Overhaul - U150E: Diagnosis Lexus ES XV30

TROUBLE SHOOTING

Note. Transaxle malfunctions may be caused by poor engine performance, improper adjustments, fluid condition or failure of hydraulic, mechanical or electronic components. Ensure all concerns have been properly checked prior to transaxle overhaul. See appropriate DIAGNOSIS article.

Drive Plate (Flexplate) Runout Test

Measure drive plate runout. (Scheme 237) If runout exceeds.008" (.20 mm), or if ring gear is damaged, replace drive plate. If installing a NEW drive plate, note position of spacers. Tighten bolts to 61 ft. lbs. (83 N.m).

Scheme 236

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

Scheme 245

Scheme 246

Scheme 247

Scheme 248

Scheme 249

Scheme 250

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

Scheme 262

Scheme 263

Scheme 264

Scheme 265

Scheme 266

1. Remove transaxle drain plug and drain transaxle. (Scheme 238) Remove nut, washer and control shaft lever. Using a screwdriver, unstake nut stopper. Remove lock nut and stopper. Remove 2 bolts and pull out park/neutral position switch. (Scheme 239)
2. Remove oil line union and elbow. Remove and discard "O" rings from union and elbow. Remove counter gear and turbine speed sensors from top of transaxle. Remove and discard speed sensor "O" rings. Remove transaxle case plugs from transaxle case. Remove and discard case plug "O" rings. (Scheme 238)
3. Place transaxle on wooden blocks. Remove 18 bolts, oil pan and gasket. Remove 3 magnets from oil pan. (Scheme 239) Disconnect 7 shift solenoid valve connectors. Remove bolt, lock plate and ATF temperature sensor. (Scheme 240) Remove bolt and transaxle wiring harness with solenoid connectors from transaxle case. Remove 3 bolts, oil strainer and gasket. Remove 17 bolts and valve body assembly. (Scheme 241)
4. Remove governor apply gasket No. 1 and 2nd brake gasket from transaxle case. (Scheme 242) Remove brake drum gasket from transaxle case. (Scheme 243) Remove check ball body and spring from transaxle case. (Scheme 244) Remove spring from underdrive clutch accumulator piston. (Scheme 245)
5. Using 57 psi (4 kg/cm 2 ) of compressed air applied to transaxle case, remove underdrive clutch accumulator piston. (Scheme 246) Cover accumulator piston with shop towel during removal. Remove and discard "O" ring from piston.
6. Using 57 psi (4 kg/cm 2 ) of compressed air applied to transaxle case, remove reverse clutch accumulator piston and spring, and underdrive brake accumulator piston with 2 springs. Cover pistons with shop towel during removal. (Scheme 247)and (Scheme 248). Remove and discard "O" rings from pistons.
7. Using needle nose pliers, remove manual valve lever retainer spring. Remove 2 bolts, manual detent spring and cover. (Scheme 239) Remove 2 bolts and parking lock pawl bracket. Using a hammer and chisel, unstake and remove spacer. Using a pin punch and hammer, drive out slotted spring pin. Ensure pin does not fall into transaxle case.
8. Remove manual valve lever shaft and manual valve lever. Remove parking lock rod from manual valve lever. Using a screwdriver, remove shaft oil seal from transaxle case. (Scheme 239) Position transaxle case with oil pump assembly facing upward. CAUTION: Use caution when removing transaxle housing. Differential assembly may attach to transaxle housing during removal.
9. Using a dial indicator, measure input shaft end play and record measurement. (Scheme 249) End play should be.0103-.0492" (.262-1.249 mm). Remove 16 transaxle housing bolts. Note bolt length and location during removal for reassembly reference. (Scheme 250)
10. Remove 7 oil pump bolts and oil pump from transaxle case. Remove thrust needle roller bearing from underdrive planetary gear. Remove thrust bearing underdrive race No. 2 from underdrive planetary gear. Remove differential assembly. (Scheme 252) Remove 2 overdrive brake gaskets from transaxle case. (Scheme 253) Remove forward clutch from transaxle case. Remove thrust needle roller bearing from forward clutch. Remove thrust needle roller bearing, multiple disc clutch hub, thrust needle roller bearing and bearing race No. 1 from transaxle case. (Scheme 251)
11. Using a dial indicator, measure inside diameter of multiple disc clutch hub bushing. (Scheme 254) Standard diameter should be.9065-.9073" (23.025-23.046 mm). Maximum diameter is.9091" (23.090 mm). If diameter exceeds maximum specification, replace multiple disc clutch hub. Check bushing contact surface in clutch hub shaft for scratches or discoloration. Replace as necessary.
12. Remove one bolt and pawl shaft clamp. Remove parking lock pawl shaft. (Scheme 252) Push parking lock pawl toward transaxle case to prevent interference during underdrive planetary gear removal. (Scheme 255) Using both hands, remove underdrive planetary gear. DO NOT allow planetary gear to separate.
13. Remove torsion spring, pawl pin and parking lock pawl. Remove underdrive clutch assembly, needle roller bearing and thrust bearing race from transaxle case. (Scheme 252) Using a screwdriver, remove underdrive one-way clutch snap ring. Remove one-way clutch from transaxle case. Note position of index marks on one-way clutch for reassembly reference. see scheme 83 Note position of outer race retainer on one-way clutch for reassembly reference. (Scheme 256) Remove outer race retainer from one-way clutch.
14. Using a screwdriver, remove underdrive clutch snap ring. Remove flange, 4 discs and 4 plates from transaxle case. Note location of components during removal for reassembly reference. (Scheme 252)
15. Remove 11 bolts and transaxle rear cover. If necessary, tap on circumference of rear cover with plastic hammer to remove cover. Remove 4 transaxle case plugs from transaxle rear cover. Remove "O" rings. (Scheme 257) Remove 3 oil seal rings from transaxle rear cover. Using appropriate puller, remove needle roller bearing from transaxle rear cover, if necessary. (Scheme 258) Using a screwdriver, remove 3 governor apply gaskets from rear of transaxle case. (Scheme 252)
16. Remove bolt, clamp and apply tube. Remove clutch apply tube. Remove brake apply tube from clamp. (Scheme 252)and (Scheme 259). Remove direct clutch with thrust bearing from transaxle case. Remove thrust bearing race, thrust bearing and overdrive direct clutch hub from planetary gear. (Scheme 251)
17. Using a dial indicator, measure inside diameter of overdrive direct clutch hub bushing. (Scheme 254) Standard diameter should be.9065-.9073" (23.025-23.046 mm). Maximum diameter is.9091" (23.090 mm). If diameter exceeds maximum specification, replace overdrive direct clutch hub. Check bushing contact surface in clutch hub shaft for scratches or discoloration. Replace as necessary.
18. Remove rear planetary sun gear from transaxle case. Remove thrust needle roller bearing and thrust bearing race from rear planetary sun gear. Remove thrust washer No. 2 from rear planetary sun gear. Remove one-way clutch and thrust bearing from transaxle case. Remove inner race from one-way clutch. (Scheme 251)
19. Remove one-way clutch outer sleeve from transaxle case. Note direction of component for reassembly reference. Remove planetary carrier thrust washer No. 1 from planetary gear. Using a screwdriver, remove 2nd brake snap ring. Remove flange, 4 discs and 4 plates from transaxle case. Note location of components during removal for reassembly reference. (Scheme 251)
20. Using a screwdriver, remove 2nd brake piston snap ring. Remove 2nd brake piston from transaxle case. Using a screwdriver, remove rear planetary gear snap ring. Remove rear planetary gear from transaxle case. Remove 2 thrust bearings, bearing race and input sun gear from transaxle case. (Scheme 251)
21. Remove 1st and reverse brake flange, 6 discs and 6 plates from transaxle case. Note location of components during removal for reassembly reference. Using a hammer and chisel, unstake washer located on counter drive gear. (Scheme 251) Ensure all claws on washer are pushed down to allow socket to fit securely on nut. Using holding tool, socket and torque wrench with a fulcrum length of 6.30" (160.0 mm), remove nut. (Scheme 260)
22. Using appropriate adapter and press, remove front planetary gear from counter drive gear. (Scheme 261) Remove front planetary gear from brake hub. (Scheme 251) Using a screwdriver, remove snap ring and front planetary ring gear from brake hub.
23. Using appropriate press, compress 1st and reverse brake piston return spring. Using snap ring expander, remove snap ring. Remove piston return spring. Using vernier calipers, measure spring free length together with spring seat. Standard length should be.611" (15.53 mm). Replace springs as needed.
24. Using 57 psi (4 kg/cm 2 ) of compressed air applied to transaxle case, remove 1st and reverse brake piston from case. (Scheme 262) Cover piston with shop towel during removal. Remove "O" rings from piston.
25. Using appropriate adapter and press, remove counter drive gear from transaxle case. Install and tighten 2 bolts opposite each other evenly on counter drive gear. Ensure clearance between counter drive gear and bearing race is about.787" (20.00 mm). Using bearing puller, remove rear tapered roller bearing from counter drive gear. (Scheme 251) Using a snap ring expander, remove snap ring. Using appropriate adapter and press, remove bearing outer race.
26. Using appropriate adapter and press, compress underdrive brake piston return spring. Using snap ring expander, remove snap ring. Remove press, adapter and return spring. (Scheme 252) Using vernier calipers, measure spring free length together with spring seat. Standard length should be.553" (14.04 mm). Replace springs as needed.
27. Using 57 psi (4 kg/cm 2 ) of compressed air applied to transaxle case, remove underdrive brake piston from transaxle case. (Scheme 263) Cover piston with shop towel during removal. Remove "O" rings from piston.
28. Using appropriate puller, remove needle roller bearing from transaxle case. Remove 2 oil seal rings from transaxle case. (Scheme 264) Remove 2 transaxle case No. 1 plugs. (Scheme 265) Remove "O" rings from plugs. Using appropriate puller, remove cylindrical roller bearing from transaxle case.
29. Remove oil seal ring from transaxle housing. (Scheme 266) Remove bolt, clamp and differential gear lube apply tube from transaxle housing. (Scheme 239)

Inspection

1. Check body clearance of driven gear. Push driven gear to one side of body. Using a feeler gauge, measure clearance. see scheme 37 Body clearance should be.0039-.0067" (.010-.170 mm). Maximum body clearance is.0067" (.170 mm). If body clearance exceeds specification, replace oil pump body.
2. Using a feeler gauge, check tip clearance between drive and driven gear teeth. see scheme 38 Tip clearance is.0028-.0059" (.070-.150 mm). Maximum tip clearance is.0059" (.150 mm). If tip clearance exceeds specification, replace oil pump body.
3. Check side clearance of both gears. Use a steel straightedge and feeler gauge to measure side clearance of both gears. see scheme 39 Clearance is.0008-.0020" (.020-.050 mm). Maximum side clearance is.0020" (.050 mm). Replace gears as necessary. Gears are available in 5 thicknesses from.4602-.4606" (11.690-11.699 mm) to.4618-.4622" (11.731-11.740 mm), in increments of.0004" (.009 mm). Gears are marked from letter "A" to letter "E". If side clearance is not within specification after gear replacement, replace oil pump body.
4. Using a dial indicator, measure inside diameter of oil pump body bushing. see scheme 40 Standard inside diameter is 1.500-1.501" (38.11-13.14 mm). Maximum inside diameter is 1.503" (38.18 mm). If inside diameter exceeds specification, replace oil pump body.
5. Using a dial indicator, measure inside diameter of stator shaft bushing. see scheme 41 Standard inside diameter is.846-.847" (21.50-21.52 mm). Maximum inside diameter is.849" (21.57 mm). If inside diameter exceeds specification, replace stator shaft.
6. Inspect front oil seal for cracks, damage or wear. Replace oil seal (if necessary). Remove oil seal with slide hammer. Install a NEW oil seal. Seal is properly installed when it is flush with outer edge of pump body.

1. Clean all parts (except discs) with solvent. Dry parts using compressed air. Inspect discs and plates for wear or burnt areas. If disc lining is peeled or discolored, replace discs as necessary. Replace all damaged components.
2. Using vernier calipers, measure clutch piston return spring free length with spring mounted to spring seat. Free length should be 1.020" (25.91 mm). Replace springs as necessary.

Note. New discs must be soaked in ATF at least 15 minutes prior to reassembly.

1. Clean all parts (except discs) with solvent. Dry parts using compressed air. Ensure check ball is free in piston. Apply low air pressure to small hole in piston to check for air leakage around piston valve. Inspect discs and plates for wear or burnt areas. If disc lining is peeled or discolored, replace discs as necessary. Replace all damaged components.
2. Using vernier calipers, measure forward clutch piston return spring free length with spring mounted to spring seat. Free length should be 1.054" (26.76 mm). Replace springs as necessary.

Note. New discs must be soaked in ATF for 15 minutes prior to reassembly.

1. Clean all parts (except discs) with solvent. Dry parts using compressed air. Inspect discs and plates for wear or burnt areas. If disc lining is peeled or discolored, replace discs as necessary. Replace all damaged components.
2. Using vernier calipers, measure underdrive clutch piston return spring free length with spring mounted to spring seat. Free length should be.675" (17.14 mm). Replace springs as necessary.
3. Using a dial indicator, measure inside diameter of underdrive clutch drum bushing. see scheme 61 Standard inside diameter is 1.4591-1.4598" (37.060-37.080 mm). Maximum inside diameter is 1.462" (37.13 mm). If inside diameter exceeds specification, replace underdrive clutch drum.

Scheme 267

Cleaning & Inspection

Clean all parts with solvent. Dry with compressed air. Check bearings, races and gears for wear or damage. Replace if necessary.

Scheme 268

1. Install original shim (if removed) into transaxle case. Using appropriate race installer and hammer, install outer race into transaxle housing and transaxle case (if removed). Drive outer races in until shim and outer race contact housing or case surface.
2. Coat thrust washers, side gears and pinion gears with ATF. Install 2 thrust washers onto 2 differential side gears. Install 2 thrust washers with 2 side gears, and 2 thrust washers with pinion gears into differential case. Install pinion shaft, aligning lock pin holes on pinion shaft and differential case.
3. Mount differential case in a soft-jawed vise. Using a dial indicator, check side gear backlash. Hold one pinion gear against case. Measure side gear backlash. (Scheme 268) Backlash must be.002-.008" (.05-.20 mm). If backlash is not within specification, side gear thrust washers must be replaced.
4. Select appropriate thrust washers to obtain correct side gear backlash. Thrust washers are available in 3 thicknesses from.064 (1.63 mm) to.072" (1.83 mm), in.004" (.10 mm) increments. Install thrust washers and side gears in differential case. If possible, install same size thrust washers on both sides. Install pinion gears and pinion shaft. Check side gear backlash to ensure proper thrust washers are used.
5. Using a pin punch and hammer, drive pinion shaft pin through transaxle case and pinion shaft. Stake differential case. Using appropriate press, install differential case tapered roller bearings.
6. Remove any material from transaxle housing and case mating surfaces. DO NOT allow oil to contact surfaces. Install differential assembly into transaxle case. Install transaxle housing onto transaxle case. Install 16 bolts and tighten bolts "A" and "D" to 16 ft. lbs. (22 N.m). Tighten bolts "B" and "C" to 21 ft. lbs. (29 N.m). Ensure bolts are in correct locations. See «TRANSAXLE HOUSING BOLT IDENTIFICATION»(ref-153090-S22797840012003031900000) table. see scheme 86 TRANSAXLE HOUSING BOLT IDENTIFICATION Bolt Application (1) In. (mm) A & B 1.969 (50.00) C 1.654 (42.00) D 2.835 (72.00) (1) For bolt locations see scheme 86
7. Using appropriate adapter and ratchet, rotate differential assembly in both directions to seat bearings. Using an INCH-lb. torque wrench, measure differential side bearing preload. see scheme 67 Preload should be 1.8-6.1 INCH lbs. (.20-.69 N.m) for new bearings and 0.9-3.1 INCH lbs. (.10-.35 N.m) for used bearings.
8. If preload is not within specifications, remove 16 transaxle housing bolts. Using a plastic hammer, remove transaxle housing from transaxle case. Remove differential assembly from transaxle case and replace shim at rear tapered roller bearing with appropriate shim.
9. Adjustment shims are marked in numeric and alphabetic order and available in thicknesses from.079 (2.00 mm), marked with a zero, to.096" (2.45 mm), marked with the number "9", and from.098" (2.50 mm), marked with the letter "A", to.112" (2.85 mm), marked with the letter "H". Shims increase in increments of.002" (.05 mm). Recheck preload after shim replacement.
10. Clean contact surface of differential case and ring gear using cleaning solvent. Heat ring gear to 212°F (100°C) in water. DO NOT heat ring gear above 230°F (110 °C).
11. After moisture on ring gear has completely evaporated, quickly align match marks made during disassembly. Install ring gear on differential case. Install 14 ring gear bolts and tighten to 70 ft. lbs. (95 N.m) in a crisscross pattern. Install NEW oil seals in transaxle housing and transaxle case to a depth of 0-0.020" (0-0.5 mm). Coat lip of oil seals with lubricant.