Lexus ES300 (2002 year). Manual — part 423

D09693

D03576

D03875

E

D25511

Dimension (1)

Dimension (2)

D08087

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U150E A/T REPAIR MANUAL (RM913U)

(b)

Install the parking lock pawl shaft.

(c)

Install the pawl shaft clamp with the bolt.
Torque: 9.8 N

⋅

m (100 kgf

⋅

cm, 87 in.

⋅

lbf)

(d)

Using a straight edge and vernier calipers as shown in the
illustration, measure the gap between the top of the differ-
ential drive pinion in the U/D planetary gear and contact
surface of the transaxle case and housing (Dimension E).

NOTICE:
Note down the dimension E as it is necessary for the follow-
ing process.

(e)

As shown in the illustration, measure the 2 places of the
transaxle housing, calculate the dimension F using the
formula.

NOTICE:
Note down the dimension F as it is necessary for the follow-
ing process.
HINT:
Dimension F = Dimension (1) - Dimension (2)

125. INSTALL MULTIPLE DISC CLUTCH CLUTCH HUB

(a)

Install the bearing race to the transaxle case while check-
ing its direction.

Bearing race diameter: mm (in.)

Inside

Outside

Bearing race

34.5 (1.358)

48.5 (1.909)

D26710

D26711

D03820

D03574

D03573

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U150E A/T REPAIR MANUAL (RM913U)

(b)

Coat the thrust bearing and race with petroleum jelly,
install them onto the multiple disc clutch hub.

Thrust bearing and race diameter: mm (in.)

Inside

Outside

Thrust Bearing

36.3 (1.429)

52.2 (2.055)

(c)

Install the bearing to the multiple clutch hub.

Bearing diameter: mm (in.)

Inside

Outside

Bearing

23.5 (0.925)

44.0 (1.732)

(d)

Install the multiple clutch hub to the transaxle case.

126. INSTALL FORWARD CLUTCH ASSY
(a)

Install the thrust bearing to the forward clutch.

Thrust bearing diameter: mm (in.)

Inside

Outside

Thrust Bearing

33.85 (1.3327)

52.2 (2.055)

NOTICE:
Install the thrust bearing properly so that the no colored
race or blue ink jet race will be visible.

(b)

Install the forward clutch to the multiple clutch hub.

NOTICE:
Align the splines of all discs in the forward clutch with
those of multiple clutch hub to assemble them securely.

127. INSTALL OVERDRIVE BRAKE GASKET

(a)

Install the 2 new O/D brake gaskets.

D26450

D25506

D25505

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U150E A/T REPAIR MANUAL (RM913U)

128. INSTALL DIFFERENTIAL GEAR ASSEMBLY
(a)

Install the differential gear assy to the transaxle case.

129. INSTALL THRUST BEARING UNDERDRIVE RACE

NO.2

(a)

Install the thrust bearing race to the U/D planetary gear
assy.

130. INSTALL THRUST NEEDLE ROLLER BEARING

(a)

Calculate the end play value using the following formula
and values of Dimension E and F that ware measured
when installing cylindrical roller bearing and U/D plane-
tary gear. Select an appropriate U/D planetary gear thrust
bearing race No. 2 which satisfies the specified end play
value, and install it.
End play: 0.498 - 0.993 mm (0.01961 - 0.03909 in.)

HINT:
End play = Dimension F - Dimension E - thrust bearing thick-
ness 2.5 mm (0.0984 in.) - U/D thrust bearing race No. 2 thick-
ness.
Race thickness: mm (in.)

F - E

Thickness

Less than 7.64 (0.3008)

3.5 (0.138)

7.64 (0.3008)

3.8 (0.150)

Bearing and bearing race diameter: mm (in.)

Inside

Outside

Bearing

57.2 (2.252)

84.96 (3.3449)

Bearing race

56.4 (2.220)

83.0 (3.268)

D03569

D03629

D03630

Seal Bend Width 1.2 mm (0.047 in.)

FIPG

D26384

C

C

C

C

A

B

D

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131. INSTALL OIL PUMP ASSY
(a)

Install the oil pump to the transaxle case with the 7 bolts.
Torque: 22.1 N

⋅

m (226 kgf

⋅

cm, 16 ft

⋅

lbf)

(b)

Coat the O-ring of oil pump with ATF.

132. INSTALL TRANSAXLE HOUSING

(a)

Remove any parking material and be careful not to get oil
on the contacting surface of the transaxle case or trans-
axle housing.

(b)

Apply FIPG to the transaxle case.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equiva-
lent

(c)

Install the transaxle housing with the 16 bolts to the trans-
axle case.
Torque:
Bolt A and D: 22.1 N

⋅

m (225 kgf

⋅

cm, 16.3 ft

⋅

lbf)

Bolt B and C: 29.4 N

⋅

m (300 kgf

⋅

cm, 21.7 ft

⋅

lbf)

HINT:
Apply seal packing or equivalent to the bolt A and D.

Seal packing:
THREE BOND 2403 or equivalent
Bolt length:
Bolt A: 50 mm (1.969 in.)
Bolt B: 50 mm (1.969 in.)
Bolt C: 42 mm (1.654 in.)
Bolt D: 72 mm (2.835 in.)

NOTICE:
Because the bolt A and D are a seal bolts, apply the seal
packing to new bolts and tighten them within 10 minutes af-
ter application.