Lexus ES300 (2002 year). Manual - part 406

400H1-01

D26715

D26753

D26754

-

AUTOMATIC TRANSMISSION / TRANS

FORWARD CLUTCH ASSY (U150E)

40-73

95

U150E A/T REPAIR MANUAL   (RM913U)

FORWARD CLUTCH ASSY (U150E)

OVERHAUL

1.

INSPECT PACK CLEARANCE OF FORWARD CLUTCH

(a)

Install the forward clutch on the oil pump.

NOTICE:
Be careful not to damage the oil seal ring of oil pump.
(b)

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

2

, 57 psi).

Pack clearance: 1.00 - 1.25 mm (0.0394 - 0.4921 in.)

If the clearance is not within standard, inspect the discs, plates
and flange.
HINT:
As the opening is large, cover it with a shop rug to prevent the
compressed air from being released.

2.

REMOVE FORWARD MULTIPLE  DISC CLUTCH
CLUTCH DISC

(a)

Using a screwdriver, remove the snap ring.

(b)

Remove the flange, 5 discs and 5 plates from the input
shaft assy.

D09189

D26418

SST

D26709

D26708

40-74

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AUTOMATIC TRANSMISSION / TRANS

FORWARD CLUTCH ASSY (U150E)

96

U150E A/T REPAIR MANUAL   (RM913U)

3.

INSPECT  FORWARD MULTIPLE  DISC CLUTCH
CLUTCH DISC

(a)

Check to see if the sliding surface of the disc, plate and
flange are worn or burnt.

If necessary, replace them.
HINT:

If the lining of the disc comes off or discolors, or even if
replace all discs.

Before assembling new discs, soak them in ATF for at
least 15 minutes.

4.

REMOVE FORWARD CLUTCH RETURN SPRING
SUB-ASSY

(a)

Place SST on the spring retainer and compress the return
spring with a press.
SST

09387-00020

(b)

Using a snap ring expander, remove the snap ring.

NOTICE:

Stop the press when the spring sheet is lowered 1 -
2 mm (0.039 - 0.078 in.) from the snap ring groove,
preventing the spring sheet from deforming.

Do not expand the snap ring excessively.

(c)

Remove the clutch balancer from the input shaft.

(d)

Remove the piston return spring from the input shaft.

D09211

D03664

C56374

D25587

A

D26707

-

AUTOMATIC TRANSMISSION / TRANS

FORWARD CLUTCH ASSY (U150E)

40-75

97

U150E A/T REPAIR MANUAL   (RM913U)

5.

INSPECT FORWARD CLUTCH RETURN SPRING
SUB-ASSY

(a)

Using vernier calipers, measure the free length of the
spring together with the spring seat.
Standard free length: 26.76 mm (1.0535 in.)

6.

REMOVE FORWARD CLUTCH PISTON  SUB-ASSY

(a)

Place the forward clutch drum onto the oil pump.

(b)

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

2

, 57 psi) to the oil pump

to remove the forward clutch piston.

HINT:
When the piston cannot be removed as it is slanted, either blow
the air again with the protruding side pushed, or remove the pis-
ton using the needle nose plier with vinyl tape on the tip.
7.

REMOVE INPUT SHAFT OIL SEAL RING

(a)

Remove the oil seal ring to the input shaft.

8.

INSTALL INPUT SHAFT OIL SEAL RING

(a)

Compress the oil seal ring from both sides to reduce di-
mension A.
Dimension A: 5 mm (0.197 in.)

(b)

Coat the oil seal ring with ATF and install it to the input
shaft.

9.

INSTALL FORWARD CLUTCH PISTON  SUB-ASSY

(a)

Coat the forward clutch piston with ATF, and install it to the
input shaft.

NOTICE:
Be careful not to damage the lip seal of the forward clutch
piston.

D26708

D26709

D26418

SST

D26788

Stopper

Stopper

40-76

-

AUTOMATIC TRANSMISSION / TRANS

FORWARD CLUTCH ASSY (U150E)

98

U150E A/T REPAIR MANUAL   (RM913U)

10.

INSTALL FORWARD CLUTCH RETURN SPRING
SUB-ASSY

(a)

Install the return spring to the input shaft.

(b)

Install the clutch balancer to the input shaft.

NOTICE:
Be careful not to damage the lip seal of the forward clutch
balancer.

(c)

Place SST on the clutch balancer, and compress the
clutch balancer with a press.
SST

09387-00020

(d)

Install the snap ring with a snap ring expander.

(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
groove.

This prevents the spring sheet from being deformed.

Do not expand the snap ring excessively.

(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.