Automatic Transaxle (On-Vehcle Service) Lexus ES XV30

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1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (See ENGINE MECHANICAL )
2. REMOVE FRONT DRIVE SHAFT ASSY RH (See «REMOVAL, OVERHAUL & INSTALLATION»(ref-164138-S14966090822004072200000) )
3. REMOVE FRONT DRIVE SHAFT ASSY LH (See «REMOVAL, OVERHAUL & INSTALLATION»(ref-164138-S14966090822004072200000) )
4. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO. 2 Remove the bolt and transmission control cable bracket No.2.
5. REMOVE WIRE HARNESS CLAMP Disconnect the wire harnesses from the clamps. Remove the 2 bolts and 2 clamps.
6. DISCONNECT WIRE HARNESS Remove the bolt and wire harness.
7. REMOVE STARTER ASSY Disconnect the connector. Remove the 2 bolts and starter assy.
8. DISCONNECT CONNECTOR Disconnect the 2 transmission wire connectors. Disconnect the park/neutral position switch connector. Disconnect the 2 speed sensor connectors.
9. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.1 Remove the bolt and oil cooler tube clamp. Remove the 2 bolts and transmission control cable bracket No. 1.
10. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSY Remove the ATF level gauge. Disconnect the vent hose from the oil filler tube. Remove the bolt and oil filler tube. Remove the O-ring from the oil filler tube.
11. REMOVE OIL COOLER INLET TUBE NO.1 Using SST and spanner, disconnect the oil cooler inlet tube No. 1. SST 09023-12700
12. REMOVE OIL COOLER OUTLET TUBE NO.1 Using SST and spanner, disconnect the oil cooler outlet tube No. 1. SST 09023-12700
13. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET Remove the 3 bolts and engine mounting bracket FR.
14. REMOVE EXHAUST PIPE SUPPORT BRACKET SUB-ASSY Remove the 2 bolts and nut. Remove the exhaust pipe support bracket and exhaust pipe support bracket No. 1 from the automatic transaxle.
15. REMOVE AUTOMATIC TRANSAXLE ASSY Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench. Remove the 9 bolts. Separate and remove the automatic transaxle.
16. REMOVE TORQUE CONVERTER CLUTCH ASSY
17. INSPECT TORQUE CONVERTER CLUTCH ASSY (See «TORQUE CONVERTER CLUTCH AND DRIVE PLATE»(/lexus/es/xv30-2001-2003/remont/automatic-trans/#automatic-transaxle-on-vehcle-service) ) SST 09350-32014 (09351-32010, 09351-32020)
18. INSTALL TORQUE CONVERTER CLUTCH ASSY Install the torque converter clutch to the automatic transaxle. Using vernier calipers, measure the dimension "A" between the transaxle fitting part and the converter fitting part of the drive plate. Using vernier calipers and a straight edge, measure the dimension "B" shown in the illustration and check that "B" is greater than "A" measured in (b). Standard: A + 1 mm or more NOTE: Do not add the thickness of straight edge.
19. INSTALL AUTOMATIC TRANSAXLE ASSY Install the automatic transaxle and 9 bolts to the engine. Torque: Bolt A: 64 N.m (650 kgf.cm, 47 ft.lbf) Bolt B: 46 N.m (470 kgf.cm, 34 ft.lbf) Bolt C: 44 N.m (449 kgf.cm, 32 ft.lbf) Apply a few drops of adhesive to each of 2 threads on the tip of the 6 torque converter clutch mounting bolts. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Install the 6 torque converter clutch mounting bolts. Torque: 41 N.m (420 kgf.cm, 30 ft.lbf) HINT: First install green colored bolt and then the 5 bolts.
20. INSTALL EXHAUST PIPE SUPPORT BRACKET SUB-ASSY Install the exhaust pipe support bracket and exhaust pipe support bracket No. 1 to the automatic transaxle with the 2 bolts and nut. Torque: Bolt: 7.8 N.m (80 kgf.cm, 69 in..lbf) Nut : 21 N.m (214 kgf.cm, 16 ft.lbf)
21. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET Install the engine mounting bracket FR and 3 bolts to the automatic transaxle. Torque: 64 N.m (653 kgf.cm, 47 ft.lbf)
22. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSY Coat a new O-ring with ATF, and install them to the oil filler tube. Install the oil filler tube and bolt to the automatic transaxle. Torque: 5.5 N.m (56 kgf.cm, 49 in..lbf) Connect the breather hose clamp to the oil filler tube. Install the ATF level gauge.
23. INSTALL TRANSMISSION CONTROL CABLE BRACKET NO.1 Install the control cable bracket No. 1 and 2 bolts. Torque: 11.8 N.m (122 kgf.cm, 9 ft.lbf)
24. INSTALL OIL COOLER INLET TUBE NO.1 Temporarily install the oil cooler outlet tube No. 1. Temporarily install the oil cooler inlet tube No. 1. Install the oil cooler tube clamp and bolt. Torque: 5.4 N.m (56 kgf.cm, 49 in..lbf) HINT: Install them so that the oil cooler tube cushion is positioned as illustrated. Using SST and spanner, tighten the oil cooler inlet tube No. 1. SST 09023-12700 Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf)
25. INSTALL OIL COOLER OUTLET TUBE NO.1 Using SST and spanner, tighten the oil cooler outlet tube No. 1. SST 09023-12700 Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf)
26. CONNECT CONNECTOR Connect the 2 transmission with connectors. Connect the park/neutral position switch connector. Connect the 2 speed sensor connectors.
27. INSTALL STARTER ASSY Install the starter assy and 2 bolts. Torque: 37 N.m (377 kgf.cm, 27 ft.lbf) Connect the connector.
28. INSTALL WIRE HARNESS Install the wire harness and bolt. Torque: 25.5 N.m (260 kgf.cm, 19 ft.lbf)
29. INSTALL WIRE HARNESS CLAMP Install the 2 clamps and 2 bolts. Torque: 8.4 N.m (86 kgf.cm, 74 in..lbf) Connect the wire harnesses to the clamps.
30. INSTALL TRANSMISSION CONTROL CABLE BRACKET NO. 2 Install the transmission control cable bracket No. 2 and bolt. Torque: 11.8 N.m (122 kgf.cm, 9 ft.lbf)
31. INSTALL FRONT DRIVE SHAFT ASSY LH (See «REMOVAL, OVERHAUL & INSTALLATION»(ref-164138-S14966090822004072200000) )
32. INSTALL FRONT DRIVE SHAFT ASSY RH (See «REMOVAL, OVERHAUL & INSTALLATION»(ref-164138-S14966090822004072200000) )
33. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (See ENGINE MECHANICAL )

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1. INSPECT TORQUE CONVERTER CLUTCH ASSY Inspect the one-way clutch. Set SST into the inner race of the one-way clutch. SST 09350-32014 (09351-32010) Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch. SST 09350-32014 (09351-32020) With the torque converter clutch setting up on its side, check that the one-way clutch locks when it is turned counterclockwise, and rotates clockwise smoothly. If necessary, clean the converter and retest the one-way clutch. Replace the converter if the one-way clutch still fails the test. Determine the condition of the torque converter clutch assy. If the inspection result of the torque converter clutch assy meets the following item, replace the torque converter clutch. Malfunction item: Any metallic sound is heard from the torque converter clutch during stall test or when the shift lever is in neutral position. One-way clutch is free or locked in both directions. Fine powders exceeding the sample limit is identified in ATF. ( (Scheme 353)) HINT: The sample shows the auto fluid of approx. 0.25 liters (0.26 US qts, 0.22 lmp. qts) that is taken out from the removed torque converter clutch Replace the ATF in the torque converter clutch. If the ATF is discolored and/or has a foul odor, completely stir the ATF in the torque converter clutch and drain it with the face for installation facing up. Clean and check the oil cooler and oil pipe line. If the torque converter clutch is inspected or the ATF is exchanged, clean the oil cooler and oil pipe line. HINT: Spray compressed air of 196 kPa (2 kgf/cm 2, 28 psi) from the inlet hose. If plenty of fine powders are identified in the ATF, add new ATF using a bucket pump and clean it again. If the ATF is cloudy, inspect the oil cooler (radiator). Prevent deformation of the torque converter clutch and damage to the oil pump gear. When any marks due to interference are found on the end of the bolt for the torque converter clutch and on the bottom of the bolt hole, replace the bolt and the torque converter clutch. All of the bolts must be have the same length. No missing spring washer.
2. INSPECT DRIVE PLATE & RING GEAR SUB-ASSY Set up a dial indicator and measure the drive plate runout. Check the damage of the ring gear. Maximum runout: 0.20 mm (0.0079 in.) If the runout is not within the specification or ring gear is damaged, replace the drive plate.

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1. REMOVE BATTERY
2. REMOVE AIR CLEANER ASSY
3. REMOVE AIR CLEANER HOSE NO.1
4. REMOVE SPEED SENSOR (NT SENSOR) Disconnect the speed sensor connector. Remove the bolt and speed sensor.
5. REMOVE SPEED SENSOR (NC SENSOR) Disconnect the speed sensor connector. Remove the bolt and speed sensor.
6. INSTALL SPEED SENSOR (NC SENSOR) Coat O-ring with ATF. Install the speed sensor with the bolt. Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf) HINT: Make sure of the manufacturer's name. Connect the speed sensor connector.
7. INSTALL SPEED SENSOR (NT SENSOR) Coat O-ring with ATF. Install the speed sensor with the bolt. Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf) HINT: Make sure of the manufacturer's name. Connect the speed sensor connector.
8. INSTALL AIR CLEANER HOSE NO.1
9. INSTALL AIR CLEANER ASSY Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf)
10. INSTALL BATTERY

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1. REMOVE ENGINE UNDER COVER NO. 2
2. DRAIN AUTOMATIC TRANSAXLE FLUID Remove the drain plug and gasket, and drain ATF. Install a new gasket and drain plug. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
3. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSY Remove the 18 bolts, oil pan and gasket. NOTE: Some fluid will remain in the oil pan. Remove all pan bolts, and carefully remove the oil pan assembly. Remove the 3 magnets from the oil pan. Examine particles in pan. Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the pan and the magnet to anticipate the type of wear you will find in the transaxle. Steel (magnetic): bearing, gear and plate wear Brass (non-magnetic): bearing wear
4. DISCONNECT TRANSMISSION WIRE Disconnect the 7 shift solenoid valve connectors. Remove the bolt and lock plate, and disconnect the ATF temperature sensor.
5. REMOVE TRANSMISSION WIRE Disconnect the transmission wire connectors. Remove the bolt and transmission wire.
6. INSTALL TRANSMISSION WIRE Coat a O-ring of the transmission wire connector with ATF. Install the transmission wire and bolt. Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf)
7. CONNECT TRANSMISSION WIRE Coat a O-ring of the ATF temperature sensor with ATF. Install the ATF temperature sensor with the lock plate and bolt. Torque: 6.6 N.m (67 kgf.cm, 58 in..lbf) Connect the 7 shift solenoid valve connectors.
8. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSY Install the 3 magnets in the oil pan. Apply seal packing or the equivalent to the 18 bolts. Seal packing: THREE BOND 2430 or equivalent Install a new gasket, oil pan and 18 bolts to the transaxle case. Torque: 7.8 N.m (80 kgf.cm, 69 in..lbf) NOTE: Because the bolts should be seal bolts, apply seal packing to bolts and tighten them within 10 minutes after application.
9. ADD AUTOMATIC TRANSAXLE FLUID
10. INSPECT AUTOMATIC TRANSAXLE FLUID (See «ON-VEHICLE INSPECTION»(ref-213131-S39981318582005122600000) )
11. INSTALL ENGINE UNDER COVER NO. 2

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1. REMOVE ENGINE UNDER COVER NO. 2
2. DRAIN AUTOMATIC TRANSAXLE FLUID Remove the drain plug and gasket, and drain ATF. Install a new gasket and drain plug. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
3. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSY Remove the 18 bolts, oil pan and gasket. NOTE: Some fluid will remain in the oil pan. Remove all pan bolts, and carefully remove the oil pan assembly. Remove the 3 magnets from the oil pan. Examine particles in pan. Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the pan and the magnet to anticipate the type of wear you will find in the transaxle. Steel (magnetic): bearing, gear and plate wear Brass (non-magnetic): bearing wear
4. DISCONNECT TRANSMISSION WIRE Disconnect the 7 shift solenoid valve connectors. Remove the bolt and lock plate, and disconnect the ATF temperature sensor.
5. REMOVE VALVE BODY OIL STRAINER ASSY Remove the 3 bolts and oil strainer. NOTE: Be careful that some fluid will come out of the oil strainer. Remove the O-ring from the oil strainer.
6. REMOVE TRANSMISSION VALVE BODY ASSY Support the valve body assy and remove the 17 bolts and the valve body assy. NOTE: Be careful not to drop the check valve body, spring and accumulator piston. Remove the check ball body and spring. Remove the 6 bolts and 7 shift solenoid valves.
7. INSTALL TRANSMISSION VALVE BODY ASSY Install the spring and check ball body. Install the 7 shift solenoid valves with the 6 bolts. Torque: Bolt A, B, C: 10.8 N.m (110 kgf.cm, 8 ft.lbf) Bolt D: 6.6 N.m (67 kgf.cm, 58 in..lbf) Bolt length: Bolt A: 16 mm (0.63 in.) Bolt B, C: 57 mm (2.2 in.) Bolt D: 12 mm (0.47 in.) Align the groove of the manual valve with the pin of lever. Install the 17 bolts. Torque: 10.8 N.m (110 kgf.cm, 8 ft.lbf) NOTE: Push the valve body against the accumulator piston spring and the check ball body to install it. Tighten those bolts marked by * in the illustration first temporarily because they are positioning bolts. Bolt length: Bolt A: 25 mm (0.984 in.) Bolt B: 57 mm (2.244 in.) Bolt C: 41 mm (1.614 in.)
8. INSTALL VALVE BODY OIL STRAINER ASSY Coat a new O-ring with ATF. Install the O-ring to the oil strainer. Install the oil strainer with the 3 bolts. Torque: 10.8 N.m (110 kgf.cm, 8 ft.lbf)
9. CONNECT TRANSMISSION WIRE Coat a O-ring with ATF. Install the ATF temperature sensor with the lock plate and bolt. Torque: 6.6 N.m (67 kgf.cm, 58 in..lbf) Connect the 7 shift solenoid valve connectors.
10. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSY Install the 3 magnets in the oil pan. Apply seal packing or equivalent to 18 bolts. Seal packing: THREE BOND 2430 or equivalent Install a new gasket, oil pan and 18 bolts to the transaxle case. Torque: 7.8 N.m (80 kgf.cm, 69 in..lbf) NOTE: Because the bolts should be seal bolts, apply seal packing to bolts and tighten them within 10 minutes after application.
11. ADD AUTOMATIC TRANSAXLE FLUID
12. INSPECT AUTOMATIC TRANSAXLE FLUID (See «ON-VEHICLE INSPECTION»(ref-213131-S39981318582005122600000) )
13. INSTALL ENGINE UNDER COVER NO. 2

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1. REMOVE FRONT WHEEL
2. REMOVE ENGINE UNDER COVER NO.1
3. DRAIN AUTOMATIC TRANSAXLE FLUID Remove the drain plug, gasket and drain ATF. Install a new gasket and drain plug. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
4. REMOVE FRONT DRIVE SHAFT ASSY RH (See «REMOVAL, OVERHAUL & INSTALLATION»(ref-164138-S14966090822004072200000) )
5. REMOVE FRONT DRIVE SHAFT ASSY LH (See «REMOVAL, OVERHAUL & INSTALLATION»(ref-164138-S14966090822004072200000) )
6. REMOVE TRANSAXLE HOUSING OIL SEAL Using SST, pull out the oil seal. SST 09308-00010
7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST, pull out the oil seal. SST 09308-00010
8. INSTALL TRANSAXLE HOUSING OIL SEAL Using SST and a hammer, drive in a new oil seal. SST 09316-60011 (09316-00011) Oil seal drive in depth: 0 +/- 0.5 mm (0 +/- 0.020 in.) Coat the lip of the oil seal with MP grease.
9. INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST and a hammer, drive in a new oil seal. SST 09223-15020, 09950-70010 (09951-07150) Oil seal drive in depth: 0 +/- 0.5 mm (0 +/- 0.020 in.) Coat the lip of the oil seal with MP grease.
10. INSTALL FRONT DRIVE SHAFT ASSY LH (See «REMOVAL, OVERHAUL & INSTALLATION»(ref-164138-S14966090822004072200000) )
11. INSTALL FRONT DRIVE SHAFT ASSY RH (See «REMOVAL, OVERHAUL & INSTALLATION»(ref-164138-S14966090822004072200000) )
12. INSTALL FRONT WHEEL Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
13. ADD AUTOMATIC TRANSAXLE FLUID
14. INSPECT AUTOMATIC TRANSAXLE FLUID (See «ON-VEHICLE INSPECTION»(ref-213131-S39981318582005122600000) )
15. CHECK ABS SPEED SENSOR SIGNAL

See also:
• TORQUE CONVERTER CLUTCH AND DRIVE PLATE