Overhaul - U140E & U140F: Other Lexus RX I

GEAR RATIOS

TRANSAXLE GEAR RATIOS

AXLE SHAFTS

Note. See appropriate article in DRIVE AXLES.

PARK/NEUTRAL POSITION SWITCH

Note. For Park/Neutral Position (PNP) switch removal, installation and adjustment, see LEXUS U140E & U140F ELECTRONIC CONTROLS article.

Vehicle Does Not Move In Any Forward Or Reverse Gear

Check manual valve, primary regulator valve, parking lock pawl, front planetary gear, rear planetary gear, underdrive planetary gear, forward clutch, underdrive brake and No. 2 one-way clutch.

Vehicle Does Not Move In Reverse

Check front planetary gear, rear planetary gear, underdrive planetary gear, direct clutch, underdrive brake and 1st/reverse brake.

No 1-2 Upshift

Check lower valve body control valves, 2nd brake and No. 1 one-way clutch.

No 2-3 Upshift

Check lower valve body control valves and direct clutch.

No 3-4 Upshift

Check 3-4 shift valve and underdrive clutch.

No Lock-Up Or Lock-Up Off

Check lock-up relay valve and torque converter clutch.

No 4-3 Downshift

Check 3-4 shift valve.

No 3-2 Downshift

Check lower valve body control valves.

No 2-1 Downshift

Check lower valve body control valves.

Harsh Engagement From Neutral To Drive

Check forward clutch accumulator, forward clutch, underdrive clutch and No. 1 one-way clutch.

Harsh Engagement From Neutral To Reverse

Check accumulators, lower valve body control valves, direct clutch and 1st/reverse brake.

Harsh Engagement From Neutral To Low

Check solenoid modulator valve.

Harsh Lock-Up Engagement

Check lock-up relay valve and torque converter clutch.

Harsh Engagement During Upshift

Check upper valve body check, control and lock valves.

No Engine Braking In Low

Check solenoid modulator valve and 1st/reverse brake.

No Engine Braking In "2" Position

Check solenoid modulator valve and 2nd brake.

No Kickdown

Check lower valve body control valves and 3-4 shift valve.

Slip Or Shudder In 1st Gear

Check No. 1 one-way clutch.

Slip Or Shudder In 2nd Gear

Check 2nd brake and No. 2 one-way clutch.

Slip Or Shudder In 3rd Gear

Check direct clutch.

Slip Or Shudder In Overdrive

Check underdrive clutch.

Slip Or Shudder In Reverse

Check direct clutch, and 1st/reverse brake.

Slip Or Shudder In Forward Position After Warm-Up

Check upper valve body, oil strainer, torque converter clutch, forward clutch, direct clutch, underdrive brake, No. 1 one-way clutch and underdrive clutch.

Poor Acceleration (All Positions)

Check torque converter clutch and underdrive planetary gear.

Poor Acceleration In Overdrive

Check underdrive clutch and underdrive planetary gear.

PRELIMINARY CHECKS

Ensure a thorough explanation of when and how transaxle malfunction occurs is received from customer. Check fluid level and condition. Retrieve diagnostic trouble codes. See LEXUS U140E & U140F ELECTRONIC CONTROLS article.

Proceed as necessary. If no codes are present, proceed with symptom diagnosis. See TROUBLE SHOOTING . Perform STALL SPEED TEST under TORQUE CONVERTER, TIME LAG TEST and HYDRAULIC PRESSURE TESTS as needed. After repairs are completed, perform ROAD TEST to confirm repairs.

"D" Position

1. Place selector lever in "D" position. Hold accelerator pedal constant at full throttle. Check 1-2, 2-3, and 3-4 upshift and lock-up points. See appropriate table under «SHIFT SPEED SPECIFICATIONS»(ref-99709-S29139876722001073000000) . NOTE: There is no overdrive lock-up when coolant temperature is less than 140°F (60°C) or when vehicle speed is 6 MPH less than the set cruise control speed. There is no lock-up when brake pedal is depressed. If no 1-2 upshift occurs, check lower valve body control valves or shift solenoid. If no 2-3 upshift occurs, check lower valve body control valves or shift solenoid. If no 3-4 upshift occurs, check 3-4 shift valve or shift solenoid. If all shift points are incorrect, check upper valve body, lower valve body control valves and 3-4 shift valve. If all lock-up points are incorrect, check lock-up relay valve or shift solenoid.
2. Use procedure outlined in step 1) to check for shock and slip between 1-2, 2-3, and 3-4 upshifts. If shock is harsh, line pressure may be too high. Check accumulator or check ball.
3. Drive vehicle in "D" position lock-up or overdrive gear. Check for abnormal noise and vibration. NOTE: Check for cause of abnormal noise and vibration must be made with extreme care as problem could be due to an unbalanced axle shaft, differential, tire, torque converter, etc.
4. While driving in "D" position, confirm correct kickdown vehicle speed limits for 2-1, 3-2, 4-3 shift points. Check for abnormal shock and slip at kickdown.
5. Check lock-up function. Drive vehicle in overdrive in "D" position with lock-up on. Hold vehicle speed steady at 37 MPH. Lightly depress accelerator pedal. Ensure engine RPM does not change abruptly. Large increase in engine RPM indicates lock-up function is faulty.

"2" Position

1. Place selector lever in "2" position. Drive vehicle with accelerator pedal held constantly at full throttle. Ensure 1-2 upshift points take place and are operating properly. NOTE: In "2" position, there will be no lock-up to 2nd gear.
2. While driving in "2" position, release accelerator pedal and check engine braking effect. If there is no engine braking effect, 2nd brake is defective. Check for abnormal noise and shock at acceleration and deceleration.

"L" Position

While driving, place selector lever to "L" position, and ensure there is no upshift to 2nd gear. While driving in "L" position, release accelerator pedal. If there is no engine braking effect, 1st/reverse brake is defective. Check for abnormal noise during acceleration and deceleration.

"R" Position

Place selector lever in "R" position. Accelerate in Reverse from a stop at full throttle. Ensure slipping does not occur.

"P" Position

Stop vehicle on grade of more than 5 percent. Place selector lever in "P" position. Release parking brake. Ensure parking lock pawl holds vehicle.

HYDRAULIC PRESSURE TESTS

1. Ensure transaxle fluid is at operating temperature. Raise and support vehicle. Remove transaxle case test plug. (Scheme 65) Install hydraulic pressure gauge. Lower vehicle.
2. Fully apply parking brake. Block all wheels. Start engine and ensure idle speed is 650-750 RPM. Place selector lever in "D" position. Read and record pressure at idle. Fully apply brakes. Depress accelerator pedal to floor. DO NOT apply full throttle for more than 5 seconds.
3. Measure highest line pressure. Refer to specifications in «LINE PRESSURE SPECIFICATIONS»(ref-99709-S36759632692001073000000) table. Repeat test in "R" position. If pressures exceed specifications in all ranges, regulator valve or control valve in upper valve body is defective. Ensure no Throttle Position (TP) sensor-related trouble codes are present.
4. If pressures in both positions are lower than specifications, oil pump, regulator valve or underdrive clutch is defective. Ensure no TP sensor related trouble codes are present.
5. If pressure is lower than specifications in "D" position only, forward clutch is defective or "D" range circuit has a fluid leak. If pressure is lower than specifications in "R" position only, direct clutch is defective, 1st/reverse brake is defective or "R" range circuit has a fluid leak.

Scheme 65

LINE PRESSURE SPECIFICATIONS

TRANSAXLE

Note. For transaxle removal and installation, see appropriate AUTOMATIC TRANSMISSION REMOVAL article in TRANSMISSION SERVICING.

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

1. On U140F transaxle, remove transfer case. Remove 2 bolts and 6 nuts. Using plastic hammer, drive transfer case from transaxle. Pull transfer case straight up to remove from transaxle. Remove round gasket and intermediate shaft. On both transaxles, remove nut, washer and control shift lever. Using a screwdriver, unstake lock tab. Remove 2 bolts and nut, and remove park/neutral position switch. (Scheme 66)
2. Remove oil line union and elbow. Remove and discard "O" rings from union and elbow. Remove input turbine and counter gear speed sensors from top of transaxle. Remove and discard speed sensor "O" rings. Remove transaxle test plug from transaxle case. (Scheme 65) Remove solenoid connector bolt located above park/neutral position switch. DO NOT try to remove solenoid connector from transaxle case at this time.
3. Place transaxle on wooden blocks. Remove 18 bolts, oil pan and gasket. Disconnect 5 shift solenoid connectors. Remove bolts, clamps and fluid temperature sensor. (Scheme 67) Remove transaxle wiring harness with solenoid connector from transaxle case. Remove oil strainer and gasket. Remove valve body assembly. See «VALVE BODY ASSEMBLY»(ref-99709-S08833830322001073000000) under ON-VEHICLE SERVICE.
4. Remove 3 apply gaskets, check ball body and spring. (Scheme 68) Remove brake drum gasket located near 3 apply gaskets. (Scheme 66) Remove underdrive clutch accumulator spring. Using 57 psi (4 kg/cm 2 ) of compressed air applied to transaxle case, remove underdrive clutch accumulator piston. (Scheme 69) Cover piston with shop towel during removal.
5. Using 57 psi (4 kg/cm 2 ) of compressed air applied to transaxle case, remove forward clutch accumulator piston and spring, and underdrive brake accumulator piston. Cover pistons with shop towel during removal. (Scheme 70)and (Scheme 71).
6. Using needle nose pliers, remove manual valve lever retainer spring. Remove 2 bolts, manual detent spring and cover. (Scheme 66) 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 roll pin. Ensure pin does not fall into transaxle case.
7. Remove manual valve lever shaft and manual valve lever. Remove parking lock pawl rod from manual valve lever. Using a screwdriver, remove shaft oil seal. (Scheme 66) 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.
8. Using a dial indicator, measure input shaft end play. (Scheme 72) End play should be.011-.049" (.27-1.24 mm). Remove 16 transaxle housing bolts. Note bolt length and location during removal for reassembly reference. (Scheme 73)
9. Remove 7 oil pump bolts and oil pump. Remove thrust bearing and bearing race from underdrive planetary gear assembly. Remove differential assembly. (Scheme 75) Remove 2 apply gaskets from front of transaxle case. Remove forward clutch from transaxle case. Remove multiple clutch hub and needle roller bearing from transaxle case. (Scheme 74)
10. Remove one bolt and parking lock pawl clamp. (Scheme 75) Remove parking lock pawl shaft. Push parking lock pawl toward transaxle case to prevent interference during underdrive planetary gear assembly removal. (Scheme 76) Using both hands, remove underdrive planetary gear assembly. DO NOT allow planetary gear assembly to separate.
11. Remove spring, pawl pin and parking lock pawl. Remove underdrive clutch assembly. (Scheme 75) Remove thrust bearing and bearing race. Using a screwdriver, remove No. 2 one-way clutch snap ring. Remove No. 2 one-way clutch from transaxle case. Note position of index marks on No. 2 one-way clutch for reassembly reference. see scheme 72 Note position of outer race retainer on No. 2 one-way clutch for reassembly reference. (Scheme 77) Remove outer race retainer from No. 2 one-way clutch.
12. Using a screwdriver, remove underdrive brake snap ring. Remove flange, 4 discs and 4 plates from transaxle case. Note location of components during removal for reassembly reference. Using appropriate press, compress underdrive brake piston return spring. Using snap ring expander, remove snap ring from underdrive brake. Remove piston return spring. (Scheme 75)
13. Remove 11 bolts and transaxle rear cover. If necessary, tap on circumference of rear cover with plastic hammer to remove cover. Remove 2 oil seal rings from rear cover. Using appropriate puller, remove needle roller bearing, if necessary. (Scheme 74) Remove bolt, clamp and 2 brake apply pipes. Using a screwdriver, remove 2 apply gaskets from rear of transaxle case. (Scheme 75)
14. Remove direct clutch with thrust bearing from transaxle case. Remove bearing race from direct clutch (shaft side). Remove rear planetary sun gear assembly from transaxle case. Remove thrust bearing from rear planetary sun gear. Remove thrust washer No. 1 from rear planetary sun gear.
15. Remove No. 1 one-way clutch and thrust bearing from transaxle case. Remove inner race from one-way clutch. Remove one-way clutch outer sleeve from transaxle case. Note direction of components for reassembly reference. 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 74)
16. Using a screwdriver, remove rear planetary gear snap ring. Remove rear planetary gear from transaxle case. Remove thrust washer No. 2 from rear planetary gear. Remove 2 bearing races, thrust bearings and front planetary sun gear from transaxle case. (Scheme 74)
17. Using a hammer and chisel, unstake washer located on counter drive gear. (Scheme 74) Ensure all claws on washer are pushed down to allow socket to fit securely on nut. Using holding tool and socket, remove nut. (Scheme 78) Using appropriate adapter and press, remove front planetary gear from counter drive gear. (Scheme 79)
18. Using a screwdriver, remove 2nd brake assembly snap ring. Remove brake hub with 2nd brake assembly. Remove brake hub from 2nd brake assembly. (Scheme 74) Using a screwdriver, remove snap ring and front planetary ring gear from brake hub. Remove 1st/reverse brake flange, 7 discs and 7 plates from transaxle case. Note location of components during removal for reassembly reference.
19. Using appropriate press, compress 1st/reverse brake piston return spring. Using snap ring expander, remove snap ring from underdrive brake. Remove piston return spring. Using 57 psi (4 kg/cm 2 ) of compressed air applied to transaxle case, remove 1st/reverse brake piston from case. (Scheme 80) Cover piston with shop towel during removal.
20. 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.79" (20.0 mm). Using bearing puller, remove rear tapered roller bearing from counter drive gear. (Scheme 74)
21. Using a brass drift and hammer, remove bearing inner and outer races. Remove snap ring at underdrive brake piston from transaxle case. Using 57 psi (4 kg/cm 2 ) of compressed air applied to transaxle case, remove underdrive brake piston from case. (Scheme 81) Cover piston with shop towel during removal.
22. Using appropriate puller, remove needle roller bearing from transaxle case. Remove 2 oil seal rings from transaxle case. (Scheme 75) Using appropriate puller, remove cylindrical roller bearing from transaxle case.
23. Remove oil seal ring from transaxle housing. (Scheme 82) Remove bolt, clamp and apply pipe from transaxle case. Remove 3 bolts and oil deflector from transaxle case. (Scheme 66)