Lexus ES300 (2002 year). Manual — part 430

0305L-05

-

SERVICE SPECIFICATIONS

AUTOMATIC TRANSMISSION / TRANSAXLE

03-7

22

U150E A/T REPAIR MANUAL (RM913U)

TORQUE SPECIFICATION

Part Tightened

N

⋅

m

kgf

⋅

cm

ft

⋅

lbf

Differential gear lube apply tube x Transaxle housing

9.8

100

87 in.

⋅

lbf

Front planetary gear lock nut

268

2,732

198

Brake apply tube clamp x Transaxle case

5.4

55

48 in.

⋅

lbf

Transaxle case No. 1 plug x Transaxle rear cover

7.4

75

65 in.

⋅

lbf

Transaxle rear cover x Transaxle case

Bolt A

Other bolt

18.6
24.5

190
250

14
18

Pawl shaft clamp x Transaxle case

9.8

100

87 in.

⋅

lbf

Oil pump assy x Transaxle case

22

226

16

Transaxle housing x Transaxle case

Bolt A,D

Bolt B, C

22.1
29.4

225
300

16.3
21.7

Automatic transmission case plug x Transaxle housing

7.4

75

65 in.

⋅

lbf

Automatic transmission case plug x Transaxle case

7.4

75

65 in.

⋅

lbf

Parking lock pawl bracket x Transaxle case

20.1

205

15

Manual detent spring x Transaxle case

Bolt A
Bolt B

20.1
11.8

205
120

15

9

Transmission wire x Transaxle housing

5.4

55

48 in.

⋅

lbf

Transmission valve body x Transaxle case

10.8

110

8

ATF temperature sensor clamp x Transmission valve body

6.6

67

58 in

⋅

lbf

Valve body oil strainer assy x Transmission valve body

10.8

110

8

Automatic transaxle oil pan sub-assy x Transaxle case

7.8

80

69 in.

⋅

lbf

Drain plug x Automatic transaxle oil pan sub-assy

49

500

36

Speed sensor x Transaxle case

11.3

115

8

Oil cooler tube union x Transaxle case

Union

Elbow

27
27

276
276

20
20

Park/neutral start switch x nut

6.9

70

61 in.

⋅

lbf

Park/neutral start switch x Bolt

5.4

55

48 in.

⋅

lbf

Park/neutral start switch x Control shaft lever

12.7

130

9

Speedometer driven hole cover sub-assy x Transaxle case

6.9

70

61

Oil pump body x Stator shaft assy

9.8

100

87 in.

⋅

lbf

U/D planetary gear x Lock nut

280

2,855

207

Line pressure control solenoid assy x Transmission valve body assy

6.6

67

58 in.

⋅

lbf

Shift solenoid valve SL1x Transmission valve body assy

6.6

67

58 in.

⋅

lbf

Shift solenoid valve SL2x Transmission valve body assy

10.8

110

8

Shift solenoid valve SL3x Transmission valve body assy

6.6

67

58 in.

⋅

lbf

Shift solenoid valve S4x Transmission valve body assy

10.8

110

8

Shift solenoid valve DSL x Transmission valve body assy

10.8

110

8

Front differential case x Front differential ring gear

95.1

970

70

400H3-01

D26429

D03701

D26430

40-88

-

AUTOMATIC TRANSMISSION / TRANS

UNDERDRIVE CLUTCH ASSY (U150E)

110

U150E A/T REPAIR MANUAL (RM913U)

UNDERDRIVE CLUTCH ASSY (U150E)

OVERHAUL

1.

INSPECT UNDERDRIVE PACK CLEARANCE

(a)

Install the U/D clutch to the transaxle case.

NOTICE:
Be careful not to damage the oil seal rings.
(b)

Install a dial indicator as shown in the illustration.

(c)

Measure the U/D clutch pack clearance while applying
and releasing compressed air (392 kPa, 4.0 kgf/cm

2

, 57

psi).
Pack clearance: 1.51 - 1.71 mm (0.0594 - 0.0673 in.)

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

2.

REMOVE UNDERDRIVE CLUTCH DISC NO.1

(a)

Using a screwdriver, remove the U/D clutch flange No. 2
snap ring.

(b)

Remove the flange, 4 discs and 4 plates from the U/D
clutch drum.

D04077

D08129

D03703

SST

C56359

-

AUTOMATIC TRANSMISSION / TRANS

UNDERDRIVE CLUTCH ASSY (U150E)

40-89

111

U150E A/T REPAIR MANUAL (RM913U)

3.

INSPECT UNDERDRIVE CLUTCH DISC NO.1

(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.

4.

INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSY

(a)

Using a dial indicator, measure the inside diameter of the
U/D clutch drum bushing.
Standard drum bushing:
37.06 - 37.08 mm (1.4591 - 1.4598 in.)
Maximum drum bushing: 37.13 mm (1.4618 in.)

If the inside diameter is greater than the maximum, replace the
U/D clutch drum.

5.

REMOVE UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY

(a)

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

09350-32014 (09351-32070)

(b)

Using a snap ring expander, remove the snap ring.

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 U/D clutch drum.

C56360

D03824

D03705

D26465

D26465

40-90

-

AUTOMATIC TRANSMISSION / TRANS

UNDERDRIVE CLUTCH ASSY (U150E)

112

U150E A/T REPAIR MANUAL (RM913U)

(d)

Remove the return spring from the U/D clutch drum.

6.

INSPECT UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY

(a)

Using a vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 17.14 mm (0.6752 in.)

7.

REMOVE UNDERDRIVE CLUTCH PISTON SET

(a)

Install the U/D clutch to the transaxle case.

NOTICE:
Be careful not to damage the oil seal ring.
(b)

Holding the U/D clutch piston by hand, apply compressed
air (392 kPa, 4.0 kgf/cm

2

, 57 psi) to the transaxle case to

remove the U/D clutch piston.

8.

REMOVE UNDERDRIVE CLUTCH DRUM O-RING

(a)

Using a screwdriver, remove the O-ring from the U/D
clutch drum.

9.

INSTALL UNDERDRIVE CLUTCH DRUM O-RING

(a)

Apply the new O-ring with ATF, install it to the U/D clutch
drum.