Lexus ES: Disassembly

(a) Remove the nut, washer and transmission control shaft lever from the manual valve lever shaft sub-assembly.

(a) Remove the 2 bolts and park/neutral position switch assembly from the automatic transaxle case sub-assembly.

(a) Remove the refill plug and gasket from the automatic transaxle case sub-assembly.

(a) Using a 10 mm socket hexagon wrench, remove the overflow plug and gasket from the transaxle housing.

(a) Using a 6 mm socket hexagon wrench, remove the No. 1 transmission oil filler tube from the transaxle housing.

(a) Remove the bolt to separate the oil cooler union sub-assembly bracket portion from the automatic transaxle case sub-assembly.

(a) Using a 19 mm union nut wrench, remove the No. 1 oil cooler outlet tube sub-assembly from the automatic transaxle case sub-assembly.

(b) Remove the O-ring from the No. 1 oil cooler outlet tube sub-assembly.

(a) Remove the 10 bolts and transmission case side cover from the automatic transaxle case sub-assembly.

(a) Disengage the clamp to disconnect the transmission wire from the solenoid lock plate.

(c) Remove the bolt and temperature sensor clamp and disconnect the temperature sensor from the transmission valve body assembly.

(d) Disconnect the transmission revolution sensor (NT) connector and transmission revolution sensor (NC) connector.

(e) Remove the bolt and transmission wire from the automatic transmission case sub-assembly.

(a) Disengage the clamp to disconnect the transmission revolution sensor (NC) wire connector.

(b) Remove the 9 bolts and transmission valve body assembly from the automatic transaxle case sub-assembly.

(c) Remove the 2 transaxle case gaskets from the automatic transaxle case sub-assembly.

(a) Remove the bolt and transmission revolution sensor (NT) from the automatic transaxle case sub-assembly.

(a) Remove the bolt, spacer and transmission revolution sensor (NC) from the counter drive gear sub-assembly.

(a) Remove the 21 bolts.

(b) Using a plastic hammer, tap on the circumference of the transaxle housing to remove it from the automatic transaxle case sub-assembly.

(c) Remove the 5 transaxle case gaskets from the front oil pump assembly.

(a) Remove the 3 bolts and transaxle housing oil separator from the transaxle housing.

(a) Remove the 3 transmission oil cleaner magnets from the transaxle housing oil separator.

(a) Remove the differential gear lube apply tube from the transaxle housing.

(a) Remove the bolt and clamp from the transaxle housing.

(b) Remove the transmission lube apply tube from the transaxle housing.

(a) Remove the differential case assembly from the automatic transaxle case sub-assembly.

(a) Remove the clutch drum oil seal ring from the front oil pump assembly.

(a) Remove the oil pump sprocket front thrust washer from the transmission oil pump drive sprocket.

(a) Remove the transmission drive chain together with the transmission oil pump drive sprocket and oil pump drive shaft sub-assembly from the front oil pump assembly.

NOTICE:

To avoid damaging the bush of the front oil pump assembly, remove the transmission drive chain, transmission oil pump drive sprocket and oil pump drive shaft sub-assembly horizontally relative to the front oil pump assembly.

(a) Remove the oil pump sprocket rear thrust washer from the front oil pump assembly.

(a) Remove the bolt and manual detent spring sub-assembly from the front oil pump assembly.

(a) Remove the 7 bolts and front oil pump assembly from the automatic transaxle case sub-assembly.

(a) Remove the planetary carrier thrust washer from the C-3 and C-4 clutch assembly.

(a) Remove the C-3 and C-4 clutch assembly from the front planetary gear assembly.

(a) Remove the No. 2 planetary carrier thrust washer from the front planetary gear assembly.

(a) Remove the planetary sun gear from the front planetary gear assembly.

(a) Remove the No. 9 thrust bearing race from the front planetary gear assembly.

(a) Remove the thrust needle roller bearing from the front planetary gear assembly.

(a) Remove the No. 8 thrust bearing race from the front planetary gear assembly.

(a) Remove the front planetary gear assembly from the front planetary ring gear.

(a) Remove the thrust needle roller bearing from the front planetary ring gear.

(a) Remove the No. 7 thrust bearing race from the front planetary gear assembly.

(a) Remove the 5 input shaft oil seal rings from the front planetary gear assembly.

(a) Remove the 2 rear input shaft oil seal rings from the front planetary gear assembly.

(a) Remove the front planetary ring gear with front planetary ring gear flange from the C-1 clutch assembly.

(b) Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the front planetary ring gear.

NOTICE:

Be careful not to damage the front planetary ring gear and front planetary ring gear flange.

(c) Remove the front planetary ring gear flange from the front planetary ring gear.

(a) Remove the thrust needle roller bearing from the C-1 clutch assembly.

(a) Remove the No. 6 thrust bearing race from the C-1 clutch assembly.

(a) Remove the C-1 clutch assembly from the sun gear input hub sub-assembly.

(a) Using a screwdriver with its tip wrapped in protective tape, remove the snap ring from the clutch drum sub-assembly.

NOTICE:

Be careful not to damage the clutch drum sub-assembly.

(b) Remove the forward clutch flange, 5 front clutch clutch discs and 5 forward multiple disc clutch clutch plates from the clutch drum sub-assembly.

(a) Place SST on the No. 1 clutch balancer and compress the rear clutch piston return compression spring with a press.

SST: 09387-00020

NOTICE:

Do not compress the rear clutch piston return compression spring excessively.

(c) Remove the No. 1 clutch balancer from the forward clutch piston.

(a) Remove the rear clutch piston return compression spring from the forward clutch piston.

(a) Apply compressed air (392 kPa (4.0 kgf/cm2, 57 psi)) to the oil hole of the clutch drum sub-assembly to remove the forward clutch piston from the clutch drum sub-assembly.

(b) Remove the O-ring from the clutch drum sub-assembly.

(c) Remove the D-ring from the clutch drum sub-assembly.

(a) Remove the sun gear input hub sub-assembly from the counter drive gear sub-assembly.

(a) Remove the thrust needle roller bearing from the sun gear input hub sub-assembly.

(a) Remove the No. 5 thrust bearing race from the sun gear input hub sub-assembly.

(a) Remove the bolt.

(b) Align the cutouts of the manual valve lever sub-assembly and manual valve lever shaft sub-assembly, and remove the manual valve lever shaft sub-assembly.

HINT:

Rotating the manual valve lever shaft sub-assembly to the area shown in the illustration will align the cutouts.

(c) Remove the O-ring from the manual valve lever shaft sub-assembly.

(a) Remove the manual valve lever sub-assembly from the automatic transaxle case sub-assembly.

(a) Remove the 2 bolts and pawl stopper plate from the automatic transaxle case sub-assembly.

(a) Remove the manual valve lever shaft retainer spring from the automatic transaxle case sub-assembly.

(a) Move the manual valve lever shaft sub-assembly and parking lock rod sub-assembly as shown in the illustration, and remove the parking lock rod sub-assembly.

HINT:

Align the cutouts of the parking lock rod sub-assembly and manual valve lever shaft sub-assembly and remove the parking lock rod sub-assembly.

(a) Remove the manual valve lever shaft sub-assembly from the automatic transaxle case sub-assembly.

(a) Remove the parking lock pawl torsion spring from the automatic transaxle case sub-assembly.

(a) Remove the parking lock pawl shaft from the automatic transaxle case sub-assembly.

(a) Remove the parking lock pawl from the automatic transaxle case sub-assembly.

(a) Remove the parking lock sleeve from the automatic transaxle case sub-assembly.

(a) Using a T50 "TORX" socket wrench, remove the 2 bolts (A) from the counter drive gear sub-assembly.

(c) Remove the counter drive gear sub-assembly together with the pinion and counter driven gear sub-assembly from the automatic transaxle case sub-assembly.

(d) Remove the O-ring from the automatic transaxle case sub-assembly.

(a) Using a screwdriver with its tip wrapped in protective tape, remove the snap ring from the counter drive gear sub-assembly.

NOTICE:

Be careful not to damage the counter drive gear sub-assembly.

(b) Remove the No. 1 brake flange, 4 No. 1 brake discs and 4 No. 1 brake plates from the counter drive gear sub-assembly.

(a) Remove the No. 3 planetary carrier thrust washer from the rear planetary gear assembly.

(a) Remove the planetary sun gear sub-assembly from the rear planetary gear assembly.

(a) Remove the rear planetary sun gear sub-assembly from the C-2 clutch assembly.

(a) Remove the rear planetary gear assembly from the C-2 clutch assembly.

(a) Remove the No. 4 planetary carrier thrust washer from the rear planetary gear assembly.

(a) Remove the No. 4 thrust bearing race from the rear planetary sun gear sub-assembly.

(a) Remove the thrust needle roller bearing from the rear planetary sun gear sub-assembly.

(a) Remove the thrust bearing race from the rear planetary sun gear sub-assembly.

(a) Remove the No. 3 thrust bearing race from the rear planetary sun gear sub-assembly.

(a) Remove the thrust needle roller bearing from the C-2 clutch assembly.

(a) Remove the No. 2 thrust bearing race from the C-2 clutch assembly.

(a) Remove the C-2 clutch assembly from the automatic transaxle case sub-assembly.

(a) Remove the thrust needle roller bearing from the C-2 clutch assembly.

(a) Remove the No. 1 thrust bearing race from the automatic transaxle case sub-assembly.

(a) Using a screwdriver with its tip wrapped in protective tape, remove the snap ring from the intermediate shaft sub-assembly.

NOTICE:

Be careful not to damage the intermediate shaft sub-assembly.

(b) Remove the direct clutch flange, 4 No. 2 clutch discs and 4 No. 2 clutch plates from the intermediate shaft sub-assembly.

(a) Place SST on the C-2 clutch balancer and compress the clutch return spring sub-assembly with a press.

SST: 09387-00020

NOTICE:

Do not compress the clutch return spring sub-assembly excessively.

(c) Remove the C-2 clutch balancer from the intermediate shaft sub-assembly.

(a) Remove the clutch return spring sub-assembly from the intermediate shaft sub-assembly.

(a) Apply compressed air (392 kPa (4.0 kgf/cm2, 57 psi)) to the oil hole of the intermediate shaft sub-assembly.

(b) Remove the C-2 clutch piston from the intermediate shaft sub-assembly.

(c) Remove the 2 O-rings from the intermediate shaft sub-assembly.

(a) Remove the 2 direct clutch drum oil seal rings from the automatic transaxle case sub-assembly.

(a) Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the automatic transaxle case sub-assembly.

NOTICE:

Be careful not to damage the automatic transaxle case sub-assembly.

(b) Remove the 2nd brake brake flange, 5 2nd brake brake discs and 5 2nd brake brake plates from the automatic transaxle case sub-assembly.

(a) Remove the No. 2 1st and reverse brake piston from the automatic transaxle case sub-assembly.

(a) Place SST on the 1st and reverse brake return spring sub-assembly and compress it with a press.

SST: 09380-60011

09381-06020

09381-06050

09381-06060

09381-06100

09381-06110

SST: 09950-70010

09951-07200

NOTICE:

Do not compress the 1st and reverse brake return spring sub-assembly excessively.

(b) Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the automatic transaxle case sub-assembly.

NOTICE:

Be careful not to damage the automatic transaxle case sub-assembly.

(c) Remove the 1st and reverse brake return spring sub-assembly from the automatic transaxle case sub-assembly.

(a) Apply compressed air (approximately 392 kPa (4.0 kgf/cm2, 57 psi)) to the ATF hole to remove the 1st and reverse brake piston from the automatic transaxle case sub-assembly.

(b) Remove the 2 O-rings from the 1st and reverse brake piston.

(a) Using SST, remove the needle roller bearing from the automatic transaxle case sub-assembly.

SST: 09303-55010

SST: 09502-12010

NOTICE:

Be careful not to damage the automatic transaxle case sub-assembly.

(a) Using a screwdriver with its tip wrapped with protective tape, remove the manual valve lever shaft oil seal from the automatic transaxle case sub-assembly.

NOTICE:

Be careful not to damage the automatic transaxle case sub-assembly.

(a) Using SST, remove the transaxle case oil seal from the transaxle housing.

SST: 09308-36010

NOTICE:

Be careful not to damage the transaxle housing.

(a) Using SST, remove the front drive shaft oil seal RH from the transaxle housing.

SST: 09308-36010

NOTICE:

Be careful not to damage the transaxle housing.

(a) Using SST, remove the front drive shaft oil seal LH from the automatic transaxle case sub-assembly.

SST: 09308-36010

NOTICE:

Be careful not to damage the automatic transaxle case sub-assembly.

(a) Using SST and a press, remove the needle roller bearing from the transaxle housing.

SST: 09950-60011

09951-00550

SST: 09950-70010

09951-07200

NOTICE:

Be careful not to damage the transaxle housing.

(a) Using SST, remove the counter driven gear rear tapered roller bearing (inner race) from the pinion and counter driven gear sub-assembly.

SST: 09950-40011

09951-04010

09952-04010

09953-04030

09954-04010

09955-04011

09957-04010

09958-04011

SST: 09950-60011

09951-00310

NOTICE:

Because SST is attached to the roller portion, there is a possibility that the roller portion could break and SST could come off before the counter driven gear tapered roller bearing (rear side inner race) comes off.

(b) If the roller portion breaks and SST comes off, reattach SST to the inner race in the position shown in the illustration, and continue removing the parts.

SST: 09950-40011

09951-04010

09952-04010

09953-04030

09954-04010

09955-04011

09957-04010

09958-04011

SST: 09950-60011

09951-00310

(a) Using SST, remove the counter driven gear front tapered roller bearing (inner race) from the pinion and counter driven gear sub-assembly.

SST: 09950-00020

SST: 09950-00030

SST: 09950-60011

09951-00380

(a) Remove the 4 No. 1 transaxle case plugs from the automatic transaxle case sub-assembly.

(b) Remove the 4 No. 1 transaxle case plugs from the transaxle housing.

(c) Remove the 8 O-rings from the 8 No. 1 transaxle case plugs.

(a) Using a 6 mm socket hexagon wrench, remove the 3 No. 2 transaxle case plugs and 3 gaskets from the automatic transaxle case sub-assembly.

(b) Using a 6 mm socket hexagon wrench, remove the 3 No. 2 transaxle case plugs and 3 gaskets from the transaxle housing.

(a) Remove the 2 automatic transmission case straight pins from the automatic transaxle case sub-assembly.

(a) Disengage each claw and remove the No. 1 breather plug (ATM) from the automatic transaxle case sub-assembly.

NOTICE:

Be careful not to damage the automatic transaxle case sub-assembly.