Lexus ES300 (2002 year). Manual — part 420

D03600

SST

D03615

D26763

-

AUTOMATIC TRANSMISSION / TRANS

AUTOMATIC TRANSAXLE ASSY (U150E)

40-43

65

U150E A/T REPAIR MANUAL (RM913U)

96.

INSTALL 1ST & REVERSE BRAKE RETURN SPRING
SUB-ASSY

(a)

Place SST on the return spring and compress the return
spring with a press.
SST

09387-00070

(b)

Using a snap ring exspander, install the snap ring to the
transaxle case.

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, preventing the spring sheet from being de-
formed.

Do not expand the snap ring excessively.

97.

INSTALL FRONT PLANETARY RING GEAR

(a)

Using a screwdriver, install the front planetary ring gear
and snap ring to the brake hub.

98.

INSTALL FRONT PLANETARY GEAR ASSY

(a)

Install the front planetary gear assy to the brake hub.

D03916

SST

Counter Drive
Gear

Transaxle
Case

2nd Brake Hub
w/ Front Planetary
Gear Assy

SST

D03917

D03596

SST

40-44

-

AUTOMATIC TRANSMISSION / TRANS

AUTOMATIC TRANSAXLE ASSY (U150E)

66

U150E A/T REPAIR MANUAL (RM913U)

(b)

Using SST and a press, press-fit the front planetary gear
assy.
SST

09950- 60010 (09951- 00500), 09950- 70010
(09951-07100)

NOTICE:
Do not apply excessive pressure to it.

(c)

Install the washer, as shown in the illustration.

(d)

Using SST, install the nut.
SST

09387-00030, 09387-00080

Torque: 268 N

⋅

m (2,732 kgf

⋅

cm, 198 ft

⋅

lbf)

D03918

SST

D08074

D03873

C B

A

D26591

-

AUTOMATIC TRANSMISSION / TRANS

AUTOMATIC TRANSAXLE ASSY (U150E)

40-45

67

U150E A/T REPAIR MANUAL (RM913U)

(e)

Using SST and a torque wrench, measure the turning
torque of the bearing while rotating SST at 60 rpm. When
the measured value is not within the specified value,
gradually tighten the nut until it reaches the specified val-
ue.
SST

09387-00080

Turning torque at 60 rpm:
New Bearing
0.51 - 1.02 N

⋅

m (5.1 - 10.0 kgf

⋅

cm, 4.4 - 8.7 in.

⋅

lbf)

Used Bearing
0.26 - 0.51 N

⋅

m (2.7 - 5.2 kgf

⋅

cm, 2.3 - 4.5 in.

⋅

lbf)

HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.3 in.).

(f)

Using a chesel and hammer, stake the front planetary
gear washer.

99.

INSTALL INPUT SUN GEAR

(a)

Install the 2 thrust bearings, the bearing race and the front
planetary sun gear to the front planetary gear assy.

Thrust bearing and bearing race diameter: mm (in.)

inside

outside

Thrust Bearing, A

34.6 (1.362)

52.2 (2.055)

Bearing Race, B

40.3 (1.587)

58.0 (2.283)

Thrust Bearing, C

38.6 (1.520)

60.0 (2.362)

100. INSTALL REAR PLANETARY GEAR ASSY

(a)

Install the rear planetary gear to the rear planetary ring
gear.

D03616

D26413

Disc

Plate

D26452

A

D03815

40-46

-

AUTOMATIC TRANSMISSION / TRANS

AUTOMATIC TRANSAXLE ASSY (U150E)

68

U150E A/T REPAIR MANUAL (RM913U)

(b)

Using a screwdriver, install the snap ring.

101. INSTALL 1ST & REVERSE BRAKE CLUTCH DISC

(a)

Coat the 6 discs with ATF.

(b)

Install the 6 plates and 6 discs.

102. INSPECT PACK CLEARANCE OF FIRST & REVERSE

BRAKE

(a)

Using vernier calipers, measure the distance between the
disc surface and the contact surface of the 2nd brake cyl-
inder and transaxle case(Dimension A).

(b)

Select an appropriate flange so that the pack clearance
will meet the specified value.
Pack clearance:1.16 - 1.35 mm (0.0457 - 0.0531 in.)

HINT:
Piston stroke = Dimension A -Flange thickness
Flange thickness: mm (in.)

Mark

Thickness

Mark

Thickness

1

1.8 (0.071)

5

2.2 (0.087)

2

1.9 (0.075)

6

2.3 (0.091)

3

2.0 (0.079)

7

2.4 (0.094)

4

2.1 (0.083)

8

2.5 (0.098)

(c)

Install the flange.