Lexus ES300 (1997 year). Service manual - part 96

AUTOMATIC TRANSAXLE

COMPONENT PARTS INSTALLATION

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AX-1 11

17. INSTALL NEW SECOND BRAKE GASKET

Install a new gasket until it makes contact with the second
brake drum.

18. CHECK OPERATION OF SECOND BRAKE

Apply compressed air into the second brake gasket and
confirm that the piston moves.

19. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM
(a)

Coat the thrust washer with petroleum jelly and install it
on the sun gear input drum.

(b)

While turning the sun gear clockwise, install it into the
No.1 one-way clutch.

20. INSTALL OIL SEAL RING TO INTERMEDIATE SHAFT

HINT: After installing the oil seal ring, check that it moves
smoothly.

AUTOMATIC TRANSAXLE

COMPONENT PARTS INSTALLATION

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AX-1 12

21. INSTALL FRONT PLANETARY GEAR
(a)

Coat the bearings with petroleum jelly, and install them
onto the both sides of planetary gear.

Bearing outer diameter: 45.5 mm (1.791 in.)

Bearing inner diameter: 30.1 mm (1.185 in.)

(b)

Install the planetary gear onto the sun gear.

22. INSTALL FRONT PLANETARY RING GEAR

23. INSTALL SECOND COAST BRAKE BAND
(a)

Place the band into the case.

(b)

Install the pin through the oil pump mounting bolt hole.

24. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH
(a)

Coat the bearing with petroleum jelly and install it onto
rear side of the forward clutch.

Bearing outer diameter: 47.6 mm (1.874 in.)

Bearing inner diameter: 31.4 mm (1.236 in.)

AUTOMATIC TRANSAXLE

COMPONENT PARTS INSTALLATION

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AX-1 13

(b)

Coat the bearing with petroleum jelly and install it onto the
front side of the forward clutch.
HINT: There are 2 different thickness bearings for adjust-
ment of the input shaft thrust play.

Bearing thickness

mm (in.)

Thickness

Outer diameter

Inner diameter

3.60 (0.1417)

45.9 (1.807)

27.7 (1.091)

4.19 (0.1650)

47.1 (1.854)

27.7 (1.091)

(c)

Coat the thrust washer with petroleum jelly and install it
with the oil groove facing upward onto the direct clutch
drum.

(d)

Mesh the hub of the forward clutch flukes with the direct
clutch discs.
HINT: Be careful that the bearing and thrust washer do not
get out of place.

(e)

Install the direct clutch and forward clutch into the case.
HINT: Hold the direct clutch toward the forward clutch to
prevent the thrust washer from getting out of place.

25. INSTALL OIL PUMP INTO CASE
(a)

Coat a new O-ring with ATF and install it to the oil pump.

AUTOMATIC TRANSAXLE

COMPONENT PARTS INSTALLATION

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AX-1 14

(b)

Place the oil pump through the input shaft, and align the
bolt holes of the pump body with the transmission case.

NOTICE: Do not push on the oil pump strongly or the oil

seal ring will stick to the direct clutch drum.

Torque: 22 N·m (225 kgf·cm, 16 ft·lbf)

26. MEASURE END PLAY OF INPUT SHAFT

Measure the end play with a dial gauge.

End play:

0.25-0.90 mm (0.0098-0.0354 in.)

HINT: There are 2 different thickness bearings for end of
stator shaft. If the end play is in excess of standard, select
one of them.

Bearing thickness:

3.60 mm (0.1417 in.)

4.19 mm (0.1650 in.)

27. CHECK INPUT SHAFT ROTATION

Make sure that the input shaft rotates smoothly.

28. INSTALL SECOND COAST BRAKE PISTON
(a)

Coat the new O-rings with ATF and install it to the cover.

(b)

Install the outer spring with the piston.

(c)

Place the cover into the bore.

(d)

Using SST, install the snap ring while pressing the cover.
SST 09350-32014  (09351-32050)

(e)

Check that the front end of the piston rod contacts the
center of the second brake band depression.

29. CHECK SECOND COAST BRAKE PISTON STROKE
(a)

Apply a small amount of paint to the piston rod at the point
it meets the case.