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Automatic Transaxle (Service Information): Diagnosis Lexus ES XV40 facelift

Automatic Trans 41 illustrations ~2858 words

ON-VEHICLE INSPECTION

  1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY OPERATION Apply the parking brake. Turn the engine switch on (IG). Depress the brake pedal and check that the engine starts when the shift lever is set in N or P, but does not start in other positions. Check that the back-up light comes on and the reverse warning buzzer sounds when the shift lever is set in R, but the light and buzzer do not operate in other positions. If a failure is found, check the park/neutral position switch for continuity.

Scheme 80

Scheme 80: REMOVAL
Scheme 80: REMOVAL

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Scheme 83

Scheme 84

Scheme 84
Scheme 84
  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
  2. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to «REMOVAL - Step 11»(ref-396638-S00213747662011050900000)
  3. REMOVE ENGINE ROOM SIDE COVER LH . Refer to «REMOVAL - Step 12»(ref-396638-S00213747662011050900000)
  4. REMOVE AIR CLEANER INLET ASSEMBLY . Refer to «REMOVAL - Step 16»(ref-396638-S00213747662011050900000)
  5. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
  6. REMOVE AIR CLEANER CASE SUB-ASSEMBLY . Refer to «REMOVAL - Step 18»(ref-396638-S00213747662011050900000)
  7. REMOVE NO. 1 AIR CLEANER INLET . Refer to «REMOVAL - Step 19»(ref-396638-S00213747662011050900000)
  8. REMOVE AIR CLEANER BRACKET Separate the wire harness clamp. Remove the 3 bolts and air cleaner bracket.
  9. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY Remove the clip from the transmission cable bracket. Remove the nut and transmission control cable from the control shaft lever. Disconnect the connector from the park/neutral position switch. Remove the nut, washer and control shaft lever from the control shaft. Remove the 2 bolts and park/neutral position switch from the control shaft. NOTE: Before removing the park/neutral position switch, remove any dirt or rust on the installation portion of the control shaft. Be sure to remove the switch straight along the shaft while being careful not to deform the plate spring that supports the shaft. If the plate spring is deformed, the park/neutral switch cannot be reinstalled correctly.

Scheme 85

Scheme 85: INSPECTION
Scheme 85: INSPECTION
  1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY Measure the resistance according to the value(s) in the table below when the shift lever is moved to each position. STANDARD RESISTANCE: Shift Position Tester Connection Specified Condition P 1 (RB) - 3 (PL) and 4 (B) - 9 (L) Below 1 ohms Except P ↑ 10 kohms or higher R 2 (RL) - 1 (RB) Below 1 ohms Except R ↑ 10 kohms or higher N 1 (RB) - 8 (NL) and 4 (B) - 9 (L) Below 1 ohms Except N ↑ 10 kohms or higher D, S, "+" and "-" 1 (RB) - 7 (DL) Below 1 ohms Except D, S, "+" and "-" ↑ 10 kohms or higher If operation cannot be done as specified, replace the park/neutral position switch.

Scheme 86

Scheme 86: INSTALLATION
Scheme 86: INSTALLATION
  1. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY Move the shift lever to N. Align the protrusions of the park/neutral position switch. Install the park/neutral position switch to the control shaft with the 2 bolts. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) NOTE: Before installing the park/neutral position switch, remove any dirt or rust on the installation portion of the control shaft. Be sure to install the switch straight along the shaft while being careful not to deform the plate spring that supports the shaft. If the plate spring is deformed, the park/neutral switch cannot be reinstalled correctly. After installing the park/neutral position switch, confirm that the 2 protrusions on the switch are aligned. Install the control shaft lever to the control shaft with the nut and washer. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) Connect the connector to the park/neutral position switch. Connect the transmission control cable to the transmission control cable bracket with a new clip. Connect the transmission control cable to the control shaft lever with the nut. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
  2. INSTALL AIR CLEANER BRACKET Install the air cleaner bracket with the 3 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) Install the wire harness clamp.
  3. INSTALL NO. 1 AIR CLEANER INLET . Refer to «INSTALLATION - Step 71»(ref-396638-S39113097262011050900000)
  4. INSTALL AIR CLEANER CASE SUB-ASSEMBLY . Refer to «INSTALLATION - Step 72»(ref-396638-S39113097262011050900000)
  5. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
  6. INSTALL AIR CLEANER INLET ASSEMBLY . Refer to «INSTALLATION - Step 74»(ref-396638-S39113097262011050900000)
  7. INSTALL ENGINE ROOM SIDE COVER LH . Refer to «INSTALLATION - Step 98»(ref-396638-S39113097262011050900000)
  8. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to «INSTALLATION - Step 100»(ref-396638-S39113097262011050900000)
  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL . Refer to «INSTALLATION - Step 79»(ref-396638-S39113097262011050900000)
  10. INSPECT PARK/NEUTRAL POSITION SWITCH ASSEMBLY OPERATION See step 1
  11. INSPECT SHIFT LEVER POSITION See step 1
  12. ADJUST SHIFT LEVER POSITION See step 2
  13. PERFORM INITIALIZATION Perform initialization procedure. Refer to «INITIALIZATION»(ref-396530-S14462624912011050900000) . NOTE: Some systems need initialization after reconnecting the cable to the negative battery terminal.

Scheme 87

Scheme 87: ILLUSTRATION
Scheme 87: ILLUSTRATION

Scheme 88

Scheme 88: REMOVAL
Scheme 88: REMOVAL

Scheme 89

Scheme 89
Scheme 89
  1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY HINT
  2. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY See step 2
  3. REMOVE VALVE BODY OIL STRAINER ASSEMBLY See step 3
  4. REMOVE TRANSMISSION VALVE BODY ASSEMBLY See step 4
  5. REMOVE TRANSMISSION WIRE Disconnect the 9 connectors. Remove the transmission wire from the clamp. Remove the bolt, lock plate and transmission wire from the valve body.

Scheme 90

Scheme 90: INSTALLATION
Scheme 90: INSTALLATION
  1. INSTALL TRANSMISSION WIRE Coat the O-ring with ATF. Coat the bolt with ATF. Install the transmission wire and lock plate to the valve body with the bolt. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) Install the transmission wire to the clamp. Connect the 9 connectors.
  2. INSTALL TRANSMISSION VALVE BODY ASSEMBLY See step 2
  3. INSTALL VALVE BODY OIL STRAINER ASSEMBLY See step 3
  4. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY See step 4
  5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY HINT

Scheme 91

Scheme 91: ILLUSTRATION
Scheme 91: ILLUSTRATION

Scheme 92

Scheme 92: REMOVAL
Scheme 92: REMOVAL

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Scheme 98
  1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY HINT
  2. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY Remove the 18 bolts and oil pan from the transaxle. NOTE: Some fluid will remain in the oil pan. Remove all the pan bolts, and carefully remove the oil pan assembly. Remove the gasket from the oil pan. Remove the 2 magnets from the oil pan. Examine particles in the oil pan. Collect any steel chips with the removed magnets. Look carefully at the chips and particles in the oil pan and on the magnets to see the type of wear which might be found in the transaxle. Result Steel (magnetic) Bearing, gear and plate wear Brass (non-magnetic) Bearing wear
  3. REMOVE VALVE BODY OIL STRAINER ASSEMBLY Remove the 2 bolts and oil strainer from the valve body. Remove the O-ring from the oil strainer.
  4. REMOVE TRANSMISSION VALVE BODY ASSEMBLY Remove the 11 bolts and valve body from the transaxle. NOTE: When removing the transmission valve body assembly, be careful not to allow the speed sensor and the transaxle case to interfere with each other.
  5. REMOVE MANUAL VALVE Remove the manual valve from the valve body.

Scheme 99

Scheme 99
Scheme 99
  1. INSTALL MANUAL VALVE Coat the manual valve with ATF and install it to the valve body.
  2. INSTALL TRANSMISSION VALVE BODY ASSEMBLY Coat the O-ring of the transmission wire with ATF. Confirm that the manual valve lever is positioned as shown in the illustration and install the valve body assembly to the transaxle case with the 11 bolts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) Bolt length Bolt A 25 mm (0.98 in.) Bolt B 30 mm (1.18 in.) Bolt C 35 mm (1.38 in.) Bolt D 45 mm (1.77 in.) Bolt E 55 mm (2.17 in.) NOTE: When installing the transmission valve body assembly, be careful not to allow the speed sensor and transaxle case to interfere with each other. Be sure to insert the pin of the manual valve lever into the groove on the end of the manual valve. First, temporarily tighten the bolts marked by (*1) in the illustration because they are positioning bolts.
  3. INSTALL VALVE BODY OIL STRAINER ASSEMBLY Coat a new O-ring with ATF and install it to the oil strainer. NOTE: Ensure that the O-ring is not twisted or pinched. Install the oil strainer to the valve body with the 2 bolts. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  4. INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY Install the 2 magnets to the oil pan. Install a new gasket to the oil pan. Apply adhesive to the 18 bolts. Adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent. Install the oil pan to the automatic transaxle with the 18 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) NOTE: In order to ensure proper sealing of the transmission oil pan bolts, apply sealant to the bolts and install them within 10 minutes of sealant application. Completely remove any oil or grease from the contact surface of the transaxle case and oil pan sub-assembly with the gasket before installation.
  5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY HINT

Scheme 100

Scheme 100: ILLUSTRATION
Scheme 100: ILLUSTRATION

Scheme 101

Scheme 101: ILLUSTRATION
Scheme 101: ILLUSTRATION
  1. INSPECT SHIFT LEVER POSITION When shifting from P to R with the engine switch on (IG) and the brake pedal depressed, make sure that the shift lever moves smoothly and moves correctly into position. Start the engine and make sure that the vehicle moves forward when shifting from N to D position and moves rearward when shifting to R position. If operation cannot be done as specified, inspect the park/neutral position switch assembly and check the shift lever assembly installation condition.

Scheme 102

Scheme 102: REMOVAL
Scheme 102: REMOVAL

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Scheme 103
Scheme 103

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Scheme 104
  1. REMOVE INSTRUMENT PANEL FINISH PANEL END LH . Refer to «REMOVAL - Step 11»(ref-396657-S18768467902011050900000)
  2. REMOVE INSTRUMENT PANEL FINISH PANEL END RH . Refer to «REMOVAL - Step 19»(ref-396657-S18768467902011050900000)
  3. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY . Refer to «REMOVAL - Step 26»(ref-396657-S18768467902011050900000)
  4. REMOVE UPPER CONSOLE PANEL ASSEMBLY WITH FRONT ASH RECEPTACLE . Refer to «REMOVAL - Step 27»(ref-396657-S18768467902011050900000)
  5. REMOVE HEATER SEAT SWITCH CONSOLE BASE (w/o Seat Heater System) . Refer to «REMOVAL - Step 31»(ref-396657-S18768467902011050900000)
  6. REMOVE HEATER SEAT SWITCH CONSOLE BASE (w/ Seat Heater System) . Refer to «REMOVAL - Step 32»(ref-396657-S18768467902011050900000)
  7. REMOVE CONSOLE BOX POCKET . Refer to «REMOVAL - Step 7»(ref-396659-S01244015242011050900000)
  8. REMOVE CONSOLE BOX CARPET . Refer to «REMOVAL - Step 8»(ref-396659-S01244015242011050900000)
  9. REMOVE CONSOLE REAR END PANEL SUB-ASSEMBLY . Refer to «REMOVAL - Step 9»(ref-396659-S01244015242011050900000)
  10. REMOVE REAR CONSOLE BOX ASSEMBLY . Refer to «REMOVAL - Step 10»(ref-396659-S01244015242011050900000)
  11. REMOVE NO. 2 CONSOLE BOX DUCT . Refer to «REMOVAL - Step 71»(ref-396681-S13602280632011050900000)
  12. REMOVE NO. 3 CONSOLE BOX DUCT . Refer to «REMOVAL - Step 72»(ref-396681-S13602280632011050900000)
  13. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Disconnect the end of the transmission control cable from the shift lever assembly. Disconnect the transmission control cable assembly from the shift lever assembly while pushing the 2 claws of the floor shift cable.
  14. REMOVE SHIFT LEVER ASSEMBLY Disconnect the shift lock control ECU connector and transmission control switch wire connector. Remove the 4 bolts and shift lever assembly.

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Scheme 105: DISASSEMBLY
Scheme 105: DISASSEMBLY

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Scheme 113
Scheme 113
  1. REMOVE SHIFT LOCK RELEASE BUTTON COVER Using a screwdriver, remove the shift lock release button cover from the position indicator housing assembly.
  2. REMOVE INDICATOR LIGHT WIRE SUB-ASSEMBLY Turn the indicator light guide counterclockwise. Align the indicator light guide key with the groove on the shift lever assembly to remove the indicator light wire. Release the indicator light wire from the 2 clamps on the shift lever assembly. Using a screwdriver, release the stopper. Using a screwdriver, disengage the locking lug of terminals (4) and (8), and pull the terminals out from the rear of the connector. Remove the bulb and cap.
  3. REMOVE POSITION INDICATOR HOUSING ASSEMBLY Detach the 4 claws and remove the position indicator housing assembly from the lower shift lever assembly.
  4. REMOVE POSITION INDICATOR LENS Detach the 4 claws and remove the position indicator lens from the lower shift lever assembly.
  5. REMOVE POSITION INDICATOR SLIDE COVER Remove the position indicator slide cover from the lower shift lever assembly. Separate the No. 2 position indicator slide cover from the position indicator slide cover.
  6. REMOVE SHIFT LOCK CONTROL ECU Detach the 3 claws and remove the shift lock control ECU from the lower shift lever assembly. Disconnect the shift lock solenoid connector.

Scheme 114

Scheme 114: INSPECTION
Scheme 114: INSPECTION
  1. INSPECT TRANSMISSION CONTROL SWITCH Measure the resistance between each terminal of the shift lever assembly when the shift lever is moved to each position. Standard resistance Shift Position Tester Connection Specified Condition S, "+" and "-" 3 - 7 Below 1 ohms Except S, "+" and "-" 3 - 7 10 kohms or higher Press continuously "+" (Upshift) 2 - 5 Below 1 ohms S 2 - 5 10 kohms or higher Press continuously "-" (Downshift) 1 - 5 Below 1 ohms S 1 - 5 10 kohms or higher If the resistance value is not as specified, replace the shift lock control ECU.

Scheme 115

Scheme 115
Scheme 115

Scheme 116

Scheme 116
Scheme 116
  1. ADJUST SHIFT LEVER POSITION Move the shift lever to N. Remove the nut and transmission control cable from the control shaft lever. Align the protrusions of the park/neutral position switch. Move the slider in the direction indicated by arrow A and pull up the lock piece in the direction indicated by arrow B. NOTE: Do not damage the boot. Connect the transmission control cable assembly to the control shaft lever with the nut. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) Push in the lock piece. NOTE: Firmly push in the lock piece until the slider lock is engaged. Start the engine and make sure that the vehicle moves forward when moving the lever from N to D and moves rearward when moving it to R. If it becomes hard to move the shift lever, readjust the shift lever position.

Scheme 117

Scheme 117
Scheme 117
  1. INSTALL SHIFT LOCK CONTROL ECU Connect the shift lock solenoid connector. Attach the shift lock control ECU to the lower shift lever assembly with the 3 claws.
  2. INSTALL POSITION INDICATOR SLIDE COVER Connect the No. 2 position indicator slide cover to the position indicator slide cover. Install the position indicator slide cover to the lower shift lever assembly.
  3. INSTALL POSITION INDICATOR LENS Attach the position indicator lens to the lower shift lever assembly with the 4 claws.
  4. INSTALL POSITION INDICATOR HOUSING ASSEMBLY Attach the position indicator housing assembly to the lower shift lever assembly with the 4 claws.
  5. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY Install the bulb and cap. Connect terminals (4) and (8) of the indicator light wire. Push the stopper. Install the indicator light wire to the 2 clamps on the lower shift lever assembly. Install the indicator light wire into the shift lever assembly while aligning the groove on the unit with the indicator light guide key. Install the indicator light guide by turning it clockwise until it securely locks.
  6. INSTALL SHIFT LOCK RELEASE BUTTON COVER Install the shift lock release button cover to the position indicator housing assembly.

Scheme 118

Scheme 118
Scheme 118
  1. INSTALL SHIFT LEVER ASSEMBLY Install the 4 bolts and shift lever assembly. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) Connect the shift lock control ECU connector and transmission control switch wire connector.
  2. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY Install the transmission control cable assembly as shown in the illustration. HINT: Install the floor shift cable with the uneven surface facing up. Securely engage the claws of the floor shift cable.
  3. INSTALL NO. 3 CONSOLE BOX DUCT . Refer to «INSTALLATION - Step 9»(ref-396681-S24332805302011050900000)
  4. INSTALL NO. 2 CONSOLE BOX DUCT . Refer to «INSTALLATION - Step 10»(ref-396681-S24332805302011050900000)
  5. INSTALL REAR CONSOLE BOX ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-396659-S30842098862011050900000)
  6. INSTALL CONSOLE REAR END PANEL SUB-ASSEMBLY . Refer to «INSTALLATION - Step 2»(ref-396659-S30842098862011050900000)
  7. INSTALL CONSOLE BOX CARPET . Refer to «INSTALLATION - Step 3»(ref-396659-S30842098862011050900000)
  8. INSTALL CONSOLE BOX POCKET . Refer to «INSTALLATION - Step 4»(ref-396659-S30842098862011050900000)
  9. INSTALL HEATER SEAT SWITCH CONSOLE BASE (w/o Seat Heater System) . Refer to «INSTALLATION - Step 23»(ref-396657-S32018792212011050900000)
  10. INSTALL HEATER SEAT SWITCH CONSOLE BASE (w/ Seat Heater System) . Refer to «INSTALLATION - Step 24»(ref-396657-S32018792212011050900000)
  11. INSTALL UPPER CONSOLE PANEL ASSEMBLY WITH FRONT ASH RECEPTACLE . Refer to «INSTALLATION - Step 28»(ref-396657-S32018792212011050900000)
  12. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY . Refer to «INSTALLATION - Step 29»(ref-396657-S32018792212011050900000)
  13. INSTALL INSTRUMENT PANEL FINISH PANEL END RH . Refer to «INSTALLATION - Step 36»(ref-396657-S32018792212011050900000)
  14. INSTALL INSTRUMENT PANEL FINISH PANEL END LH . Refer to «INSTALLATION - Step 45»(ref-396657-S32018792212011050900000)
  15. INSPECT SHIFT LEVER POSITION See step 1
  16. ADJUST SHIFT LEVER POSITION See step 2

Scheme 119

Scheme 119: ILLUSTRATION
Scheme 119: ILLUSTRATION

Scheme 120

Scheme 120: REMOVAL
Scheme 120: REMOVAL
  1. REMOVE AIR CONDITIONING UNIT HINT
  2. REMOVE CENTER AIRBAG SENSOR ASSEMBLY . Refer to «REMOVAL - Step 28»(ref-396531-S14885397942011050900000)
  3. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to «REMOVAL - Step 11»(ref-396638-S00213747662011050900000)
  4. REMOVE ENGINE ROOM SIDE COVER LH . Refer to «REMOVAL - Step 12»(ref-396638-S00213747662011050900000)
  5. REMOVE AIR CLEANER INLET ASSEMBLY . Refer to «REMOVAL - Step 16»(ref-396638-S00213747662011050900000)
  6. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
  7. REMOVE AIR CLEANER CASE SUB-ASSEMBLY . Refer to «REMOVAL - Step 18»(ref-396638-S00213747662011050900000)
  8. REMOVE NO. 1 AIR CLEANER INLET . Refer to «REMOVAL - Step 19»(ref-396638-S00213747662011050900000)
  9. DISCONNECT NO. 2 SHIFT CABLE GROMMET RETAINER Turn back the carpet. Remove the 2 bolts and disconnect the No. 2 shift cable grommet retainer. Remove the No. 2 shift cable grommet retainer.
  10. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY Disconnect the end of the transmission control cable assembly from the shift lever assembly. Disconnect the transmission control cable assembly from the shift lever assembly while pushing the 2 claws of the floor shift cable. Remove the nut and transmission control cable from the control shaft lever. Remove the clip and disconnect the transmission control cable assembly from the No. 1 control cable bracket. Pull out the transmission control cable assembly from the body.

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