Lexus RX300 (MCU15). Service manual - part 580

AX0AR–03

D03680

D03678

D03677

SST

D03676

–

AUTOMATIC TRANSAXLE

DIRECT CLUTCH

AX–63

U140F AX   (RM848E)

REASSEMBLY

1.

INSTALL DIRECT CLUTCH PISTON

Coat the direct clutch piston with ATF, install it to the direct
clutch drum.
NOTICE:
Be careful not to damage the lip seal of direct clutch piston.

2.

INSTALL PISTON RETURN SPRING

(a)

Install the piston return spring and clutch balancer to the
direct clutch drum.

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

(b)

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

09387–00020

(c)

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

NOTICE:

S

Be sure the end gap of the snap ring is not aligned
with the clutch balancer claw.

S

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, preventing the spring sheet from the deform-
ing.

S

Do not expand the snap ring excessively.

3.

INSTALL PLATE, DISC AND FLANGE

(a)

Install the 4 plates, 4 discs and flange.
Install in order: P=Plate, D=Disc, F=Flange
P – D – P – D – P – D – P – D – F

D03675

D03877

D03682

AX–64

–

AUTOMATIC TRANSAXLE

DIRECT CLUTCH

U140F AX   (RM848E)

(b)

Using a screwdriver, install the snap ring.

(c)

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

4.

CHECK PISTON STROKE OF DIRECT CLUTCH

(a)

Install the direct clutch on the transaxle rear cover.

(b)

Using and a dial indicator, measure the direct clutch pis-
ton stroke while applying and releasing compressed air
(392 kPa, 4.0 kgf/cm

2

, 57 psi).

Piston stroke: 0.605 – 0.825 mm (0.02382 – 0.03248
in.)

If the piston stroke is less than the limit of piston stroke, parts
may have been assembled incorrectly, so check and reas-
semble again.
If the stroke is non–standard, select another flange.
HINT:
There are 6 flanges in different thickness.
Flange Thickness: mm (in.)

No.

Thickness

No.

Thickness

1

3.0 (0.118)

4

3.3 (0.130)

2

3.1 (0.122)

5

3.4 (0.134)

3

3.2 (0.126)

6

3.5 (0.138)

5.

CHECK DISK ROTATE

Check that the disc rotates when rotating the disk after inserting
the rear planetary sun gear.
NOTICE:
Do not place the rear planetary sun gear in a vise.

AX0AS–05

D03656

Forward Clutch Drum

Forward Clutch Piston

Piston Return Spring

Snap Ring

Plate

Disc

Flange

Thrust Bearing

Thrust Bearing

Multiple Disc Clutch Hub

z Non–reusable part

z O–ring

Snap Ring

–

AUTOMATIC TRANSAXLE

FORWARD CLUTCH

AX–65

U140F AX   (RM848E)

FORWARD CLUTCH

COMPONENTS

AX0AT–03

D03659

D03660

D03661

D03662

SST

AX–66

–

AUTOMATIC TRANSAXLE

FORWARD CLUTCH

U140F AX   (RM848E)

DISASSEMBLY

1.

CHECK PISTON STROKE 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 piston
stroke while applying and releasing compressed air (392
kPa, 4.0 kgf/cm

2

, 57 psi).

Piston stroke: 2.09 – 2.23 mm (0.0823 – 0.0878 in.)

If the clearance is non–standard, inspect the discs, plates
flange.
HINT:
As the opening is big, cover it with a shop rug as well as an com-
pressed air th prevent the air from discharging.

2.

REMOVE FLANGE, PLATE AND DISC

(a)

Using a screwdriver, remove the snap ring from the for-
ward clutch drum.

(b)

Remove the flange, 6 discs and 6 plates.

3.

REMOVE PISTON RETURN SPRING

(a)

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

09350–32014 (09351–32070)

(b)

Using a snap ring expander, remove the snap ring.