake Return
Spring Sub-assyUnderdrive Clutch
Drum Oil Seal RingNeedle Roller
Bearing Underdrive Brake Piston

Parking Lock Pawl
Parking Lock Pawl Shaft
Torsion
Spring
Parking Lock Pawl Pin
Pawl Shaft Clamp
9.8 (100, 87 in.Vlbf)
Front Differential Assy
Clutch Apply Tube
Brake Apply Tube
Transaxle Apply
Tube Clamp
Governor Apply Gasket No. 1 
5.4 (55, 48 in.Vlbf)
U151E:
Thrust Bearing 40-4
- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
28 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)

C89116
N´m (kgf´cm, ft´lbf): Specified torque
 Non-reusable partO-Ring 
 Precoated partx 18
Automatic Transaxle
Oil Pan Sub-assyAutomatic Transaxle
Oil Pan Gasket Valve Body
Oil Strainer AssyOil Cleaner
Magnet
 
Oil Strainer Gasket
11 (110, 8 )
x 17 Transmission Valve Body Assy
Parking Lock
Rod Sub-assy
Parking Lock
Pawl Bracket
Manual Detent
Spring Sub-assy11 (110, 8)
20.1 (205, 15)
20 (205, 15)
C-3 Accumulator
Piston
O-Ring 
Compression
Spring
O-Ring O-Ring 
B-3 Accumulator
Piston Compression Spring
Reverse Clutch
Accumulator PistonCompression Spring
Washer Control Shaft Lever
Nut Stopper Park/ Neutral
Position SwitchManual Valve Lever Shaft Oil Seal Manual Valve Lever Shaft Sloted Spring Pin Retainer Spring Spacer
13 (130, 9)
6.9 (70, 61 in.Vlbf)
5.4 (55, 48 in.Vlbf)
x 5 O-Ring x 8O-Ring  Transaxle Apply Tube ClampAutomatic Transaxle
Case Sub-assyTransaxle Rear Cover
x 11
Governor Apply Gasket
Transaxle Case
2nd Brake Gasket Differential Gear
Lube Apply Tube
Brake Drum Gasket
7.4 (75, 65 in.Vlbf)
29.4 (300, 21.7)
9.8 (100, 87 in.Vlbf)Case Plug
Spring
Check Ball
Body
Bolt A: 18.6 (190, 14)
Other bolt: 24.5 (250, 18)
U151F:
x 3
33 (337, 24)
12 (120, 9)
7.8 (80, 69 in.Vlbf)
25 (255, 18)
40-6- AUTOMATIC TRANSMISSION / TRANSAUTOMATIC TRANSMISSION /
TRANSAXLE (U151E/U151F)
30 Author
: Date
:
U151E, U151F A/T REPAIR MANUAL (RM1021U)