Overhaul - A650E: Diagnosis Lexus LS III

TROUBLE SHOOTING

Note. Transmission 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 transmission overhaul. See appropriate DIAGNOSIS article.

Cleaning & Inspection

1. Clean all components in solvent. Dry with compressed air. Inspect contact surfaces between housing and driven gear for wear. Check gears for wear and body crescent for damage. Check pump gear contact surface on stator shaft for damage and wear.
2. Measure inside diameter of oil pump housing and stator shaft bushings. see scheme 19and see scheme 20. Measure driven gear-to-housing clearance and gear tip clearance. Using feeler gauge and straightedge, measure gear side clearance between pump housing face and top of gears. see scheme 18 See «OIL PUMP CLEARANCE SPECIFICATIONS»(ref-141730-S30174680312002070300000) table.
3. If clearance(s) are not within specifications, replace worn component(s). Pump gears must be replaced as a matched set. For available gear thicknesses, see «DRIVE & DRIVEN GEAR THICKNESS SPECIFICATIONS»(ref-141730-S10751246202003042300000) table. If bushing diameter exceeds specification, oil pump housing or stator shaft must be replaced.

OIL PUMP CLEARANCE SPECIFICATIONS

DRIVE & DRIVEN GEAR THICKNESS SPECIFICATIONS

Inspection

1. Replace brake band if lining is peeled off or discolored or printed numbers are defaced. Before assembling NEW band, soak band in ATF for at least 15 minutes.
2. If brake band is serviceable but piston rod stroke is not within specification, select replacement rod. Rods are available in lengths of 3.057" (77.65 mm), 3.087" (78.40 mm), 3.116" (79.15 mm) and 3.146" (79.90 mm). V8 models also have a 3.175" (80.65 mm) rod available.

Clean all components with solvent. Dry with compressed air. Inspect components for damage. Measure return spring free length. Include spring seat in measurement. Free length should be .702" (17.82 mm). Replace components as necessary.

1. Clean all components (except discs) with solvent. Dry with compressed air. Inspect plates and discs for flaking or burnt areas. Ensure check ball does not allow air to bleed through piston.
2. Measure inside diameter of clutch drum bushing and planetary gear bushing. Maximum diameter for overdrive direct clutch drum bushing is 1.067" (27.11 mm). Maximum diameter for overdrive planetary gear bushing is.444" (11.27 mm). (Scheme 53)and (Scheme 54). Replace components if damaged or not within specifications.
3. Measure planetary pinion gear thrust clearance. (Scheme 55) Standard clearance should be.008-.024" (.20-.61 mm). Maximum clearance is.039" (1.00 mm). If clearance is not within specifications, replace planetary gear assembly. Check OD direct clutch return spring free length. Include spring seat in measurement. Standard free length is.622" (15.80 mm).

Scheme 52

Scheme 53

Scheme 54

Scheme 55

1. Clean all components (except discs) with solvent. Dry with compressed air. Inspect plates and discs for flaking or burnt areas.
2. Ensure check ball is free in clutch piston. Apply air pressure to check ball area. Ensure check ball does not allow air to bleed through piston. Measure free length of piston return spring. Include spring seat in measurement. Length should be.915" (23.25 mm).
3. Measure inside diameter of clutch drum bushing. see scheme 33 Bushing diameter should be 2.125" (53.97 mm). Replace clutch drum if bushing diameter exceeds specification.

Clean all components (except discs) with solvent. Dry with compressed air. Inspect plates and discs for flaking or burnt areas. Ensure check ball is free in clutch piston. Apply air pressure to check ball area. Ensure check ball does not allow air to bleed through piston. Measure inside diameter of clutch drum bushing. Replace clutch drum if bushing diameter exceeds.791" (20.08 mm). see scheme 36

1. Clean all components (except discs) with solvent. Dry with compressed air. Inspect plates and discs for flaking or burnt areas.
2. Measure inside diameter of front and center planetary sun gear bushing. Maximum diameter for both bushings is.976" (24.79 mm). see scheme 38 Replace components if damaged or not within specification.
3. Measure planetary pinion gear thrust clearance. (Scheme 55) Standard clearance should be.008-.024" (.20-.61 mm). Maximum clearance is.039" (1.00 mm). If clearance is not within specification, replace planetary gear assembly. Check brake return spring free length. Include spring seat in measurement. Standard free length is 1.449" (36.80 mm).
4. Check operation of one-way clutch. Hold front and center planetary sun gear and turn hub. see scheme 39 Hub should turn freely clockwise and locks counterclockwise.

1. Measure inside diameter of center planetary bushing. see scheme 42 Maximum bushing diameter is 1.626" (41.31 mm). Replace components if damaged or not within specification.
2. Measure planetary pinion gear thrust clearance. see scheme 43 Standard clearance should be.008-.024" (.20-.61 mm). Maximum clearance is.039" (1.00 mm). If clearance is not within specification, replace planetary gear assembly.

1. Measure inside diameter of rear planetary ring gear bushing. see scheme 46 Maximum bushing diameter is 1.518" (38.56 mm). Replace component if damaged or not within specification.
2. Measure inside diameter of output shaft bushing. see scheme 47 Maximum bushing diameter is.791" (20.08 mm). Replace component if damaged or not within specifications.
3. Measure planetary pinion gear thrust clearance. see scheme 48 Standard clearance should be.008-.024" (.20-.61 mm). Maximum clearance is.039" (1.00 mm). If clearance is not within specifications, replace planetary gear assembly.

Clean all components with solvent. Dry with compressed air. Inspect components for damage. Measure return spring free length with spring seat. Free length should be .787" (20.00 mm). Replace components as necessary.

1. Clean all parts in solvent. Dry with compressed air. Ensure all valve body passages are clear. Ensure strainers are not damaged or clogged. Inspect valves for scoring or roughness.
2. Ensure valves slide freely in bores. Inspect valve springs for damage, squareness and collapsed coils. Measure spring free length. Replace spring if not within specification. See appropriate VALVE BODY SPRING SPECIFICATIONS table. Ensure valve body springs correspond with appropriate valve. Ensure retainers are installed in appropriate locations. See «VALVE BODY RETAINER SPECIFICATIONS»(ref-141730-S03856547042002070300000) table.

UPPER VALVE BODY SPRING SPECIFICATIONS (GS 300 & IS 300)

UPPER VALVE BODY SPRING SPECIFICATIONS (GS 430 & LS 430)

LOWER VALVE BODY NO. 1 SPRING SPECIFICATIONS

LOWER VALVE BODY NO. 2 SPRING SPECIFICATIONS (GS 300 & IS 300)

LOWER VALVE BODY NO. 2 SPRING SPECIFICATIONS (GS 430 & LS 430)

VALVE BODY RETAINER SPECIFICATIONS

Scheme 56

Scheme 57

Scheme 58

Scheme 59