Lexus ES300 (2002 year). Manual - part 402

D26463

D26425

D26464

D26464

D26462

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AUTOMATIC TRANSMISSION / TRANS

DIRECT CLUTCH ASSY (U150E)

40-81

103

U150E A/T REPAIR MANUAL   (RM913U)

9.

REMOVE OVERDRIVE DIRECT CLUTCH PISTON

(a)

Install intermediate shaft on the transaxle rear cover.

(b)

Holding the direct clutch piston with your hand, apply
compressed air (392 kPa, 4.0 kgf/cm

2

, 57 psi) to the

transaxle rear cover to remove the direct clutch piston.

10.

REMOVE OVERDRIVE DIRECT CLUTCH DRUM
SUB-ASSY

(a)

Holding the direct clutch drum by hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm

2

, 57 psi) to the transaxle

rear cover to remove the direct clutch drum.

11.

REMOVE OVERDRIVE DIRECT CLUCH O-RING

(a)

Using a screwdriver, remove the O-ring from the direct
clutch drum.

12.

INSTALL OVERDRIVE DIRECT CLUCH O-RING

(a)

Coat a O-ring with ATF, and install it to the direct clutch
drum.

13.

INSTALL OVERDRIVE DIRECT CLUTCH DRUM
SUB-ASSY

(a)

Coat the direct clutch drum with ATF, and install it to the
intermediate shaft.

NOTICE:

Be careful not to damage the O-ring.

Be careful not to damage the lip seal of the direct
clutch drum.

D26461

D26423

D26424

D03677

SST

40-82

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AUTOMATIC TRANSMISSION / TRANS

DIRECT CLUTCH ASSY (U150E)

104

U150E A/T REPAIR MANUAL   (RM913U)

14.

INSTALL OVERDRIVE DIRECT CLUTCH PISTON

(a)

Apply the direct clutch piston with ATF, and install it to the
direct clutch drum.

NOTICE:
Be careful not to damage the lip seal of the direct clutch pis-
ton.

15.

INSTALL OVERDRIVE CLUTCH RETURN SPRING
SUB-ASSY

(a)

Install the piston return spring to the intermediate shaft.

(b)

Install the clutch balancer to the intermediate shaft.

NOTICE:
Be careful not to damage the lip seal of the direct clutch ba-
lancer.

(c)

Place SST on the clutch balancer and compress the pis-
ton return spring with a press.
SST

09387-00020

(d)

Using a snap ring expander, install the snap ring to the di-
rect clutch drum.

(e)

Be sure the end gap of the snap ring is not aligned with
the spring retainer claw.

NOTICE:

Stop the press when the spring sheet is lowered to the
place 1 - 2 mm (0.039 - 0.078 in.) from the snap ring
grove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.

D25588

Stopper

Stopper

D26417

Disc

Flange

Plate

D26421

D26416

Disc

Flange

Plate

Cushion 
Plate

D26419

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AUTOMATIC TRANSMISSION / TRANS

DIRECT CLUTCH ASSY (U150E)

40-83

105

U150E A/T REPAIR MANUAL   (RM913U)

(f)

Set the end gap of the snap ring in the piston shown in the
illustration.

NOTICE:
The end gap of the snap ring should not coincide with any
of the stoppers.

16.

INSTALL OVERDRIVE DIRECT CLUTCH DISC

(a)

Coat the 4 discs with ATF.

(b)

Install the 4 plates, 4 discs and flange to the intermediate
shaft.

(c)

Using a screwdriver, install the snap ring.

(d)

Check that the end gap of the snap ring is not aligned with
one of the cutouts.

17.

INSTALL REVERSE CLUTCH DISC

(a)

Apply the 3 discs with ATF.

(b)

Install the cushion plate, 3 plates, 3 discs and flange to the
intermediate shaft.

NOTICE:
Install the cushion plate with the mark on the white surface
facing to plate.

(c)

Using a screwdriver, install the snap ring.

(d)

Check that the end gap of the snap ring is not aligned with
one of the cutouts.

D26426

D26427

D26428

40-84

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AUTOMATIC TRANSMISSION / TRANS

DIRECT CLUTCH ASSY (U150E)

106

U150E A/T REPAIR MANUAL   (RM913U)

18.

INSPECT PACK CLEARANCE OF REVERSE CLUTCH

(a)

Install the intermediate shaft on the transaxle rear cover.

(b)

Using a dial indicator, measure the direct clutch pack
clearance while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm

2

, 57 psi).

Pack clearance:0.60 - 0.82 mm (0.02362 - 0.03228 in.)

If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the stroke is not within standard, select another flange.
HINT:
There are 6 flanges of different thickness.

Flange thickness: mm (in.)

No.

Thickness

No.

Thickness

1

3.0 (0.118)

5

3.4 (0.134)

2

3.1 (0.122)

6

3.5 (0.138)

3

3.2 (0.126)

7

3.6 (0.142)

4

3.3 (0.130)

-

-

19.

INSPECT PACK CLEARANCE OF DIRECT CLUTCH &
OVERDRIVE CLUTCH

(a)

Using a dial indicator, measure the direct clutch & over-
drive clutch pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm

2

, 57 psi).

Pack clearance:0.61 - 0.83 mm (0.02401 - 0.03268 in.)

If the pack clearance is less than the minimum, parts may have
been assembled incorrectly, so check and reassemble again.
If the stroke is not within standard, select another flange.
HINT:
There are 7 flanges in different thickness.

Flange thickness: mm (in.)

No.

Thickness

No.

Thickness

0

2.5 (0.098)

4

2.9 (0.114)

1

2.6 (0.102)

5

3.0 (0.118)

2

2.7 (0.106)

6

3.1 (0.122)

3

2.8 (0.110)

-

-

(b)

Check that the disc rotates when rotating the disc after in-
serting the rear planetary sun gear.

NOTICE:
Do not place the rear planetary sun gear in a vise.