Lexus ES300 (2002 year). Manual — part 427

D26706

D26706

D26775

D26704

40-86

-

AUTOMATIC TRANSMISSION / TRANS

SECOND BRAKE PISTON ASSY (U150E)

108

U150E A/T REPAIR MANUAL (RM913U)

4.

REMOVE 2ND BRAKE PISTON O-RING

(a)

Remove the 2 O-rings from the 2nd brake piston.

5.

INSTALL 2ND BRAKE PISTON O-RING

(a)

Apply the 2 new O-rings with ATF, install them in the 2nd
brake piston.

6.

INSTALL 2ND BRAKE PISTON

(a)

Apply the 2nd brake piston with ATF, and install it to the
2nd brake cylinder.

NOTICE:
Be careful not to damage the O-ring.

7.

INSTALL 2ND BRAKE PISTON RETURN SPRING
SUB-ASSY

(a)

Install the piston return spring.

D26703

SST

-

AUTOMATIC TRANSMISSION / TRANS

SECOND BRAKE PISTON ASSY (U150E)

40-87

109

U150E A/T REPAIR MANUAL (RM913U)

(b)

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

09387-00060

(c)

Using a screwdriver, install the snap ring.

(d)

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
groove.

This prevents the spring sheet from being deformed.

0305K-05

03-4

-

SERVICE SPECIFICATIONS

AUTOMATIC TRANSMISSION / TRANSAXLE

19

U150E A/T REPAIR MANUAL (RM913U)

AUTOMATIC TRANSMISSION / TRANSAXLE

SERVICE DATA

Oil pump

Body clearance

STD

Max.

0.10 - 0.17 mm (0.0039 - 0.0067 in.)

0.17 mm (0.0067 in.)

Tip clearance

STD

Max.

0.07 - 0.15 mm (0.0028 - 0.0059 in.)

0.15 mm (0.0059 in.)

Side clearance

STD

Max.

0.02 - 0.05 mm (0.0008 - 0.0020 in.)

0.05 mm (0.0020 in.)

Drive gear thickness

Mark

A
B

C
D

E

11.690 - 11.699 mm (0.4602 - 0.4606 in.)
11.700 - 11.709 mm (0.4606 - 0.4610 in.)
11.710 - 11.720 mm (0.4610 - 0.4614 in.)
11.721 - 11.730 mm (0.4615 - 0.4618 in.)
11.731 - 11.740 mm (0.4619 - 0.4622 in.)

Driven gear thickness

Mark

A
B

C
D

E

11.690 - 11.699 mm (0.4602 - 0.4606 in.)
11.700 - 11.709 mm (0.4606 - 0.4610 in.)
11.710 - 11.720 mm (0.4610 - 0.4614 in.)
11.721 - 11.730 mm (0.4615 - 0.4618 in.)
11.731 - 11.740 mm (0.4619 - 0.4622 in.)

Pump body bushing inside diameter

STD

Max.

38.113 - 38.138 mm (1.50050 - 1.50149 in.)

38.138 mm (1.50149 in.)

Stator shaft bushing inside diameter

STD

Max.

21.500 - 21.526 mm (0.84646 - 0.84748 in.)

21.526 mm (0.84748 in.)

Multiple disc clutch

Inside diameter

STD

Max.

23.025 - 23.045 mm (0.9065 - 0.9073 in.)

23.09 mm (0.9091 in.)

Forward clutch

Pack clearance

1.00 - 1.25 mm (0.0394 - 0.4921 in.)

Return spring free length

26.76 mm (1.0535 in.)

Flange thickness

Mark

1

2

3

4

5

3.00 mm (0.1181 in.)

3.15 mm (0.1240 in.)

3.30 mm (0.1299 in.)

3.45 mm (0.1358 in.)

3.60 mm (0.1417 in.)

Reverse clutch

Pack clearance:

0.60 - 0.82 mm (0.02362 - 0.03228 in.)

Flange thickness

Mark

1

2

3

4

5

6

7

3.0 mm (0.118 in.)

3.1 mm (0.122 in.)

3.2 mm (0.126 in.)

3.3 mm (0.130 in.)

3.4 mm (0.134 in.)

3.5 mm (0.138 in.)

3.6 mm (0.142 in.)

-

SERVICE SPECIFICATIONS

AUTOMATIC TRANSMISSION / TRANSAXLE

03-5

20

U150E A/T REPAIR MANUAL (RM913U)

Direct clutch & O/D clutch

Pack clearance

0.60 - 0.82 mm (0.02362 - 0.03228 in.)

Return spring free length

25.91 mm (1.0201 in.)

Flange thickness

Mark

0
1
2
3
4
5
6

2.5 mm (0.098 in.)
2.6 mm (0.102 in.)
2.7 mm (0.106 in.)
2.8 mm (0.110 in.)
2.9 mm (0.114 in.)
3.0 mm (0.118 in.)
3.1 mm (0.122 in.)

2nd brake

Pack clearance

0.62 - 0.91 mm (0.0244 - 0.0358 in.)

Return spring free length

16.61 mm (0.6539 in.)

Flange thickness

Mark

1
2
3
4
5
6
7

3.0 mm (0.118 in.)

3.1 mm (0.122 in.)

3.2 mm (0.126 in.)

3.3 mm (0.130 in.)

3.4 mm (0.134 in.)

3.5 mm (0.138 in.)

3.6 mm (0.142 in.)

U/D clutch

Pack clearance

1.51 - 1.71 mm (0.0594 - 0.0673 in.)

U/D clutch drum bushing inside diameter

STD

Max.

37.06 - 37.08 mm (1.4591 - 1.4598 in.)

37.13 mm (1.4618 in.)

Return spring free length

17.14 mm (0.6752 in.)

Flange thickness

Mark

1

2
3

4
5

3.0 mm (0.118 in.)

3.1 mm (0.122 in.)

3.2 mm (0.126 in.)

3.3 mm (0.130 in.)

3.4 mm (0.134 in.)

U/D brake

Pack clearance

1.81 - 2.20 mm (0.0713 - 0.0866 in.)

Return spring free length

14.04 mm (0.5528 in.)

Flange thickness

Mark

1

2

3

3.0 mm (0.118 in.)

3.2 mm (0.126 in.)

3.4 mm (0.134 in.)

1st & reverse brake

Pack clearance

1.16 - 1.35 mm (0.0457 - 0.0531in.)

Return spring free length

15.53 mm (0.6114 in.)

Flange thickness

Mark

1
2
3
4
5
6
7
8

1.8 mm (0.071 in.)
1.9 mm (0.075 in.)
2.0 mm (0.079 in.)
2.1 mm (0.083 in.)
2.2 mm (0.087 in.)
2.3 mm (0.091 in.)
2.4 mm (0.094 in.)
2.5 mm (0.098 in.)