Lexus RX300 (MCU15). Service manual - part 585

D03704

D03705

D04078

–

AUTOMATIC TRANSAXLE

UNDERDRIVE CLUTCH

AX–83

U140F AX   (RM848E)

(c)

Remove the clutch balancer and piston return spring from
the U/D clutch drum.

4.

REMOVE U/D CLUTCH PISTON

(a)

Install the U/D clutch to the transfer case.

NOTICE:
Be careful not to damage the oil seal rings.
(b)

Holding the U/D clutch piston with your hand, apply com-
pressed air (392 kPa, 4.0 kgf/cm

2

, 57 psi) to the transaxle

case to remove the U/D clutch piston.

5.

REMOVE O–RING

AX0B2–05

D04077

D03706

D03824

AX–84

–

AUTOMATIC TRANSAXLE

UNDERDRIVE CLUTCH

U140F AX   (RM848E)

INSPECTION

1.

INSPECT DISC, PLATE AND FLANGE

Check to see if the sliding surface of the disc, plate and flange
are worn or burnt. If necessary, replace them.
HINT:

S

If the lining of the disc is peeling off or discolored, or even
if a part of the printed mark is defaced, replace all discs.

S

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

2.

CHECK U/D CLUTCH DRUM BUSHING

Using a dial indicator, measure the inside diameter of the U/D
clutch drum bushing.

Standard drum bushing: 
37.06 – 37.08 mm (1.4591 – 1.4598 in.)
Maximum drum bushing: 37.13 mm (1.4618 in.)

If the inside diameter is greater than the maximum, replace the
U/D clutch drum.

3.

CHECK U/D CLUTCH PISTON RETURN SPRING

Using vernier calipers, measure the free length of the spring to-
gether with spring seat.

Standard free length: 17.14 mm (0.6748 in.)

AX0B3–05

D04078

D03860

D03704

D03703

SST

–

AUTOMATIC TRANSAXLE

UNDERDRIVE CLUTCH

AX–85

U140F AX   (RM848E)

REASSEMBLY

1.

INSTALL O–RING

Coat new O–ring with ATF, install it to the U/D clutch drum.

2.

INSTALL U/D CLUTCH PISTON

Coat the U/D clutch piston with ATF, install it to the U/D clutch
piston drum.
NOTICE:
Be careful not to damage the O–ring.

3.

INSTALL PISTON RETURN SPRING

(a)

Install the piston return spring and clutch balancer to the
U/D clutch drum.

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

(b)

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

09350–32014 (09351–32070)

(c)

Using a snap ring expander, install the snap ring to U/D
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 deforming.

S

Do not expand the snap ring excessively.

D03702

D03701

D03699

D03700

AX–86

–

AUTOMATIC TRANSAXLE

UNDERDRIVE CLUTCH

U140F AX   (RM848E)

4.

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

(b)

Using a screwdriver, install the snap ring.

(c)

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

5.

CHECK PISTON STROKE OF U/D CLUTCH

(a)

Install the U/D clutch to the transaxle case.

NOTICE:
Be careful not to damage the oil seal rings.
(b)

Install the dial indicator, as shown in the illustration.

(c)

Measure the U/D clutch piston stroke while applying and
releasing compressed air (392 kgf/cm

2

, 4.0 kPa, 57 psi).

Piston stroke: 1.51 – 1.77 mm (0.059 – 0.070 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 3 flanges in different thickness.
Flange Thickness: mm  (in.)

No.

Thickness

No.

Thickness

1

3.0 (0.118)

3

3.4 (0.134)

2

3.2 (0.126)