Lexus ES300 (2002 year). Manual — part 401

0103C-02

01-6

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INTRODUCTION

TERMS FOR AUTOMATIC TRANSAXLE REPAIR
MANUAL

6

U150E A/T REPAIR MANUAL (RM913U)

TERMS FOR AUTOMATIC TRANSAXLE REPAIR MANUAL

ABBREVIATIONS USED IN THIS MANUAL

Abbreviations

Meaning

ASSY

Assembly

ATF

Automatic Transaxle Fluid

B

3

U/D Brake

C

2

Reverse Clutch

C

3

U/D Clutch

FIPG

Formed In Place Gasket

O/D

Overdrive

SSM

Special Service Materials

SST

Special Service Tools

U/D

Underdrive

w/

With

w/o

Without

1st

First

2nd

Second

400H2-01

D26426

D26427

40-78

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AUTOMATIC TRANSMISSION / TRANS

DIRECT CLUTCH ASSY (U150E)

100

U150E A/T REPAIR MANUAL (RM913U)

DIRECT CLUTCH ASSY (U150E)

OVERHAUL

1.

INSPECT PACK CLEARANCE OF REVERSE CLUTCH

(a)

Install the intermediate shaft and needle roller bearing on
the transaxle rear cover .

(b)

Using a dial indicator, measure the reverse clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm

2

, 57 psi).

Pack clearance:0.60 - 0.82 mm (0.02362 - 0.03228 in.)

If the pack clearance is not within standard, inspect the discs,
plates and flange.

2.

INSPECT PACK CLEARANCE OF DIRECT CLUTCH &
OVERDRIVE CLUTCH

(a)

Using a dial indicator, measure the direct clutch & over-
drive clutch pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm

2

, 57 psi).

Pack clearance:0.61 - 0.83 mm (0.02401 - 0.03268 in.)

If the pack clearance is not within standard, inspect the discs,
plates and flange.

D26419

D26420

D26718

D26422

D26719

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AUTOMATIC TRANSMISSION / TRANS

DIRECT CLUTCH ASSY (U150E)

40-79

101

U150E A/T REPAIR MANUAL (RM913U)

3.

REMOVE REVERSE CLUTCH DISC

(a)

Using a screwdriver, remove the snap ring from the inter-
mediate shaft.

(b)

Remove the flange, 3 discs,, 3 plates and cushion plate
from the intermediate shaft.

4.

INSPECT REVERSE CLUTCH DISC

(a)

Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.

If necessary, replace them.
HINT:

If the lining of the disc comes off or discolors, or even if a
part of the groove is defaced, replace all discs.

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

5.

REMOVE OVERDRIVE DIRECT CLUTCH DISC

(a)

Using a screwdriver, remove the snap ring from the inter-
mediate shaft.

(b)

Remove the flange, 4 discs and 4 plates from the inter-
mediate shaft.

6.

INSPECT OVERDRIVE DIRECT CLUTCH DISC

(a)

Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.

If necessary, replace them.
HINT:

If the lining of the disc comes off or discolors, or even if a
part of the groove is defaced, replace all discs.

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

D03677

SST

D26424

D26423

D09211

40-80

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AUTOMATIC TRANSMISSION / TRANS

DIRECT CLUTCH ASSY (U150E)

102

U150E A/T REPAIR MANUAL (RM913U)

7.

REMOVE OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSY

(a)

Place SST on the clutch balancer and compress the
spring with a press.
SST

09387-00020

(b)

Using a snap ring expander, remove the snap ring from
the direct clutch drum.

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
groove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.

(c)

Remove the clutch balancer from the direct clutch drum.

(d)

Remove the return spring from the direct clutch drum.

8.

INSPECT OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSY

(a)

Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 25.91 mm (1.0201 in.)