Lexus ES300 (2002 year). Service manual — part 421

D26396

D08058

C92977

D03909

D09638

Free

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AUTOMATIC TRANSMISSION / TRANS

AUTOMATIC TRANSAXLE ASSY (U150E)

40-47

69

U150E A/T REPAIR MANUAL (RM913U)

103. INSTALL SECOND BRAKE PISTON ASSY
(a)

Install the 2nd brake piston assy to the transaxle case.

(b)

Install the snap ring and measure the inside diameter.
Inside diameter: More than 167 mm (6.57 in.)

NOTICE:

Because the taper snap ring has the positioning
direction, check it when installing.

When the diameter does not meet the specified value,
replace the snap ring with new one.

104. INSTALL 1WAY CLUTCH SLEEVE OUTER

(a)

Install the sleeve outer to the 2nd brake cylinder assy.

NOTICE:
Check the positioning direction of the outer sleeve.

105. INSTALL 1 WAY CLUTCH ASSY

(a)

Install the inner race to the 1-way clutch.

NOTICE:
Check the direction of the inner race.

(b)

Check the rotating direction of 1-way clutch for the lock
or free operation, as shown in the illustration.

D03588

D26394

D26393

D26404

B

A

D26714

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AUTOMATIC TRANSMISSION / TRANS

AUTOMATIC TRANSAXLE ASSY (U150E)

70

U150E A/T REPAIR MANUAL (RM913U)

(c)

Install the 1-way clutch and bearing to the 1-way clutch
sleeve outer.

Bearing diameter: mm (in.)

Inside

Outside

Bearing

53.6 (2.110)

69.6 (2.740)

NOTICE:
Install the thrust bearing properly so that no-colored race
will be visible.

106. INSTALL PLANETARY CARRIER THRUST WASHER

NO.1

(a)

Coat the thrust washer No. 1 with petroleum jelly, install
it onto the planetary gear assy.

107. INSTALL REAR PLANETARY SUN GEAR ASSY

(a)

Coat the thrust washer No. 2 with petroleum jelly, install
it onto the rear planetary sun gear.

(b)

Coat the bearing with petroleum jelly, install it onto the
rear planetary sun gear.

Bearing diameter: mm (in.)

Inside

Outside

Race, A

33.1 (1.303)

45.4 (1.787)

Bearing, B

31.85 (1.254)

45.2 (1.780)

(c)

Install the rear planetary sun gear assy to the rear plane-
tary gear.

D26412

Plate

Disc

D26453

B

D03623

D26392

B

A

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AUTOMATIC TRANSMISSION / TRANS

AUTOMATIC TRANSAXLE ASSY (U150E)

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71

U150E A/T REPAIR MANUAL (RM913U)

108. INSTALL 2ND BRAKE CLUTCH DISC

(a)

Coat the 4 discs with ATF.

(b)

Install the 4 discs and 4 plates to the transaxle case.

(c)

Temporarily install the snap ring.

109. INSPECT PACK CLEARANCE OF SECOND BRAKE
(a)

Using a vernier calipers, measure the distance between
the disc surface and snap ring surface (Dimension B).

(b)

Select an appropriate flange so that the pack clearance
will meet the specified value.
Pack clearance: 0.62 - 0.91 mm (0.0244 - 0.0358 in.)

HINT:
Piston stroke = Dimension B - Flange thickness - Snap ring
thickness 1.6 mm (0.063 in.)
Flange thickness: mm (in.)

Mark

Thickness

Mark

Thickness

1

3.0 (0.118)

5

3.4 (0.134)

2

3.1 (0.122)

6

3.5 (0.138)

3

3.2 (0.126)

7

3.6 (0.142)

4

3.3 (0.130)

8

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(c)

Temporarily remove the snap ring, attach the selected
flange and restore the snap ring.

NOTICE:
Secure the snap ring so that its gap is visible through the
groove of the transaxle case.

110. INSTALL OVERDREVE DIRECT CLUTCH HUB

SUB-ASSY

(a)

Install the direct clutch hub to the planetary gear assy.

(b)

Install the bearing race and the thrust bearing to the direct
clutch hub.

Bearing and race diameter: mm (in.)

Inside

Outside

Bearing, A

25.0 (0.984)

39.5 (1.555)

Race, B

23.6 (0.929)

36.6 (1.441)

D26403

D26469

C

D26470

D

D03923

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AUTOMATIC TRANSMISSION / TRANS

AUTOMATIC TRANSAXLE ASSY (U150E)

72

U150E A/T REPAIR MANUAL (RM913U)

111. INSTALL DIRECT CLUTCH ASSY
(a)

Install the direct clutch assy and thrust bearing to the rear
planetary sun gear assy.

NOTICE:
The disc in the direct clutch should completely match with
the hub attached outside the rear planetary sun gear.
Otherwise, the rear cover can not be installed.

(b)

Clean the connecter part of the transaxle case and the
rear cover.

(c)

As shown in the illustration, place a straight edge on the
direct clutch drum and measure the distance between
transaxle case and the straight edge using vernier cali-
pers (Dimension C).

(d)

Using vernier calipers and a simple straightedge, mea-
sure the position shown in the illustration.

(e)

Calculate the end play value using the following formula.
Select a thrust bearing which satisfies the end play value
and install it.
End play: 0.260 - 0.917 mm (0.01024 - 0.03610 in.)

NOTICE:
Make sure that the no colored race side is facing the direct
clutch assy.
HINT:
End play = Dimension D - Dimension C
Bearing thickness and diameter : mm (in.)

Thickness

Inside

Outside

3.4 (0.1339)

55.9 (2.201)

76.0 (2.992)

3.7 (0.1457)

55.9 (2.201)

76.6 (3.016)

112. INSTALL BRAKE APPLY TUBE

(a)

Install the clamp to the brake apply tube.

NOTICE:
Make sure to install the clamp to the apply tube before
installing the apply tube to the transaxle case. This pre-
vents the apply tube from being deformed or damaged.
(b)

Install the clutch apply tube.