Technical Service Information

Toyota/Lexus U140/U240
Transmission Application by Vehicle

MAKE MODEL YEAR ENGINE TRANSMISSION

LEXUS ES 300 1999 - 2001 V6 3.0L U140E

LEXUS RX 300 1998 - 2003 V6 3.0L U140E

LEXUS RX 300 1998 - 2003 V6 3.0L 4X4 U140F

TOYOTA CAMRY 2002 - 2004 L4 2.0L U240E

TOYOTA CAMRY 2002 - 2003 V6 3.0L U140E

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TOYOTA CELICA GTS 2000 - 2005 L4 1.8L U240E

TOYOTA HIGHLANDER 2001 - 2003 L4 2.4L - V6 3.0L U140F

4X4

TOYOTA HIGHLANDER 2001 - 2003 V6 3.0L U140E

TOYOTA HIGHLANDER 2004 - 2007 L4 2.4L U240E

TOYOTA HIGHLANDER 2004 - 2007 L4 2.4L - V6 3.0L U140F

4X4

TOYOTA MATRIX 2003 - 2006 L4 1.8L U240E

TOYOTA RAV4 2000 - 2007 L4 2.0L/2.4L 4X4 U140F

TOYOTA RAV4 2000 - 2007 L4 2.0L/2.4L U241E

TOYOTA SCION tc 2004 - 2007 L4 2.4L U241E

TOYOTA SOLARA 2002 - 2005 L4 2.4L U241E

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Figure 1
3
 Technical Service Information

IDENTIFICATION CODE STAMPING LOCATION

Identification code is cast into the case

over the Underdrive Section.

U241
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Figure 2
4 AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
TOYOTA U240
NT AND NC SENSOR CHECK

(NT) (NC)
TURBINE COUNTER GEAR
SPEED SENSOR SPEED SENSOR
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2 1 2 1

NT NC
Turbine Speed Counter Gear Speed
Sensor Sensor
(sensor connector view) (sensor connector view)

Connect ohm meter between the terminals 1&2 on each sensor, the value should be 620 +/- 60 Ω
NT &NC Partial wire Schematic
RED 14
NC+
GREEN 26
NC-
BLACK 15
NT-
WHITE 16
NT+

ENGINE CONTROL
1 GREEN

1 BLACK

2 WHITE

MODULE (ECM)
2 RED

(BEHIND RIGHT
SIDE OF DASH)

COUNTER TURBINE
GEAR SPEED SPEED
SENSOR SENSOR
Copyright © 2009 ATSG
Figure 10
12 AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

TRANSAXLE DISASSEMBLY (CONT’D)

14.Remove the C1, C3 and B3 accumulator pistons 16.Remove the anti-drain back check valve as
and springs as shown in Figure 20. shown in Figure 21.
Note: Spring colors and dimensions have been 17.Remove the B1 and B2 valvebody to case seals
provided in Figure 20, however, there may be as shown in Figure 21.
variations from model to model.. 18.Remove the B1 tube seal as shown in Figure 21.
15.Remove and discard the accumulator piston 19.Discard the B1 and B2 valvebody to case seals,
o-rings. and the B1 tube seal.

C1 C3 B3
Continued on Page 21
ACCUMULATOR ACCUMULATOR ACCUMULATOR
LINE UP LINE UP LINE UP

O-RING
O-RING

VALVEBODY TO B1 BRAKE VALVEBODY TO

CASE SEAL B1 TUBE SEAL CASE SEAL B2
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O-RING

O-RING

ACCUMULATOR OUTSIDE FREE ID

SPRING DIAMETER LENGTH COLOR
C1 18.5 mm (.728 in.) 90.53 mm (3.564 in.) RED

C3 19.2 mm (.756 in.) 86.66 mm (3.411 in.) WHITE

ANTI-DRAIN BACK
B3 INNER 15.9 mm (.626 in.) 60.24 mm (2.371 in.) GREEN CHECK VALVE
B3 OUTER 16.7 mm (.657 in.) 72.61 mm (2.858 in.) BLUE

Copyright © 2009 ATSG Copyright © 2009 ATSG

Figure 20 Figure 21
20 AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
TRANSAXLE DISASSEMBLY (CONT’D)
92.Using a hammer and suitable chisel, carefully
un-stake the folded tabs on the locking washer as SST (SPECIAL SERVICE TOOL)
shown in Figure 54. 09950-60010 (09951-00450)
OR SUITABLE
93.Using SST 09387-00030, 09387-00080 or a BUSHING DRIVER
suitable drift punch, loosen the retaining nut by
turning counter-clockwise as shown in Figure 54.
94.Remove the retaining nut and the retaining nut
lock washer as shown in Figure 54.
95.Place transaxle housing in a suitable press, then
using SST 09950-60010 (09951-00450) or a
suitable bushing driver, carefully press the front
planetary assembly through the counter drive
gear as shown in Figure 55.
96.Once the front planetary assembly splines are
pressed down and through the counter drive gear,
remove the counter drive gear by lifting straight
up as shown in Figure 56.
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Continued on Page 33. Copyright © 2009 ATSG

Figure 55

LOOSEN
COUNTER
CLOCKWISE

COUNTER DRIVE
GEAR
LOCKING TAB

RETAINING NUT

RETAINING NUT
LOCK WASHER

Copyright © 2009 ATSG Copyright © 2009 ATSG

Figure 54 Figure 56
32 AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
COMPONENT REBUILD (CONT’D)
Torque Converter Housing.

15. Using a plastic hammer, with even taps,

carefully install the torque converter housing
axle seal into the case as shown in Figure 66.
16. Coat inside of axle seal with a small amount of
Trans-Jel®.
17. Set aside the completed torque converter
housing shown in Figure 67 for final assembly.
Continued on Page 39.
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COMPLETED TORQUE CONVERTER

HOUSING ASSEMBLY
TORQUE CONVERTER
HOUSING
AXLE SEAL

Copyright © 2009 ATSG Copyright © 2009 ATSG

Figure 66 Figure 67
38 AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
COMPONENT REBUILD (CONT’D) 1. Remove the front and rear differential tapered
Differential Assembly roller bearings using SST 09950-04011 (09951-
04010, 09952-04010, 09953-04030, 09954-
04010, 09955-04061, 09957-04010, 09958-
04011), 09950-60010 (09951-00440). Refer to
FRONT TAPERED
ROLLER BEARING
Figure 81 for disassembly diagram.
2. Use a dial indicator and measure the backlash
between the side gears and pinion gears as
shown in Figure 82. (Backlash is referred to as
the amount of free-play between the gears).
3. If backlash is not within specification, remove
the cross shaft retaining pin and dissassemble
the differential carrier assembly using the
diagram in Figure 80 as a reference, and refer to
thrust washer thickness chart in Figure 82 and
select an appropriate washer to bring backlash
into proper tolerance. Adjust until backlash is
equal at both side gears.
Note: If removing ring gear from carrier, both
carrier and ring gear bolt holes must be
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marked and matched for proper alignment

during reassembly.

Component Rebuild Continued on Page 47.

THRUST WASHER THICKNESS: mm. (in.)
0.95 (0.0373) 1.00 (0.0393)
1.05 (0.0413) 1.10 (0.0433)
REAR TAPERED 1.15 (0.0453) 1.20 (0.0472)
ROLLER BEARING

NOMINAL SIDE GEAR BACKLASH

0.05 - 0.20 mm (0.002 - 0.0008 in.)

0
10 10
20 20

30 30

40 40
50 0 50

Copyright © 2009 ATSG Copyright © 2009 ATSG

Figure 81 Figure 82
46 AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
COMPONENT REBUILD (CONT’D)
Forward (C1) Clutch Drum Assembly 9. Install the forward (C1) clutch plates beginning
with a steel plate, then alternating frictions and
steels until there are four steel and four lined
plates installed into the drum housing as shown
RETAINING in Figure 102.
SNAP RING
Note: All Friction Plates should be soaked in
the appropriate ATF for the vehicle for 30
minutes prior to installation.
10. Install the forward (C1) clutch backing plate into
FORWARD (C1)
the drum housing as shown in Figure 102.
CLUTCH 11. Install the retaining snap ring into the drum
BACKING housing as shown in Figure 102.
PLATE
Check the forward (C1) clutch clearance using a
feeler gauge between the backing plate and snap
ring as shown in Figure 103.
FORWARD (C1) 12. Note: Forward (C1) clutch clearance should be
CLUTCH between 0.61mm - 1.041mm (.024” - .041”)
LINED PLATE
(4 REQUIRED) 13. Change the “Selective” backing plate as
necessary to attain proper clutch clearance using
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the chart in Figure 103.

Component Rebuild Continued on Page 58.

SELECTIVE BACKING PLATES
AVAILABLE FROM DEALER.
ORDER BY THICKNESS.

FORWARD (C1)
CLUTCH
STEEL PLATE
(4 REQUIRED)

FORWARD (C1)
CLUTCH
DRUM ASSEMBLY

Forward (C1)Clutch Clearance Should Be

0.61mm - 1.041mm (.024" - .041”)
Selective Forward Clutch Backing Plates
3.0mm (.118”) 3.45mm (.135”)
3.15mm (.124”) 3.6mm (.141”)
Copyright © 2009 ATSG 3.3mm (.130”) Copyright © 2009 ATSG
Figure 102 Figure 103
AUTOMATIC TRANSMISSION SERVICE GROUP 57
 Technical Service Information
COMPONENT REBUILD (CONT’D) NO. 1 ONE-WAY
CLUTCH (F1)
No. 1 One-Way Clutch (F1) Assembly ASSEMBLY

1. Disassemble the No. 1 one-way clutch (F1)

assembly using the diagram in Figure 115 as a
guide.
2. Clean all No. 1 one-way clutch (F1) assembly
parts thoroughly with solvent and dry with NO. 1 ONE-WAY
compressed air. LIP FACING CLUTCH (F1)
UP OUTER RACE
3. Inspect all No. 1 one-way clutch (F1) assembly
parts for wear and/or damage and replace as
necessary.
4. Install the retaining plate (lower) to the No. 1
one-way clutch (F1) outer race and snap into
place as shown in Figure 117.
5. Install the end bearing (lower) into the No. 1
one-way clutch (F1) outer race as shown in
Figure 117.

Component Rebuild Continued on Page 67. ID GROOVE

FACING UP
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Copyright © 2009 ATSG

NO. 1 ONE-WAY Figure 118
CLUTCH (F1)
END BEARING
(LOWER) NO. 1 ONE-WAY
CLUTCH (F1)
RETAINING PLATE
(UPPER)

NO. 1 ONE-WAY
CLUTCH (F1)
OUTER RACE

NO. 1 ONE-WAY
CLUTCH (F1)
END BEARING
(UPPER)

NO. 1 ONE-WAY
CLUTCH (F1)
RETAINING PLATE
(LOWER)

Copyright © 2009 ATSG Copyright © 2009 ATSG

Figure 117 Figure 119
66 AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
COMPONENT REBUILD SECTION
VALVE BODY ASSEMBLY (CONT’D)
25. Disassemble upper valve body and place valves, 27. Assemble the upper valve body parts as shown
springs and retainers in appropriate trays exactly in Figure 131, and lube the valves with a small
as they were removed as shown in Figure 131. amount of ATF as they are installed.
26. Clean all valve body parts thoroughly with Note: Items 49 and 32 are commonly worn
solvent and dry with compressed air. Inspect the and may require replacement. Also note there
accumulator bores on top of the upper valve are different lengths on some of the retainers
body for any wear and replace the valve body as listed below in Figure 131.
necessary.
Valve body assembly continued on Page 75.

60
61
62
48
49 53 57
UPPER VALVE BODY
50 54 58 63
51 55 59
44 56
52
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45
46
47
40

41
42
43
39
35
36
38
Retainer Lengths 34
33
8 mm 10 mm 30
21 36 31 37
60 31 29 32
53 23 26 27
44 27
23
40 25
28
Accumulator 24
bores UPPER VALVEBODY LEGEND
23. C2 Lock Valve retainer 44. C2 Exhaust Valve retainer
24. C2 Lock Valve bore plug 45. C2 Exhaust Valve bore plug
25. C2 Lock Valve 46. C2 Exhaust Valve Spring
26. C2 Lock Valve Spring 47. C2 Exhaust Valve
27. Secondary Regulator Valve retainer 48. Clutch Apply Control Valve retainer
28. Secondary Regulator Valve bore plug 49. Clutch Apply Control Valve Sleeve
29. Secondary Regulator Valve 50. Clutch Apply Control Valve plunger
30. Secondary Spring 51. Clutch Apply Control Valve Spring
31. Lock-up Control Valve retainer 52. Clutch Apply Control Valve
32. Lock-up Control Valve Sleeve 53. B-1 Lock Valve retainer
33. Lock-up Control Valve Spring 54. B-1 Lock Valve bore plug
34. Lock-up Control Valve Plunger 55. B-1 Lock Valve Spring
35. Lock-up Control Valve 56. B-1 Lock Valve
36. Lock-up Relay Valve retainer 57. B-3 Orifice Control Valve retainer
37. Lock-up Relay Valve bore plug 58. B-3 Orifice Control Valve Spring
38. Lock-up Relay Valve Spring 59. B-3 Orifice Control Valve
39. Lock-up Relay Valve 60. Solenoid Modulator Valve retainer
40. 3 Way Check Valve Retainer 61. Solenoid Modulator Valve bore plug
41. 3 Way Check Valve outer ball seat 62. Solenoid Modulator Valve
42. 3 Way Check Valve .250" steel ball 63. Solenoid Modulator Spring
43. 3 Way Check Valve inner ball seat
Copyright © 2009 ATSG
Figure 131
74 AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
COMPONENT REBUILD SECTION
VALVE BODY ASSEMBLY (CONT’D)
49. Install the seven 10 mm bolts identified with the 52. Install relief ball into the valve body then install
letter "C," and torque to 11Nm, 8ft.lb. See the spring, retainer and bolt identified with the
Figure 142. letter "B" and torque to 6.6 Nm, 8ft.lb. as shown
50. Install the S4, SL2 and DSL solenoids into their in Figure 142.
bores, and install the bolts identified with the Note: Ball diameter is 10mm.
letter"A," and torque to 11Nm, 8ft.lb. as shown 53. Install the Manual valve as shown in Figure 142.
in Figure 142.
51. Install the SL1 and SLT solenoids into their
bores, and the two, 8 mm bolts identified with Continued on Page 82.
. the letter "B," and torque to 6.6 Nm, 58 in.lb. as
shown in Figure 142.

SOLENOID AND VALVE BODY

BOLT INSTALLATION IDENTIFICATION
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MANUAL VALVE
SHIFT SOLENOID VALVE S4
“SOLENOID D”
A C
C
SHIFT SOLENOID VALVE SL2
“SOLENOID B”

C
A

A C
SHIFT SOLENOID VALVE
DSL “LOCKUP SOLENOID”
B
C
RELIEF SPRING
AND BALL
RETAINER B

SHIFT SOLENOID VALVE SL1 SOLENOID VALVE SLT

“SHIFT SOLENOID A” “LINE PRESSURE SOLENOID”

Relief Spring
and ball removed
Bolt Lengths and Torque Specs
Bolt A = 45mm. (1.770 in.) Torque- 11 Nm, 8ft.lb
Bolt B = 12mm. (.450 in.)Torque- 6.6 Nm, 58in.lb
Bolt C = 41mm. (1.614 in.) Torque- 11 Nm, 8ft.lb
Copyright © 2009 ATSG
Figure 142
AUTOMATIC TRANSMISSION SERVICE GROUP 81
 Technical Service Information
FINAL ASSEMBLY
Internal components

32. Coat the rear planetary thrust washer with a

small amount of Trans-Jel® and install into the
locating holes in the rear planetary as shown in
Figure 161.
33. Install the No. 1 one way clutch (F1) outer
REAR PLANETARY sleeve so that the narrow lugs fit into the
THRUST WASHER
locating slots in the 2nd brake (B1) piston
housing assembly as shown in Figure 162.
34. Install the No. 1 one way clutch (F1) assembly
so it fits into the lugs in the outer shell as shown
in Figure 163.
35. Make sure the id groove on the one way clutch
assembly is facing up (toward the back cover)
when installed as shown in Figure 163.

Final Assembly Continued on Page 89.

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Copyright © 2009 ATSG

Figure 161

WIDE
LUGS

NO. 1 ONE WAY

CLUTCH (F1)
NO 1 ONE WAY
OUTER SLEEVE
CLUTCH (F1)

ID GROOVE
NARROW FACES UPWARD
LUGS

Copyright © 2009 ATSG Copyright © 2009 ATSG

Figure 162 Figure 163
88 AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
FINAL ASSEMBLY
Internal components

67. Using a plastic hammer, with even taps,

carefully install the torque converter housing DIFFERENTIAL TAPERED
ROLLER BEARING RACE
axle seal into the case as shown in Figure 178.
68. Coat inside of axle seal with a small amount of
Trans-Jel®.
69. Flip the transaxle housing over then coat the
differential tapered roller bearings with a small
amount of ATF and place the differential carrier
into the case as shown in Figure 179.
70. Install the sixteen differential housing to
transaxle case attaching bolts and torque them as
shown in Figure 180.

Final Assembly Continued on Page 95.

Copyright © 2009 ATSG

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Figure 179

A B

TRANSAXLE CASE
AXLE SEAL

A
C

BOLT LENGTH TORQUE

BOLT A: (7 REQUIRED) 42 mm (1.654 in.) 29 N m (22 ft. lb.)
BOLT B: (4 REQUIRED) 50 mm (1.969 in.) 29 N m (22 ft. lb.)
BOLT C: (5 REQUIRED) 50 mm (1.969 in.) 22 N m (16 ft. lb.)
Copyright © 2009 ATSG Copyright © 2009 ATSG
Figure 178 Figure 180
94 AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
FINAL ASSEMBLY
Internal components

115. Coat the forward (C1) clutch hub thrust bearing

race with a small amount of Trans-Jel® and
install the race onto the transfer drive gear as
FORWARD (C1) CLUTCH HUB shown Figure 207.
THRUST BEARING
RACE 116. Coat the forward (C1) clutch hub thrust bearing
with a small amount of Trans-Jel® and install
the thrust bearing onto the splined side of the
forward clutch hub as shown in Figure 208.
117. Install the forward (C1) clutch hub into the
transmission while turning to engage the splines
as shown in Figure 208.
118. Coat the forward (C1) clutch thrust bearing with
a small amount of Trans-Jel® and install into the
forward clutch hub with the lip facing down into
the hub as shown in Figure 208.
119. Install the forward (C1) clutch drum assembly
with a twisting motion so the lined plates spline
with the hub as shown in Figure 209.
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Final Assembly Continued on Page 104.

Copyright © 2009 ATSG
Figure 207

FORWARD (C1) CLUTCH

FORWARD (C1) CLUTCH DRUM ASSEMBLY
THRUST BEARING

FORWARD (C1)
CLUTCH
HUB

FORWARD (C1) CLUTCH

HUB THRUST BEARING
SPLINED
SIDE

Copyright © 2009 ATSG Copyright © 2009 ATSG

Figure 208 Figure 209
AUTOMATIC TRANSMISSION SERVICE GROUP 103
 Technical Service Information

CASE PASSAGE I.D.

AIR TEST PORTS

Torque Converter
Apply
x
C3 Apply
Pinion Shaft
lube
B2 Apply
B3 Apply B1 Apply
x
Pump
Suction
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C2 Apply
Pump
Output
Central
lube
Rear Lube (not all models)
x Torque Converter
Off
x
x C1 Apply

From Cooler
(to sump) To Cooler C1 Accumulator
B3 Accumulator
C3
Accumulator Accumulator
Back Pressure

Copyright © 2009 ATSG

Figure 229
114 AUTOMATIC TRANSMISSION SERVICE GROUP