2010 Lexus ES 350 V6-3.5L (2GR-FE)
Technical Service Bulletin # SB0144-10 Date: 101001
A/T - Removal/Replacement Service Manual Supplement
L-SB-0144-10
October 1, 2010
Repair Manual Supplement: Transaxle Replacement
Service Category
Drivetrain
Section
Automatic Transmission/Transaxle
Market
USA
Applicability
Introduction
This bulletin supplements the Repair Manual procedures for transaxle removal and replacement with details on the use of a new Engine Support
Bar (ESB) SST P/N 00002-ESUPPT-01 to assist in the removal and installation of the transaxle assembly. With the use of the Engine Support Bar
it is no longer required for the engine assembly to be removed from the vehicle when removing and installing the transaxle assembly.
Parts Information
Warranty Information
APPLICABLE WARRANTY
Warranty application is limited to defects in material or workmanship under normal use. Length of coverage is determined by the OFR For more
information regarding warranty coverage, please refer to the Warranty Policy & Procedures Manual. For more information regarding the Engine
Support Bar, please refer to Warranty Procedures Bulletin PRO10-11.
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Required Tools & Equipment
Repair Procedure: Removal
1. Remove the V-bank cover sub-assembly.
A. Hold the front of the V-bank cover and raise it to disengage the 2 clips on the front of the cover.
B. Continue to raise the cover to disengage the clip on the rear of the cover and remove the cover.
NOTICE
Attempting to disengage both front and rear clips at the same time may cause the cover to break.
2. Remove the cool air intake duct seal by removing the 7 clips.
3. Remove the engine room side covers.
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A. Remove the hood hinge cover LH.
B. Remove the 6 clips and engine room side cover LH.
C. Remove the hood hinge cover RH.
D. Remove the 5 clips and engine room side cover RH.
4. Remove the battery.
A. Loosen the bolt and nut and remove the battery clamp.
B. Remove the battery and battery tray.
5. Remove the intake tubing and assembly.
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A. Remove the 2 bolts clamp and air cleaner inlet.
B. Disconnect the 3 vacuum hoses.
C. Disconnect the mass air flow meter connector No.2 ventilation hose and hose band.
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D.Remove the 3 band clamps and remove the air filter.
E. Disconnect the vacuum hose and hose clamp then remove the 3 bolts and air cleaner case.
6. Remove the starter.
A. Disconnect the terminal 50 connector from the starter assembly.
B. Turn back the terminal cap.
C. Remove the nut and disconnect the wire harness from terminal 30.
D. Remove the 2 bolts and starter assembly.
7. Remove the transaxle breather hose.
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A. Remove the bolt and breather bracket from the camshaft housing sub-assembly LH.
B. Remove the breather hose from the breather bracket.
8. Remove the 2 bolts and 2 clamps from the body then unclip the wiring harness on the transmission.
9. Disconnect the park/neutral position switch connector.
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10. Remove the upper bell housing (5) bolts.
11. Disconnect the transmission control cable assembly.
Remove the clip and nut and separate the cable from the transaxle.
12. Install the 2 engine hangers with the 4 bolts as shown in the illustration.
Part Number:
^ No.1 engine hanger: P/N 12281-31120
^ No.2 engine hanger: P/N 12282-31100
^ Bolts: P/N 91671-10825 (or equivalent)
Torque: 33 N*m (337 kgf*cm, 24 ft*lbf)
13. Install the Engine Support Bar and secure engine weight with chain.
SST: 00002-ESUPPT-01
NOTE
Refer to the assembly instructions supplied with the Engine Support Bar.
A. Assemble and place the main bar onto the vehicle's strut towers.
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NOTICE
^ To prevent damage caused by contact between the main bar legs and body panels, apply protective tape on the strut tower before
installing the main bar.
^ To prevent dents in the strut tower panel, please assure that the main bar legs with 90 degree brackets are installed.
NOTE
^ Ensure that the main bar swivel is already installed on the main bar and that the main bar legs are oriented correctly (passenger
side/drivers side).
^ The plastic cowl cover and/or cowl may need to be removed to accommodate the bar.
B. Assemble the front bar assembly and position the legs so they can sit onto the right and left frame rails.
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C. Adjust the front bar arms so they can be bolted to the upper radiator core support mounting holes.
D. Place the front bar on the vehicle with the legs sitting firmly on the right and left frame rails near the radiator support and secure the front
bar arms to the radiator core support.
NOTE
Once in position, ensure that the hex nuts on the front bar legs are tight and the front bar is still square after installation.
E. Install the Engine Support Bar hook # 2 onto the crossbar and place the crossbar assembly through the swivel on the main bar.
HINT
The main bar swivel may be placed above or below the main bar.
NOTICE
Be sure not to let the main bar swivel fall and damage the windshield, or damage the hood when installing the crossbar assembly.
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F. Insert the straddle bar into the crossbar.
G. Adjust the height of the crossbar so it is level and insert the quick release pin through the nearest open slot in the straddle bar.
H. Attach the chain from the engine hooks to the hook # 2 of the Engine Support Bar and place tension on the chain until the Engine Support
Bar self centers.
Ensure the Engine Support Bar is stable when fully assembled and mounted to the vehicle to ensure no damage to vehicle or technician.
14. Remove the front wheels.
15. Remove the front wheel opening extension pad LH.
16. Remove the engine under cover LH.
17. Remove the front wheel opening extension pad RH.
18. Remove the front fender apron seal LH.
19. Remove the front fender apron seal RH.
20. Drain the transmission fluid.
A. Remove the refill plug and gasket.
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B. Using a 6 mm hexagon socket wrench remove the overflow plug and gasket.
C. Using a 6 mm hexagon socket wrench remove the No.1 transmission oil filler tube.
D. Drain the automatic transaxle fluid.
E. Using a 6 mm hexagon socket wrench install the No.1 transmission oil filler tube.
Torque: 1.7 N*m (17 kgf*cm, 15 in*lbf)
F. Using a 6 mm hexagon socket wrench install the overflow plug.
Torque: 40 N*m (408 kgf*cm, 30 ft*lbf)
G. Install the refill plug.
Torque: 49 N*m (500 kgf*cm, 36 ft*lbf)
21. Remove the axle nuts.
A. Using the SST and a hammer release the staked part of the front axle hub nut.
SST: 09930-00010-01
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NOTICE
Loosen the staked part of the nut completely; otherwise the thread of the drive shaft may be damaged.
B. While applying the brakes use the SST to remove the front axle hub nut.
SST: 09017-12301 (or equivalent)
22. Separate the front suspension lower No.1 arms.
Remove the bolt and 2 nuts and separate the front suspension lower No.1 arm from the lower ball joint.
23. Using the SST and a 5 lb. slide hammer remove the front drive shaft assembly LH.
SST: 09520-01010-02
NOTICE
^ Be careful NOT to damage the drive shaft dust cover, boot, or oil seal.
^ Be careful NOT to drop the drive shaft assembly.
24. Remove the front drive shaft assembly RH.
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A. Using a screwdriver remove the bearing bracket hole snap ring.
B. Remove the bolt and front drive shaft assembly RH from the drive shaft bearing bracket.
25. Separate the front stabilizer link assembly by removing the nut.
26. Disconnect the oil cooler hoses.
A. Release the clamp and disconnect the oil cooler inlet hose.
B. Release the clamp and disconnect the oil cooler outlet hose.
27. Disconnect the two 02 sensor connectors from the wiring harness and unhook from the sub-frame wiring bracket.
28. Remove the exhaust front pipe assembly.
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29. Remove the flywheel housing under cover by removing the 2 bolts and exhaust pipe support bracket.
30. Remove the drive plate and 6 torque converter mounting bolts.
Turn the crankshaft to gain access and remove the bolts while holding the crankshaft pulley bolt with a wrench.
31. Remove the engine mounting insulators bolts and nuts from sub-frame assembly.
A. Remove the 5 hole plugs.
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B. Remove the 9 nuts and separate the front frame assembly.
32. Remove the bolts that hold down the power steering line to the sub frame.
33. Remove the bolts that hold the power steering link assembly to the sub frame.
Remove the 2 bolts 2 nuts and the power steering link assembly.
NOTICE
Because the nut has its own stopper, do NOT turn the nut. Loosen the bolt with the nut fixed.
34. Install the SST 00002-2SUPR secondary safety support straps.
SST: 00002-2SUPP
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A. Loop the strap over the frame rail rearward of the radiator support and secure the hook to the strap's floating D-ring.
B. Feed the strap over the sub-frame and under the engine in an "X" pattern.
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C. Connect the strap's hook into the torque box tie-down holes. This allows the sub frame to be removed without the need to remove the
support strap.
D. Ratchet the support strap until it is snugly seated on the engine and transaxle assembly.
NOTE
Make sure that the engine moving control rod is NOT disconnected because the rod is also used as additional safety support.
35. Place a lift under the sub frame.
36. Remove the remaining (12) bolts holding the sub frame to the vehicle.
CAUTION
Before removing the bolts ensure the Engine Support Bar is secure and is supporting the engine weight to ensure no damage to vehicle or
technician.
37. Slowly lower the sub frame.
38. Place a transmission jack under the transmission.
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39. Remove the lower (6) bell housing bolts.
40. Lower the transmission away from the vehicle.
Repair Procedure: Installation
1. Install the torque converter clutch assembly.
A. Engage the splines of the input shaft and turbine runner.
B. Engage the splines of the stator shaft and the stator while turning the torque converter clutch assembly.
If the stator shaft splines are difficult to engage with the stator splines, move the torque converter back approximately 10 mm and engage the
splines while rotating the torque converter.
C. Turn the torque converter clutch assembly to engage the key of the oil pump drive gear into the slot on the torque converter clutch assembly.
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D. Using a vernier caliper and a straightedge measure dimension "A" between the transaxle contact surfaces of the engine and the converter
contact surfaces of the drive plate.
Make sure to deduct the thickness of the straightedge.
E. Using a vernier caliper and a straightedge measure dimension "B" shown in the illustration and check that "B" is greater than "A" which was
measured in the previous step.
Standard: A + 1 mm (0.0394 in.) or more
NOTICE
^ Make sure to deduct the thickness of the straightedge.
^ If the transaxle is installed to the engine with the torque converter not sufficiently inserted, the torque converter may be damaged.
2. Install the oil cooler hoses.
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A. Install the oil cooler inlet hose.
B. Install the oil cooler outlet hose.
3. Install the No. 1 transmission control cable bracket with the 2 bolts.
Torque: 12 N*m (122 kgf*cm, 9 ft*lbf)
4. Install the 4 wire harness clamp brackets and 4 bolts.
Torque: 8.4 N*m (86 kgf*cm, 74 in*lbf)
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5. Install the speedometer driven hole cover sub-assembly.
A. Coat a new 0-ring with ATF and install it to the hole cover.
B. Install the hole cover to the transaxle case with the bolt.
Torque: 5.5 N*m (56 kgf*cm, 49 in*lbf)
6. Install the Transmission Control Module (TCM) to the transaxle and tighten the 2 bolts in the order shown in the illustration.
Torque: 11 N*m (112 kgf*cm, 9 ft*lbf)
7. Install the engine mounting front bracket to the automatic transaxle with the 3 bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft*lbf)
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8. Install the automatic transaxle assembly.
A. Apply clutch spline grease to the contact surface between the crankshaft and torque converter centerpiece.
Clutch spline grease:
Toyota Genuine Clutch Spline Grease, or equivalent
Maximum Amount:
1 g (0.0353 oz.)
B. Keeping the engine and automatic transaxle assembly in a horizontal position align the knock pins with each hole on the automatic transaxle
assembly and tighten the 6 bolts shown in the illustration.
Bolt A:
Torque: 64 N*m (653 kgf*cm, 47 ft*lbf)
Bolt B:
Torqu4e6: N*m (469 kgf*cm, 34 ft*lbf)
Bolt C:
Torque: 43 N*m (439 kgf*cm, 32 ft*lbf)
NOTICE
^ Confirm that the 2 knock pins are on the transaxle contact surface of the engine block before transaxle installation.
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^ Do NOT forcibly pry on the automatic transaxle assembly.
^ Check that the torque converter rotates.
9. Lower transmission jack away from engine and transmission.
10. Install the drive plate and torque converter clutch setting bolt.
A. Apply a few drops of adhesive to 2 threads on the tip of the 6 torque converter clutch mounting bolts.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324, or equivalent
B. Install the 6 torque converter clutch mounting bolts.
Torque: 41 N*m (418 kgf*cm, 30 ft*lbf)
NOTICE
First install the black colored bolt, and then the remaining 5 bolts.
11. Install the flywheel housing under cover and exhaust pipe support bracket to the automatic transaxle with the 2 bolts.
Torque: 7.8 N*m (80 kgf*cm, 69 in*lbf)
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12. Install the engine mounting insulators with the 3 nuts.
Torque: 87 N*m (887 kgf*cm, 64 ft*lbf)
13. Install the 5 hole plugs.
14. Remove the secondary safety support straps.
15. Install the power steering link assembly with the 2 bolts and 2 nuts.
Torque: 70 N*m (714 kgf*cm, 52 ft*lbf)
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16. Install the sub frame using the SST.
SST: 00002-90080
A. Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts.
Nut A:
Torque: 85 N*m (867 kgf*cm, 63 ft*lbf)
Bolt B:
Torque: 32 N*m (329 kgf*cm, 24 ft*lbf)
B. Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.
Nut C:
Torque: 85 N*m (867 kgf*cm, 63 ft*lbf)
Bolt D:
Torque: 32 N*m (329 kgf*cm, 24 ft*lbf)
HINT
SST 00002-90080 will ensure all engine and transmission mount studs have lined up with their corresponding holes.
17. Install the front stabilizer link assembly with the nut.
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Torque: 74 N*m (755 kgf*cm, 55 ft*lbf)
18. Install the power steering line back onto the sub frame.
19. Connect the oil cooler hoses.
A. Install the clamp and connect the oil cooler inlet hose.
B. Install the clamp and connect the oil cooler outlet hose.
20. Install the front exhaust pipe assembly back onto the vehicle.
A. Install 2 new gaskets to the exhaust front pipe.
B. Install the exhaust front pipe to the exhaust manifolds with the 4 nuts.
Torque: 62 N*m (632 kgf*cm, 46 ft*lbf)
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21. Install the front exhaust pipe No. 1 support brackets with the 2 nuts.
Torque: 33 N*m (337 kgf*cm, 24 ft*lbf)
NOTICE
Be sure to install the support brackets in the correct direction.
22. Reconnect the 02 sensors.
23. Install the front drive shaft assembly LH.
A. Coat the spline of the inboard joint shaft assembly with ATF.
B. Align the shaft splines and install the drive shaft assembly LH with a brass bar and hammer.
NOTICE
^ Set the shaft snap ring with the opening side facing down.
^ Be careful NOT to damage the drive shaft dust cover, boot, or oil seal.
^ Move the drive shaft assembly while keeping it level.
24. Install the front drive shaft assembly RH.
A. Coat the spline of the inboard joint shaft assembly with ATF.
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B. Install the front drive shaft assembly RH.
C. Using a screwdriver install a new bearing bracket hole snap ring.
D. Install a new bolt.
Torque: 32 N*m (330 kgf*cm, 24 ft*lbf)
NOTICE
^ Do NOT damage the boot and oil seal.
^ Move the drive shaft assembly while keeping it level.
25. Install the front axle assembly.
Align the matchmarks and install the front drive shaft assembly to the front axle hub sub-assembly.
26. Install the front suspension lower No.1 arm.
Install the lower ball joint to the front suspension lower No.1 arm with the bolt and 2 nuts.
Torque: 75 N*m (765 kgf*cm, 55 ft*lbf)
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27. Install the axle hub nuts.
A. Clean the threaded parts on the drive shaft and axle hub nut using a non-residue solvent.
B. Using the SST and applying the brakes install a new front axle hub nut.
SST: 09017-12301 (or equivalent)
Torque: 294 N*m (3,000 kgf*cm, 217 ft*lbf)
C. Using a chisel and hammer stake the front axle hub nut.
28. Remove the Engine Support Bar.
29. Install the upper bell housing bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft*lbf)
30. Connect the transmission control cable assembly.
Install a new clip and the nut and connect the cable to the transaxle.
Torque: 13 N*m (130 kgf*cm, 9 ft*lbf)
31. Install the starter assembly.
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A. Install the starter assembly with the 2 bolts.
Torque: 37 N*m (380 kgf*cm, 28 ft*lbf)
B. Connect the wire harness to terminal 30 and install the nut. Then attach the terminal cap.
Torque: 9.8 N*m (100 kgf*cm, 87 in*lbf)
C. Connect the terminal 50 connector to the starter assembly.
32. Clip in wiring harness to transmission.
A. Connect the park/neutral position switch connector.
B. Connect the wire harness with the bolt.
Torque: 12 N*m (122 kgf*cm, 9 ft*lbf)
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C. Install the 2 bolts and 2 clamps to the body.
Bolt A:
Torque: 12 N*m (123 kgf*cm, 9 ft*lbf)
Bolt B:
Torque: 8.4 N*m (85 kgf*cm, 74 in*lbf)
33. Install the transaxle breather tube.
A. Install the breather bracket to the camshaft housing sub-assembly LH with the bolt.
Torque: 5.5 N*m (56 kgf*cm, 49 in*lbf)
B. Install the breather hose to the breather bracket.
34. Install the intake case and tube assembly.
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A. Install the air cleaner case with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf)
B. Install the No.1 air cleaner inlet with the bolt.
Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf)
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C. Install the air cleaner inlet with the clamp and 2 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf)
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D. Connect the mass air flow meter connector No. 2 ventilation hose and hose band.
35. Install the plastic covers inside of each fender well.
36. Fill transmission to correct level with transaxle fluid using SST 00002-11100-02.
SST: 00002-11100-02
37. Install the wheels onto the vehicle.
Torque: 103 N*m (1,050 kgf*cm, 76 ft*lbf)
38. Fit the 3 retainers and install the V-bank cover sub-assembly.
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39. Install the battery.
A. Install the battery and battery tray.
B. Install the battery clamp with the bolt and nut.
Bolt:
Torque: 9.0 N*m (92 kgf*cm, 80 in*lbf)
Nut:
Torque: 3.5 N*m (36 kgf*cm, 31 in*lbf)
40. Install the engine room side covers.
A. Install the engine room side cover LH with the 6 clips.
B. Install the hood hinge cover LH.
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C. Install the engine room side cover RH with the 5 clips.
D. Install the hood hinge cover RH.
41. Install the cool air intake duct seal with the 7 clips.
42. Check for exhaust leaks.
43. Check for fluid leaks.
44. Check shift lever position and operation.
45. Install the engine under covers.
46. Re-initialize auto-power windows and moon roof (if equipped).
47. Test drive vehicle insuring proper operation.
48. Adjust wheel alignment as needed.
