Lexus ES300 (2002 year). Manual - part 407

D26415

Flange

Plate

Disc

D26753

D26715

D03672

-

AUTOMATIC TRANSMISSION / TRANS

FORWARD CLUTCH ASSY (U150E)

40-77

99

U150E A/T REPAIR MANUAL   (RM913U)

11.

INSTALL FORWARD MULTIPLE DISC CLUTCH
CLUTCH DISC

(a)

Coat the 5 discs with ATF.

(b)

Install the 5 plates, 5 discs and flange input 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.

12.

INSPECT PACK CLEARANCE OF FORWARD CLUTCH

(a)

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

⋅

cm

2

, 4.0 kPa, 57 psi).

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

If the piston stroke is less than the minimum, parts may have
been assembled incorrectly. Check and reassemble again.
If the clearance is not standard, select another flange.
HINT:
There are 5 different flanges in thickness.

Flange thickness: mm (in.)

No.

Thickness

No.

Thickness

1

3.00 (0.1181)

4

3.45 (0.1358)

2

3.15 (0.1240)

5

3.60 (0.1417)

3

3.30 (0.1299)

-

-

13.

INSPECT  FORWARD MULTIPLE  DISC CLUTCH
CLUTCH DISC

(a)

Check if the disc lightly rotates when rotating the forward
clutch assy after inserting the multiple disc clutch into it.

NOTICE:
Do not place the forward clutch assy in a vise.

4006M-02

D26445

Mark

D26446

C50237

D25595

Hold

Turn

SST

SST

40-102

-

AUTOMATIC TRANSMISSION / TRANS

FRONT DIFFERENTIAL ASSY (U150E)

124

U150E A/T REPAIR MANUAL   (RM913U)

FRONT DIFFERENTIAL ASSY (U150E)

OVERHAUL

1.

REMOVE FRONT DIFFERENTIAL RING GEAR

(a)

Place the match-marks on the ring gear and differential
case.

(b)

Remove the 14 bolts.

(c)

Using a plastic hammer, tap on the ring gear to remove it
from the case.

2.

REMOVE FR DIFFERENTIAL CASE FRONT TAPERED
ROLLER BEARING

(a)

Using SST, remove the front differential case front ta-
pered roller bearing from the differential case.
SST

09950- 00020, 09950- 00030, 09950- 60010
(09951-00490),  09950-40011 (09957-04010)

D25596

SST

D25597

Hold

Turn

SST

SST

D25598

SST

C50240

C50241

-

AUTOMATIC TRANSMISSION / TRANS

FRONT DIFFERENTIAL ASSY (U150E)

40-103

125

U150E A/T REPAIR MANUAL   (RM913U)

(b)

Using SST, remove the front differential case front ta-
pered roller bearing outer race.
SST

09308-00010

3.

REMOVE FR DIFFERENTIAL CASE REAR TAPERED
ROLLER BEARING

(a)

Using SST, remove the front differential case rear tapered
roller bearing from the differential case.
SST

09950- 00020, 09950- 00030, 09950- 60010
(09951-00490),  09950-40011 (09957-04010)

(b)

Using SST, remove the front differential case rear tapered
roller bearing outer race.
SST

09308-00010

4.

REMOVE FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN

(a)

Using a pin punch and hammer, install the straight pin.

NOTICE:
Before removing the straight pin, unstake it with a pin
punch.

5.

REMOVE FRONT DIFFERENTIAL PINION SHAFT
NO.1

(a)

Remove the front differential pinion shaft No. 1 from the
differential case.

C50242

D25599

SST

D25600

SST

C50242

C50241

40-104

-

AUTOMATIC TRANSMISSION / TRANS

FRONT DIFFERENTIAL ASSY (U150E)

126

U150E A/T REPAIR MANUAL   (RM913U)

6.

REMOVE FRONT DIFFERENTIAL SIDE GEAR

(a)

Remove the 2 front differential pinions, 2 pinion thrust
washers, 2 front differential side gears and 2 side gear
thrust washers from the differential case.

7.

REMOVE TRANSAXLE HOUSING OIL SEAL

(a)

Using SST, remove the oil seal.
SST

09950- 70010 (09951- 07100), 09215- 00013
(09215-00471)

8.

REMOVE DIFFERENTIAL SIDE BEARING RETAINER
OIL SEAL

(a)

Using SST, remove the oil seal.
SST

09950-70010 (09951-07100), 09608-10010

9.

INSTALL FRONT DIFFERENTIAL SIDE GEAR

(a)

Apply the 2 front differential side gears, 2 side gear thrust
washers, 2 front differential pinions and 2 pinion thrust
washers with ATF and install them to the differential case.

10.

INSTALL FRONT DIFFERENTIAL PINION SHAFT NO.1

(a)

Apply the front differential pinion shaft No. 1 with ATF,
install it to the differential case.