Lexus ES300 (1997 year). Service manual — part 79

AUTOMATIC TRANSAXLE

FORWARD CLUTCH

-

AX-43

2.

REMOVE SNAP RING FROM CLUTCH DRUM

3.

REMOVE FLANGE, DISCS AND PLATES

4.

REMOVE RETURN SPRING

(a)

Place SST on the spring retainer and compress the
springs with a press.
SST 09350-32014 (09351-32070)

(b)

Using snap ring pliers, remove the snap ring.

(c)

Remove the return spring.

5.

REMOVE CLUTCH PISTON

(a)

Apply compressed air into the oil passage to remove the
piston.
If the piston does not come out, use needle-nose pliers
to remove it.

AUTOMATIC TRANSAXLE

FORWARD CLUTCH

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AX-44

(b)

Remove the 2 O-rings from the piston.

6.

IF NECESSARY, REMOVE OIL SEAL RINGS
Remove the 3 oil seal rings from the shaft.

FORWARD CLUTCH INSPECTION

1.

INSPECT CLUTCH PISTON

(a)

Check that the check ball is free by shaking the piston.

(b)

Check that the valve does not leak by applying low-pres-
sure compressed air.

2.

INSPECT DISCS, PLATES AND FLANGE
Check if the sliding surfaces of the discs, plates and
flange are worn or burnt. If necessary, replace them.
HINT:

If the lining of the disc is peeling off or discolored, or
even if a part of the printed numbers are defaced, re-
place all discs.

Before assembling new discs, soak them in ATF for
at least 15 minutes.

FORWARD CLUTCH ASSEMBLY

1.

INSTALL OIL SEAL RINGS
Install the 3 oil seal rings to the shaft.

NOTICE: Do not spread the ring ends more than necessary.

HINT: After installing the oil seal rings, check that they
move smoothly.

AX038-03

AX039-04

AUTOMATIC TRANSAXLE

FORWARD CLUTCH

-

AX-45

2.

INSTALL CLUTCH PISTON TO CLUTCH DRUM

(a)

Install the 2 new O-rings to the piston.

(b)

Coat the O-ring with ATF.

(c)

Press the piston into the drum with the cup side up, being
careful not to damage the O-rings.

3.

INSTALL PISTON RETURN SPRINGS

(a)

Place the return spring and snap ring onto the piston.

(b)

Place SST on the spring retainer, and compress the
springs with a press.
SST 09350-32014 (09351-32070)

(c)

Install the snap ring with snap ring pliers.
Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.

4.

INSTALL PLATES, DISCS AND FLANGE

(a)

Install the plates and discs.
Install in order:
P=Plate D=Disc
P-D-P-D-P-D-P-D-P-D

(b)

Install the flange with the flat end facing downward.

5.

INSTALL SNAP RING
Check that the end gap of snap ring is not aligned with one
of the cutouts.

AUTOMATIC TRANSAXLE

FORWARD CLUTCH

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AX-46

6.

RECHECK PISTON STROKE OF FORWARD CLUTCH
Install a dial indicator and measuring terminal (SST) to-
gether, measure the forward clutch piston stroke while ap-
plying and releasing compressed air (392-785 kPa, 4-8
kgf/cm

2

, 57-114 psi).

SST 09350-32014 (09351-32190)

Piston stroke:

1.79-2.21 mm (0.0704-0.0870 in.)

If the piston stroke is non- standard, select another
flange.
HINT: There are 2 different thicknesses for the flange.

Flange thickness:

2.30 mm (0.0906 in.)

2.70 mm (1.0630 in.)