Lexus ES300 (1997 year). Manual — part 78

AUTOMATIC TRANSAXLE

DIRECT CLUTCH

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AX-39

2.

REMOVE SNAP RING FROM CLUTCH DRUM

3.

REMOVE FLANGE, DISCS AND PLATES

4.

REMOVE PISTON RETURN SPRING

(a)

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

(b)

Remove the snap ring with snap ring pliers.

(c)

Remove the piston return spring.

5.

REMOVE CLUTCH PISTON

(a)

Install the direct clutch onto the oil pump.

(b)

Apply compressed air to the oil pump to remove the piston
(if the piston does not come out completely, use needle-
nose pliers to remove it).

(c)

Remove the direct clutch from the oil pump.

(d)

Remove the 2 O-rings from the piston.

AUTOMATIC TRANSAXLE

DIRECT CLUTCH

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AX-40

DIRECT CLUTCH INSPECTION

1.

INSPECT CLUTCH PISTON

(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 FLANGE
Check if the sliding surfaces of the discs, plates and
flange 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
direct clutch bushing.

Maximum inside diameter:

48.27 mm (1.9004 in.)

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

DIRECT CLUTCH ASSEMBLY

1.

INSTALL CLUTCH PISTON IN DIRECT CLUTCH DRUM

(a)

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

(b)

Being careful not to damage the O-rings, press the piston
into the drum with the cup side up.

2.

INSTALL PISTON RETURN SPRING

(a)

Place the return spring and snap ring onto the piston.

AX034-03

AX035-06

AUTOMATIC TRANSAXLE

DIRECT CLUTCH

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AX-41

(b)

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

(c)

Install the snap ring using snap ring pliers. Be sure the
end gap of snap ring is aligned with the spring retainer
claw.

3.

INSTALL PLATES, DISCS AND FLANGE

(a)

Install plates and discs.
Install in order:
P=Plate D=Disc
P-D-P-D-P-D

(b)

Install the flange with the flat end facing downward.

4.

INSTALL SNAP RING
Check that the end gap of the snap ring is not aligned with
one of the cutouts.

5.

RECHECK PISTON STROKE OF DIRECT CLUTCH

(a)

Install the direct clutch on the oil pump.

(b)

Install a dial indicator and measuring terminal (SST) to-
gether, measure the direct clutch piston stroke while ap-
plying and releasing compressed air (392-785 kPa, 4-8
kgf/cm

2

, 57-114 psi).

SST 09350-32014 (09351-32190)

Piston stroke:

0.91-1.35 mm (0.0358-0.0531 in.)

If the piston stroke is non- standard, select another
flange.
HINT: There are 2 different thickness for the flange.

Flange thickness:

2.70 mm (0.1063 in.)

3.00 mm (0.1181 in.)

AUTOMATIC TRANSAXLE

FORWARD CLUTCH

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AX-42

FORWARD CLUTCH

COMPONENTS

FORWARD CLUTCH DISASSEMBLY

1.

CHECK PISTON STROKE OF FORWARD CLUTCH
Install a dial indicator and measuring terminal (SST) to-
gether, measure the forward clutch piston stroke while ap-
plying and releasing compressed air (392-785 kPa, 4-8
kgf/cm

2

, 57-114 psi).

SST 09350-32014 (09351-32190)

Piston stroke:

1.79-2.21 mm (0.0704-0.0870 in.)

each component.

AX036-02

AX037-04