Lexus ES300 (1997 year). Manual — part 83

AUTOMATIC TRANSAXLE

OVERDRIVE UNIT

-

AX-59

4.

REMOVE SNAP RING WITH SCREWDRIVER

5.

REMOVE FLANGES, DISCS AND PLATES

6.

REMOVE PISTON RETURN SPRING

(a)

Place SST on the spring retainer and compress the spring
with a press.
SST 09350-32014 (09351-32070, 09351-32200)

(b)

Remove the snap ring.

(c)

Remove the piston return spring.

7.

REMOVE PISTON FROM CLUTCH DRUM

(a)

Install the clutch drum on the case.

(b)

Apply compressed air to the pressure apply hole of the
case.

(c)

Remove the piston from the clutch drum.
If the piston does not come out completely, use needle-
nose pliers to remove it.

(d)

Remove the clutch drum from the case.

AUTOMATIC TRANSAXLE

OVERDRIVE UNIT

-

AX-60

8.

REMOVE O-RINGS
Remove the 2 O-rings from the piston.

OVERDRIVE DIRECT CLUTCH INSPECTION

1.

INSPECT OVERDRIVE DIRECT CLUTCH

(a)

Check that the check ball is free by shaking the piston.

(b)

Check that the valve does not leak by applying low-pres-
sure compressed air.

2.

INSPECT DISCS, PLATES AND FLANGES
Check if the sliding surfaces of the discs, plates and
flanges are worn or burnt. If necessary, replace them.
HINT:

If the lining of the disc is peeling off or discolored, or
even if a part of the printed numbers are defaced, re-
place all discs.

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

3.

CHECK DIRECT CLUTCH BUSHING
Using a dial indicator, measure the inside diameter of the
2 direct clutch bushings.

Maximum inside diameter:

22.13 mm (0.8713 in.)

If the inside diameter is greater than the maximum, re-
place the direct clutch drum.

OVERDRIVE DIRECT CLUTCH ASSEMBLY

1.

INSTALL CLUTCH PISTON

(a)

Install new O-rings to the piston. Coat the O-rings with
ATF.

AX03W-03

AX03X-06

AUTOMATIC TRANSAXLE

OVERDRIVE UNIT

-

AX-61

(b)

Press the piston into the drum with the cup side up, being
careful not to damage the O-ring.

2.

INSTALL PISTON RETURN SPRING

(a)

Install the return spring and seat snap ring in place.

(b)

Place SST on the spring retainer, and compress the
spring with a press.
SST 09350-32014 (09351-32070, 09351-32200)

(c)

Install the snap ring with a screwdriver. Be sure end gap
of snap ring is aligned with the groove of the clutch drum.

3.

INSTALL PLATES, DISCS AND FLANGE
Install in order:
P=Plate D=Disc
P-D-P-D-Flange

4.

INSTALL SNAP RING
Be sure end gap of the snap ring is not aligned with the
groove of the clutch drum.

AUTOMATIC TRANSAXLE

OVERDRIVE UNIT

-

AX-62

5.

INSTALL BEARING AND RACE

(a)

Coat the bearing with petroleum jelly and install it facing
the race side downward to the clutch drum.

Bearing outer diameter: 46.3 mm (1.823 in.)

Bearing inner diameter: 26.2 mm (1.031 in.)

(b)

Coat the race with petroleum jelly and install it to the case.

Race outer diameter: 43.0 mm (1.693 in.)

Race inner diameter: 24.5 mm (0.965 in.)

6.

INSTALL DIRECT CLUTCH ON CASE

7.

RECHECK PISTON STROKE OF DIRECT CLUTCH
Install a dial indicator and measuring terminal (SST) to-
gether, measure the piston stroke while applying and re-
leasing compressed air (392- 785 kPa, 4- 8 kgf/cm

2

,

57-1 14 psi).

Piston stroke:

1.75-2.49 mm (0.0689-0.0980 in.)

SST 09350-32014 (09351-32190)

COUNTER DRIVE GEAR DISASSEMBLY

1.

CHECK OPERATION OF ONE-WAY CLUTCH

(a)

Install the O/D direct clutch into the one-way clutch.

(b)

Hold the O/D direct clutch and turn the intermediate shaft.
The shaft should turn freely clockwise and should lock
counterclockwise.

(c)

Remove the O/D direct clutch.

AX03Y-03