Lexus ES300 (2002 year). Service manual — part 431
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D03860
C56360
C56359
D03703
SST
-
AUTOMATIC TRANSMISSION / TRANS
UNDERDRIVE CLUTCH ASSY (U150E)
40-91
113
U150E A/T REPAIR MANUAL (RM913U)
10.
INSTALL UNDERDRIVE CLUTCH PISTON SET
(a)
Coat the U/D clutch piston with ATF, install it to the U/D
clutch piston drum.
NOTICE:
Be careful not to damage the O-ring.
Be careful not to damage the lip seal of the piston.
11.
INSTALL UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY
(a)
Install the return spring to the U/D clutch drum.
(b)
Install the clutch balancer to the U/D clutch drum.
NOTICE:
Be careful not to damage the lip seal of the clutch balancer.
(c)
Place SST on the clutch balancer and compress the pis-
ton return spring with a press.
SST
09350-32014 (09351-32070)
(d)
Using a snap ring expander, install the snap ring to the
U/D clutch drum.
(e)
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
grove.
This prevents the spring sheet from being deformed.
Do not expand the snap ring excessively.
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D25592
Stopper
Stopper
D26431
Disc
Flange
Plate
D03701
D26429
40-92
-
AUTOMATIC TRANSMISSION / TRANS
UNDERDRIVE CLUTCH ASSY (U150E)
114
U150E A/T REPAIR MANUAL (RM913U)
(f)
Set the end gap of the snap ring in the U/D clutch drum
shown in the illustration.
NOTICE:
The end gap of the snap ring should not coincide with any
of the stopper.
12.
INSTALL UNDERDRIVE CLUTCH DISC NO.1
(a)
Apply the 4 discs with ATF.
(b)
Install the 4 plates, 4 discs and flange to the U/D clutch
drum.
(c)
Using a screwdriver, install the U/D clutch flange No. 2
hole snap ring.
(d)
Check that the end gap of snap ring is not aligned with one
of the cutouts.
13.
INSPECT UNDERDRIVE PACK CLEARANCE
(a)
Install the U/D clutch to the transaxle case.
NOTICE:
Be careful not to damage the oil seal ring.
(b)
Set a dial indicator as shown in the illustration.
(c)
Measure the U/D clutch piston stroke while applying and
releasing compressed air (392 kPa, 4.0 kgf/cm
2
, 57 psi).
Park clearance: 1.51 - 1.71 mm (0.0594 - 0.0673 in.)
If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the pack clearance is not within standard, select another
flange.
HINT:
There are 5 flanges in different thickness.
Flange thickness: mm (in.)
No.
Thickness
No.
Thickness
1
3.0 (0.118)
4
3.3 (0.130)
2
3.1 (0.122)
5
3.4 (0.134)
3
3.2 (0.126)
-
-
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4006K-02
D25593
SST
D25594
SST
D03686
SST
D03687
-
AUTOMATIC TRANSMISSION / TRANS
UNDERDRIVE PLANETARY GEAR ASSY (U150E)
40-93
115
U150E A/T REPAIR MANUAL (RM913U)
UNDERDRIVE PLANETARY GEAR ASSY (U150E)
OVERHAUL
1.
INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD
(a)
Using SST, fix the U/D planetary gear assy.
SST
09387-00050
(b)
Using SST and a torque wrench, measure the turning
torque of U/D planetary gear assy while rotating the
torque wrench at 60 rpm.
SST
09387-00050
Turning torque at 60 rpm.:
2.14 - 5.40 N
⋅
m (21.8 - 55.1 kgf
⋅
cm, 0.24 - 0.61 in.
⋅
lbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).
2.
REMOVE FRONT PLANETARY GEAR NUT
(a)
Using SST, loosen the staked part of the nut.
SST
09930- 00010 (09931- 00010, 09931- 00020),
09387-00050
(b)
Clamp the U/D planetary gear in soft jaw vise.
NOTICE:
Be careful not to damage the differential drive pinion.
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D25609
D03689
SST
Hold
Turn
D26437
SST
D03691
SST
SST
Hold
Turn
D03826
40-94
-
AUTOMATIC TRANSMISSION / TRANS
UNDERDRIVE PLANETARY GEAR ASSY (U150E)
116
U150E A/T REPAIR MANUAL (RM913U)
(c)
Using a socket wrench, remove the lock nut.
3.
REMOVE CYLINDRICAL ROLLER BEARING RACE
INNER
(a)
Using SST, remove the cylindrical roller bearing race in-
ner.
SST
09950- 00020, 09950- 00030, 09950- 60010
(09951-00320), 09950-40011 (09957-04010)
4.
REMOVE UNDERDRIVE PLANETARY GEAR ASSY
(a)
Using SST and a press, remove the differential drive pin-
ion, parking lock gear, counter driven gear with U/D plane-
tary ring gear and front tapered roller bearing.
SST
09950-60010 (09951-00320), 09387-00050
(b)
Clamp the U/D planetary gear in soft jaw vise.
(c)
Using SST, remove the rear tapered roller bearing form
the U/D planetary gear.
SST
09950- 00020, 09950- 00030, 09950- 60010
(09951-00320), 09950-40011 (09957-04010)
5.
REMOVE UNDERDRIVE PLANETARY RING GEAR
(a)
Using a snap ring pliers, remove the snap ring.
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