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Servicing - Es 300: Removal & Installation Lexus ES XV30 facelift

Automatic Trans 10 illustrations ~1018 words

REMOVAL & INSTALLATION

WARNINGVehicles are equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicles, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicles, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. Before disconnecting battery, see appropriate COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION.

Removal

  1. Remove battery.
  2. Remove air cleaner assembly.
  3. Remove air cleaner hose No. 1.
  4. Remove air intake resonator sub-assembly.
  5. Remove engine under cover No. 2.
  6. Disconnect shift cable assembly using the following steps: Remove nut from shift lever. see scheme 7 Disconnect shift cable from shift lever. Remove clip and disconnect shift cable from shift cable bracket. (Scheme 88)
  7. Remove PNP switch assembly using the following steps: Disconnect PNP switch connector. Remove nut, washer and shift lever. (Scheme 89) Pry out lock plate. Remove lock nut and lock plate. Remove 2 bolts and pull out PNP switch. (Scheme 90)

Installation

  1. Install PNP switch assembly using the following steps: Install PNP switch to manual valve shaft. Temporarily install 2 bolts. Place lock plate and tighten nut. (Scheme 90) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156107-S16841401952003070700000). Temporarily install shift lever. Turn lever counterclockwise until it stops, then turn it clockwise 2 notches. see scheme 8 Remove shift lever. Align groove with neutral basic line. (Scheme 91) Hold switch in position and tighten 2 bolts. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156107-S16841401952003070700000). Use screwdriver to stake nut with lock plate. Install shift lever, washer and nut. (Scheme 89) Connect PNP switch connector.
  2. Install shift cable assembly using the following steps: Temporarily install shift cable to shift lever with NEW nut. see scheme 7 Install shift cable and a NEW clip to bracket. (Scheme 88)
  3. Adjust shift lever position. See «SHIFT CABLE»(ref-156107-S16244375032003070700000) under ADJUSTMENTS.
  4. Inspect shift lever position. See «SHIFT CABLE»(ref-156107-S16244375032003070700000) under ADJUSTMENTS.
  5. Inspect PNP switch assembly. See «PARK/NEUTRAL POSITION SWITCH»(ref-156107-S04550542832003070700000) under ADJUSTMENTS.
  6. Install engine under cover No. 2.
  7. Install air intake resonator sub-assembly.
  8. Install air cleaner hose No. 1.
  9. Install air cleaner assembly.
  10. Install battery.

Scheme 88

Scheme 88
Scheme 88

Scheme 89

Scheme 89
Scheme 89

Scheme 90

Scheme 90
Scheme 90

Scheme 91

Scheme 91
Scheme 91
  1. Remove instrument panel components. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
  2. Disconnect shift cable from rod of floor shift assembly. (Scheme 92)
  3. Remove air conditioning condenser assembly. See «AUTOMATIC A/C-HEATER SYSTEMS»(ref-139243) article in HVAC.
  4. Remove air bag sensor assembly center. See appropriate AIR BAG RESTRAINT SYSTEM article in ACCESSORIES & EQUIPMENT.
  5. Remove battery.
  6. Remove air cleaner assembly.
  7. Remove air cleaner hose No. 1.
  8. Remove air intake resonator sub-assembly.
  9. Remove shift cable using the following steps: Remove nut from shift lever. see scheme 7 Disconnect shift cable from shift lever. Remove clip and disconnect shift cable from shift cable bracket. (Scheme 88) Disconnect shift cable from shift cable clamp. Disconnect shift cable from shift rod assembly. (Scheme 92) Remove 2 bolts and shift cable grommet retainer No. 2. (Scheme 93) Pull out shift cable from body.
  1. Install shift cable assembly using the following steps: Install shift cable to body. Install shift cable grommet retainer No. 2 to shift cable. Install shift cable with uneven surface facing up. (Scheme 92) Install shift cable grommet retainer No. 2 with 2 bolts. (Scheme 93) Connect shift cable to shift cable clamp. Temporarily install shift cable to shift lever with nuts. see scheme 7 Install shift cable and new clip to bracket. (Scheme 88)
  2. Install air intake resonator sub-assembly.
  3. Install air cleaner hose No. 1.
  4. Install air cleaner assembly.
  5. Install air bag sensor assembly center. See appropriate AIR BAG RESTRAINT SYSTEM article in ACCESSORIES & EQUIPMENT.
  6. Install air conditioning condenser assembly. See «AUTOMATIC A/C-HEATER SYSTEMS»(ref-139243) article in HVAC.
  7. Install instrument panel components. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
  8. Install battery.
  9. Inspect and adjust shift lever position. See «SHIFT CABLE»(ref-156107-S16244375032003070700000) under ADJUSTMENTS.

Scheme 92

Scheme 92
Scheme 92

Scheme 93

Scheme 93
Scheme 93
  1. Raise and support the vehicle.
  2. Remove the engine under cover No. 2.
  3. Drain automatic transaxle fluid. See «DRAINING & REFILLING»(ref-156107-S15652889302003070700000) under LUBRICATION.
  4. Remove automatic transaxle oil pan sub-assembly using the following steps: Remove 18 bolts, oil pan and gasket. see scheme 4 Remove 3 magnets from oil pan and use them to collect any steel chips. Examine particles in pan. 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 is magnetic and is typically resulting from bearing, gear and plate wear. Brass is non-magnetic and is typically from bearing wear.
  5. Disconnect transmission wire using the following steps: Disconnect 7 shift solenoid valve connectors. (Scheme 94) Remove bolt and lock plate, and disconnect ATF temperature sensor.
  6. Remove valve body oil filter assembly using the following steps: Remove 3 bolts and oil filter. Be aware that some fluid will come out of oil filter. see scheme 5 Remove "O" ring from oil filter.
  7. Remove transmission valve body assembly using the following steps: Support valve body assembly and remove 17 bolts and valve body assembly. Be careful not to drop check valve body, spring and accumulator piston. (Scheme 95) Remove check ball body and spring. (Scheme 96) Remove 6 bolts and 7 shift solenoid valves. (Scheme 97)
  1. Install transmission valve body assembly using the following steps: Install spring and check ball body. (Scheme 95) Install 7 shift solenoid valves with 6 bolts. (Scheme 97) Align the groove of manual valve with pin of lever. Install the 17 bolts. Push the valve body against the accumulator piston spring and the check ball body to install it. (Scheme 96) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-156107-S16841401952003070700000).
  2. Install valve body oil filter assembly using the following steps: Coat new "O" ring with ATF. Install "O" ring to the oil filter. Install oil filter with 3 bolts. see scheme 5
  3. Connect transmission wire using the following steps: Coat an "O" ring with ATF. Install ATF temperature sensor with lock plate and bolt. Connect 7 shift solenoid valve connectors. (Scheme 94) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156107-S16841401952003070700000).
  4. Install automatic transaxle oil pan sub-assembly using the following steps: Install the 3 magnets in the oil pan. Apply appropriate seal packing to 18 bolts. NOTE: Apply seal packing to seal bolts and tighten them within 10 minutes after application. Install new gasket, oil pan and 18 bolts to the transaxle case.
  5. Add automatic transaxle fluid.
  6. Inspect automatic transaxle fluid. See «CHECKING FLUID LEVELS»(ref-156107-S41070298232003070700000) under LUBRICATION.
  7. Install engine under cover No. 2.

Scheme 94

Scheme 94
Scheme 94

Scheme 95

Scheme 95
Scheme 95

Scheme 96

Scheme 96
Scheme 96

Scheme 97

Scheme 97
Scheme 97

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