Lexus Car ES, IS, LS 1998-06

Transaxle Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Turn the ignition switch to the LOCK position and disconnect the negative battery cable. Wait at least 90 seconds or longer before doing any work on the vehicle.
  4.  
  5. Remove or disconnect the following:

    Battery
     
    Air cleaner assembly
     
    Throttle cable from the throttle body
     
    Cruise control actuator cover and detach the connector
     
    Ground wire
     
    Starter
     
    Vehicle Speed Sensor (VSS) connectors
     
    Direct clutch speed sensor
     
    Park/Neutral Position (PNP) switch connector on the transaxle
     
    Solenoid connector on the transaxle
     
    Shift control cable
     
    Oil cooler hoses
     
    2 front side transaxle mounting bolts
     
    2 front engine mounting bolts
     
    Oil cooler line mounting bolts from the front frame
     
    3 upper transaxle to engine mounting bolts
     

  6.  
  7. Install an engine support fixture. Tie steering gear housing to engine support fixture.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Drain the transaxle/differential fluid.
  12.  
  13. Remove or disconnect the following:

    Front wheels
     
    Front exhaust pipe
     
    Engine side covers and undercovers
     
    Both halfshafts
     
    Front side engine mounting nut
     
    Rear side engine mounting bolts (remove hole plugs)
     
    4 left side transaxle mounting bolts
     
    Steering gear housing
     
    Front frame assembly
     

  14.  
  15. Properly support the transaxle assembly.
  16.  
  17. Remove or disconnect the following:

    Rear end plate mounting bolts
     
    Torque converter cover
     
    Torque converter retaining bolts
     
    Remaining transaxle mounting bolts
     

  18.  
  19. Carefully remove the transaxle assembly from the vehicle.
  20.  

To install:

  1. Position the transaxle, aligning the 2 dowel pins on the block with the converter housing. Tighten the bolts as follows: 10mm-34 ft. lbs. (46 Nm); 12mm-47 ft. lbs. (64 Nm).
  2.  
  3. Install or connect the following:

    Torque converter bolts. Coat the threads with sealer. Install the bolts starting with the green bolt followed by the rest and tighten the bolts evenly to 20 ft. lbs. (27 Nm).
     
    End plate and tighten the bolts to 27 ft. lbs. (37 Nm)
     
    Front frame assembly and tighten the fasteners as follows: 12mm-24 ft. lbs. (32 Nm); 19mm-134 ft. lbs. (181 Nm); nut-27 ft. lbs. (36 Nm).
     
    2 fender liner set screws
     
    Steering gear to the frame and tighten the bolts and nuts to 134 ft. lbs. (181 Nm)
     
    Sway bar brackets and toque the bolts to 14 ft. lbs. (19 Nm)
     
    Left transaxle mounting bolts and tighten them to 38 ft. lbs. (52 Nm)
     
    Rear side mounting bolts and nuts and tighten them to 48 ft. lbs. (66 Nm). Install the plugs.
     
    Front engine mounting nut and tighten it to 59 ft. lbs. (80 Nm)
     
    Halfshafts
     
    Right and left engine side covers
     
    Lower engine cover
     
    Exhaust pipe to the engine with new gaskets and tighten the nuts to 46 ft. lbs. (62 Nm). Connect the exhaust pipe to the converter with a new gasket and tighten the nuts and bolts to 32 ft. lbs. (43 Nm).
     
    Wheel
     
    Engine support
     
    4 upper transaxle mounting bolts and tighten them to 47 ft. lbs. (64 Nm)
     
    Oil cooler clamping bolts to the front frame
     
    2 front side engine mounting bolts and tighten them to 59 ft. lbs. (80 Nm)
     
    2 front side transaxle mounting bolts and tighten them to 59 ft. lbs. (80 Nm)
     
    Remaining components
     
    Battery and connect the battery cables
     

  4.  
  5. Fill the transaxle/differential to the proper level with Dexron®II, or equivalent.
  6.  
  7. Check the transaxle/differential fluid level.
  8.  
  9. Check the front wheel alignment.
  10.  



Click image to see an enlarged view

Fig. Exploded view of the transaxle assembly components for removal-ES 330

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Turn the ignition switch to the LOCK position and disconnect the negative battery cable. Wait at least 90 seconds or longer before doing any work on the vehicle.
  4.  
  5. Remove the engine and transaxle assembly from the vehicle, following procedures for engine removal.
  6.  
  7. Remove both front driveshaft assemblies.
  8.  
  9. With engine/transaxle assembly on the workbench, or in a suitable holding fixture, remove or disconnect the following:

    Transmission control cable bracket No. 2
     
    Wiring harness and clamp
     
    Starter
     
    Connectors for transmission wire, park/neutral position switch, and 2 transmission revolution sensors
     
    Transmission control cable bracket No. 1
     
    Oil cooler tube clamp (near control cable bracket)
     
    Oil filler tube
     
    Oil cooler inlet and outlet tubes
     
    Front right engine mount bracket
     
    2 bolts and flywheel housing under cover
     
    Transaxle mounting bolts (through access hole)
     
    Transaxle from engine
     
    Transaxle case upper cover
     

  10.  
  11. If necessary, remove the torque converter clutch assembly at this time.
  12.  

To install:

Click image to see an enlarged view

Fig. Measuring the torque converter installed position-ES 330

  1. Install the transaxle case upper cover.
  2.  
  3. Install the torque converter into the transaxle, if removed.
  4.  
  5. Using calipers, measure the installed dimension -A-, as shown. Then, using a straightedge and calipers, measure dimension -B-. Ensure dimension -B- is at least 0.25- (1mm) more than dimension -A-. If not, recheck the torque converter installation.
  6.  
  7. Install the automatic transaxle assembly to the engine and torque the bolts as follows:

    Bolt A: 47 ft. lbs. (64 Nm)
     
    Bolt B: 34 ft. lbs. (46 Nm)
     
    Bolt C: 27 ft. lbs. (37 Nm)

    Click image to see an enlarged view

    Fig. Identifying the automatic transaxle mounting bolts for specific tightening requirements-ES 330

     

  8.  
  9. Apply a few drops of thread lock compound to 2 threads of each of the 6 torque converter mounting bolts. Install the bolts through the cover plate access hole and torque the bolts to 30 ft. lbs. (41 Nm).
    NOTE
    First install the Green-colored bolt, then install the other 5 bolts.

  10.  
  11. Install or connect the following:

    Flywheel housing under cover; torque bolts to 69 inch lbs. (7.8 Nm)
     
    Engine right front mounting bracket; torque 3 bolts to 47 ft. lbs. (64 Nm)
     
    Transaxle oil filler tube assembly, with a new O-ring
     
    Dipstick
     
    Breather hose to wiring harness bracket
     
    Transaxle control cable bracket No. 1; torque bolts to 9 ft. lbs. (12 Nm)
     
    Oil cooler inlet tube No. 1; torque bolt to 48 inch lbs. (5.4 Nm) temporarily until assembly is installed, then torque to 25 ft. lbs. (34 Nm)
     
    Oil cooler outlet tube No. 1; torque bolt to 25 ft. lbs. (34 Nm)
     
    Connectors for transmission revolution sensors, park/neutral position switch, and transmission wire.
     
    Starter; torque bolts to 27 ft. lbs. (37 Nm)
     
    Starter wiring
     
    Wiring harness (ground strap) to transaxle; torque bolt to 9 ft. lbs. (12 Nm)
     
    2 wiring harness clamps
     
    Transaxle control cable bracket No. 2; torque bolt to 9 ft. lbs. (12 Nm)
     

  12.  
  13. Install both front driveshafts.
  14.  
  15. Install the engine assembly, with transaxle, into the vehicle.
  16.  
  17. Refill the transaxle with recommended fluid type.
  18.  
  19. Check the front wheel alignment.
  20.  

 
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