Lexus ES300 (2002 year). Service manual - part 431

D03860

C56360

C56359

D03703

SST

-

AUTOMATIC TRANSMISSION / TRANS

UNDERDRIVE CLUTCH ASSY (U150E)

40-91

113

U150E A/T REPAIR MANUAL   (RM913U)

10.

INSTALL UNDERDRIVE CLUTCH PISTON SET

(a)

Coat the U/D clutch piston with ATF, install it to the U/D
clutch piston drum.

NOTICE:

Be careful not to damage the O-ring.

Be careful not to damage the lip seal of the piston.

11.

INSTALL UNDERDRIVE CLUTCH RETURN SPRING
SUB-ASSY

(a)

Install the return spring to the U/D clutch drum.

(b)

Install the clutch balancer to the U/D clutch drum.

NOTICE:
Be careful not to damage the lip seal of the clutch balancer.

(c)

Place SST on the clutch balancer and compress the pis-
ton return spring with a press.
SST

09350-32014 (09351-32070)

(d)

Using a snap ring expander, install the snap ring to the
U/D clutch drum.

(e)

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
grove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.

D25592

Stopper

Stopper

D26431

Disc

Flange

Plate

D03701

D26429

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AUTOMATIC TRANSMISSION / TRANS

UNDERDRIVE CLUTCH ASSY (U150E)

114

U150E A/T REPAIR MANUAL   (RM913U)

(f)

Set the end gap of the snap ring in the U/D clutch drum
shown in the illustration.

NOTICE:
The end gap of the snap ring should not coincide with any
of the stopper.

12.

INSTALL UNDERDRIVE CLUTCH DISC NO.1

(a)

Apply the 4 discs with ATF.

(b)

Install the 4 plates, 4 discs and flange to the U/D clutch
drum.

(c)

Using a screwdriver, install the U/D clutch flange No. 2
hole snap ring.

(d)

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

13.

INSPECT UNDERDRIVE PACK CLEARANCE

(a)

Install the U/D clutch to the transaxle case.

NOTICE:
Be careful not to damage the oil seal ring.
(b)

Set a dial indicator as shown in the illustration.

(c)

Measure the U/D clutch piston stroke while applying and
releasing compressed air (392 kPa, 4.0 kgf/cm

2

, 57 psi).

Park clearance: 1.51 - 1.71 mm (0.0594 - 0.0673 in.)

If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the pack clearance is not within standard, select another
flange.
HINT:
There are 5 flanges in different thickness.

Flange thickness: mm (in.)

No.

Thickness

No.

Thickness

1

3.0 (0.118)

4

3.3 (0.130)

2

3.1 (0.122)

5

3.4 (0.134)

3

3.2 (0.126)

-

-

4006K-02

D25593

SST

D25594

SST

D03686

SST

D03687

-

AUTOMATIC TRANSMISSION / TRANS

UNDERDRIVE PLANETARY GEAR ASSY (U150E)

40-93

115

U150E A/T REPAIR MANUAL   (RM913U)

UNDERDRIVE PLANETARY GEAR ASSY (U150E)

OVERHAUL

1.

INSPECT UNDERDRIVE PLANETARY GEAR
PRELOAD

(a)

Using SST, fix the U/D planetary gear assy.
SST

09387-00050

(b)

Using SST and a torque wrench, measure the turning
torque of U/D planetary gear assy while rotating the
torque wrench at 60 rpm.
SST

09387-00050

Turning torque at 60 rpm.:
2.14 - 5.40 N

⋅

m (21.8 - 55.1 kgf

⋅

cm, 0.24 - 0.61 in.

⋅

lbf)

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

2.

REMOVE FRONT PLANETARY GEAR NUT

(a)

Using SST, loosen the staked part of the nut.
SST

09930- 00010 (09931- 00010, 09931- 00020),
09387-00050

(b)

Clamp the U/D planetary gear in soft jaw vise.

NOTICE:
Be careful not to damage the differential drive pinion.

D25609

D03689

SST

Hold

Turn

D26437

SST

D03691

SST

SST

Hold

Turn

D03826

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AUTOMATIC TRANSMISSION / TRANS

UNDERDRIVE PLANETARY GEAR ASSY (U150E)

116

U150E A/T REPAIR MANUAL   (RM913U)

(c)

Using a socket wrench, remove the lock nut.

3.

REMOVE CYLINDRICAL ROLLER BEARING RACE
INNER

(a)

Using SST, remove the cylindrical roller bearing race in-
ner.
SST

09950- 00020, 09950- 00030, 09950- 60010
(09951-00320),  09950-40011 (09957-04010)

4.

REMOVE UNDERDRIVE PLANETARY GEAR ASSY

(a)

Using SST and a press, remove the differential drive pin-
ion, parking lock gear, counter driven gear with U/D plane-
tary ring gear and front tapered roller bearing.
SST

09950-60010 (09951-00320), 09387-00050

(b)

Clamp the U/D planetary gear in soft jaw vise.

(c)

Using SST, remove the rear tapered roller bearing form
the U/D planetary gear.
SST

09950- 00020, 09950- 00030, 09950- 60010
(09951-00320),  09950-40011 (09957-04010)

5.

REMOVE UNDERDRIVE PLANETARY RING GEAR

(a)

Using a snap ring pliers, remove the snap ring.