Lexus ES300 (1997 year). Manual - part 97

AUTOMATIC TRANSAXLE

COMPONENT PARTS INSTALLATION

-

AX-1 15

(b)

Using SST, measure the piston stroke while applying and
releasing compressed air (392-785 kPa, 4-8 kgf/cm

2

,

57-1 14 psi).
SST 09240-00020

Piston stroke:

2.0-3.5 mm (0.079-0.138 in.)

If the stroke is more than specified, replace the piston rod
with a longer one.

Piston rod length:

95.2 mm (3.748 in.)

96.3 mm (3.791 in.)

If the still more than standard value, replace the brake
band with a new one.

HYDRAULIC CONTROL UNIT INSTALLATION

1.

INSTALL ACCUMULATOR PISTONS AND SPRINGS

(a)

Install the new O-rings to the pistons.

(b)

Install the springs and pistons into the bores.

Spring dimensions

mm (in.)

Spring

Color

Free length

C

2

Yellow/Purple

51.8 (2.039)

B

2

None

88.2 (3.473)

B

2

None

70.3 (2.767)

C

1

None

73.6 (2.898)

(c)

Place the cover with a new gasket and gradually tighten
the bolts a little at a time in sequence.

Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)

AX0U3-02

AUTOMATIC TRANSAXLE

COMPONENT PARTS INSTALLATION

-

AX-1 16

2.

PLACE NEW SECOND BRAKE APPLY GASKET

3.

INSTALL SOLENOID WIRE

4.

INSTALL THROTTLE CABLE

5.

INSTALL VALVE BODY TO TRANSAXLE CASE

(a)

While holding the cam down with your hand, slip the cable
end into the slot.

(b)

Lower the valve body into place.

NOTICE: Do not entangle the solenoid wire.

AUTOMATIC TRANSAXLE

COMPONENT PARTS INSTALLATION

-

AX-1 17

(c)

Install and tighten the 9 bolts.
HINT:

Each bolt length is indicated below.

Hand tighten the 9 bolts first, then torque with a
torque wrench.

Bolt length:

Bolt A: 30 mm (1.181 in.)

Bolt B: 43 mm (1.693 in.)

Bolt C: 48 mm (1.890 in.)

Bolt D: 52 mm (2.047 in.)

Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)

6.

INSTALL B

3

 APPLY PIPE

NOTICE: Be careful not to bend or damage the pipe.

7.

INSTALL CONNECTOR CLAMP AND PIPE RETAINER
HINT: Each bolt length is indicated below.

Bolt length:

Bolt A: 48 mm (1.890 in.)

Bolt B: 39 mm (1.535 in.)

Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)

8.

CONNECT SOLENOID CONNECTORS

AUTOMATIC TRANSAXLE

COMPONENT PARTS INSTALLATION

-

AX-1 18

9.

INSTALL OIL PIPES
Using a plastic hammer, install the pipes into the posi-
tions.

NOTICE: Be careful not to bend or damage the pipes.

10. INSTALL MANUAL VALVE BODY AND DETENT

SPRING
HINT: Each bolt length is indicated below.

Bolt length:

Bolt A: 22 mm (0.866 in.)

Bolt B: 37 mm (1.457 in.)

(a)

Align the manual valve with the pin on the manual shaft
lever.

(b)

Lower the manual valve body into place.

(c)

Hand tighten the 5 bolts first. Then, tighten them with a
torque wrench.

Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)

(d)

Place the detent springs on the manual valve body and
hand tighten the 2 bolts first.
Then, tighten them with a torque wrench.

Torque: 11 N·m (110 kgf·cm, 8 ft·lbf)

HINT: Each bolt length is indicated below.

Bolt length:

Bolt A: 14 mm (0.551 in.)

Bolt B: 37 mm (1.457 in.)

(e)

Check that the manual valve lever is touching the center
of the detent spring tip roller.

11. INSTALL PIPE BRACKET AND OIL STRAINER

Each bolt length is indicated below.

Bolt length:

Bolt A: 22 mm (0.866 in.)

Bolt B: 53 mm (2.087 in.)

Torque:

Pipe bracket: 10 N·m (100 kgf·cm, 7 ft·lbf)

Oil strainer: 11 N·m (110 kgf·cm, 8 ft·lbf)