Lexus IS250 · Service Manual TRANSMISSION

DISASSEMBLY

Removal / installation

CAUTION:
When working with FIPG material, perform the following:
  1. Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
  1. Thoroughly clean all components to remove any loose material.
  1. Clean both sealing surfaces with a non-residue solvent.
  1. Apply FIPG in a continuous line (width approximately 1 mm (0.04 in.)) along the sealing surface.
  1. Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied.


1. REMOVE TRANSMISSION CASE COVER

  1. C106915
    Remove the 2 bolts and the transmission case cover.


2. REMOVE TRANSMISSION CONTROL SHAFT LEVER RH

  1. C128080
    Remove the nut, spring washer and the transmission control shaft lever RH.


3. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

  1. C106914
    Using a screwdriver, unstake the lock washer.

  1. Remove the nut and lock washer.

  1. Remove the bolt and park/neutral position switch.


4. REMOVE TRANSMISSION OIL COOLER

  1. C106919
    Remove the 3 bolts and transmission oil cooler.

  1. C120827E01
    Remove the 2 O-rings from the transmission oil cooler.


5. REMOVE TRANSMISSION REVOLUTION SENSOR

  1. C108619
    Remove the 2 bolts and the 2 transmission revolution sensors.

  1. Remove the O-ring from each sensor.


6. REMOVE AUTOMATIC TRANSMISSION BREATHER TUBE

  1. C109351
    Remove the 2 bolts.

  1. Remove the breather tube.


7. REMOVE AUTOMATIC TRANSMISSION HOUSING

  1. C106907
    Remove the 10 bolts.

  1. Remove the transmission housing.


8. REMOVE EXTENSION HOUSING DUST DEFLECTOR

  1. C122826
    Using a brass bar and a hammer, remove the extension housing dust deflector.

    NOTICE:
    Be careful not to damage the extension housing.


9. REMOVE EXTENSION (ATM) HOUSING SUB-ASSEMBLY

  1. C106925
    Remove the 6 bolts.

  1. C106924
    Using a screwdriver, remove the extension housing sub-assembly.

  1. C106927
    Using a snap ring pliers, remove the snap ring from the extension housing sub-assembly.

  1. Remove the transmission case adaptor radial ball bearing.

  1. C106923
    Using a snap ring expander, remove the snap ring.

  1. Remove the thrust needle roller bearing and the 2 thrust bearing races.


10. REMOVE AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL

  1. C106926
    Using a screwdriver, remove the oil seal.


11. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY

  1. D031356
    Install the transmission case on the overhaul attachment.


12. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

NOTICE:
Do not turn the transmission over as this will contaminate the valve body with foreign matter located at the bottom of the pan.

  1. Remove the overflow plug and the gasket.

  1. Remove the drain plug and the gasket.

  1. C109360
    Remove the 20 bolts, oil pan and gasket.

  1. AT00103
    Examine particles in the pan.

    1. Remove the magnets from the oil pan and use them to collect any steel chips. Look carefully for the chips and particles in the pan and on the magnet to anticipate the type of wear which might be found in the transaxle.
      Steel (magnetic): bearing, gear, and plate wear
      Brass (non-magnetic): bearing wear


13. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

  1. C106929
    Turn over the transmission.

  1. Remove the 4 bolts and valve body oil strainer assembly from the valve body.

  1. C108414E02
    Remove the O-ring from the valve body oil strainer assembly.


14. REMOVE TRANSMISSION WIRE

  1. C122839
    Remove the bolt and temperature sensor clamp, and separate the ATF temperature sensor.

  1. C122841
    Remove the 2 bolts and disconnect the 2 clamps.

  1. C122840
    Disconnect the 9 connectors from the solenoid valves.

  1. D027912
    Pull the transmission wire out of the transmission case.

  1. C101505E03
    Remove the O-ring from the transmission wire.


15. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

  1. C106931
    Remove the bolt, detente spring cover and detente spring.

  1. C106932
    Remove the 19 bolts.

  1. Remove the valve body assembly.


16. REMOVE TRANSAXLE CASE GASKET

  1. D027968
    Remove the 3 transaxle case gaskets.


17. REMOVE BRAKE DRUM GASKET

  1. D027969
    Remove the 3 brake drum gaskets.


18. REMOVE CHECK BALL BODY

  1. D027914E02
    Remove the check ball body and the spring.


19. REMOVE C-2 ACCUMULATOR PISTON

  1. D027915
    While blowing compressed air into the oil hole, remove the C-2 accumulator piston and the spring.

  1. Remove the 2 O-rings from the piston.

    NOTICE:
    Take care as the C-3 and B-3 accumulator pistons may jump out.


20. REMOVE B-3 ACCUMULATOR PISTON

  1. Applying compressed air to the oil hole, remove the B-3 accumulator piston and the spring.

  1. Remove the 2 O-rings from the piston.

    NOTICE:
    Take care as the C-3 accumulator piston may jump out.


21. REMOVE C-3 ACCUMULATOR PISTON

  1. D027916
    While blowing compressed air into the oil hole, remove the C-3 accumulator piston and the 2 springs.

  1. Remove the 2 O-rings from the piston.


22. REMOVE B-1 ACCUMULATOR VALVE

  1. C122853
    Remove the B-1 accumulator valve and the spring.


23. REMOVE PARKING LOCK PAWL BRACKET

  1. D031361
    Remove the 3 bolts and the parking lock pawl bracket.


24. REMOVE PARKING LOCK ROD SUB-ASSEMBLY

  1. D031551
    Disconnect the parking lock rod from the manual valve lever.


25. REMOVE PARKING LOCK PAWL SHAFT

  1. C122830E03
    Pull out the parking lock pawl shaft from the front side, then remove the lock pawl and the spring.

  1. Remove the E-ring from the shaft.


26. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY

  1. D031553
    Using a hammer and a screwdriver, cut off the spacer and remove it from the shaft.

  1. C106933
    Using a pin punch and a hammer, drive out the spring pin.

    HINT:
    Slowly drive out the spring pin so that it does not fall into the transmission case.

  1. Pull the manual valve lever shaft out through the case and remove the manual valve lever.


27. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

  1. D031362
    Using a screwdriver, remove the 2 oil seals.


28. REMOVE OIL PUMP ASSEMBLY

  1. C106934
    Remove the 9 bolts from the transmission case.

  1. C106935E03
    Using a screwdriver with its tip wrapped with tape, pull out the oil pump.

    NOTICE:
    Do not damage the oil pump.

  1. C122832E01
    Remove the No. 1 thrust bearing race from the oil pump.

  1. Remove the O-ring from the oil pump.


29. REMOVE CLUTCH DRUM AND INPUT SHAFT

  1. D027923
    Remove the clutch drum and input shaft from the transmission case.

  1. C109327E04
    Remove the clutch drum thrust washer, 2 thrust needle roller bearings and bearing race.


30. INSPECT NO. 2 ONE WAY CLUTCH ASSEMBLY

  1. D027993E02
    Hold the reverse clutch hub and turn the No. 2 one way clutch assembly.

  1. Check that the No. 2 one way clutch assembly turns freely clockwise and locks counterclockwise.
    If there is a problem with the one way clutch, replace the one way clutch.


31. REMOVE NO. 2 ONE WAY CLUTCH ASSEMBLY

  1. D027994
    Remove the No. 2 one way clutch assembly and clutch drum thrust washer from the clutch drum and input shaft.


32. REMOVE NO. 3 BRAKE SNAP RING

  1. D027925
    Using a screwdriver, remove the No. 3 brake snap ring from the transmission case.


33. REMOVE 2ND BRAKE DISC SET

  1. C122833
    Remove the flange, 3 discs and 3 plates from the transmission case.


34. INSPECT 2ND BRAKE DISC SET

  1. D001216
    Check whether the sliding surfaces of the discs, the plates, or the flange are worn or burnt.
    If necessary, replace them.

    NOTICE:
    1. If the linings of the discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all discs.
    2. Before assembling new discs, soak them in ATF for at least 15 minutes.


35. REMOVE 2ND BRAKE PISTON HOLE SNAP RING

  1. D027927E07
    Using SST, remove the snap ring.
    SST
    09350-30020   (09350-07060)


36. REMOVE ONE WAY CLUTCH ASSEMBLY

  1. D027928
    Remove the one way clutch assembly and the No. 1 planetary carrier thrust washer from the transmission case.


37. REMOVE 2ND BRAKE CYLINDER

  1. C108608
    Remove the 2nd brake cylinder from the transmission case.


38. REMOVE FRONT PLANETARY GEAR ASSEMBLY

  1. D027930
    Remove the front planetary gear assembly and the one way clutch inner race from the transmission case.

  1. D027931
    Remove the thrust needle roller bearing, the No. 3 thrust bearing race and the No. 2 planetary carrier thrust washer from the transmission case.


39. INSPECT FRONT PLANETARY GEAR ASSEMBLY

  1. D028544
    Using a feeler gauge, measure the front planetary pinion gear thrust clearance.

    Standard clearance:
    0.20 to 0.60 mm (0.008 to 0.024 in.)

    If the clearance is greater than the standard clearance, replace the front planetary gear assembly.

  1. D028543
    Using a dial indicator, measure the inside diameter of the front planetary gear bushing.

    Standard inside diameter:
    48.78 mm (1.9205 in.)

    If the inside diameter is greater than the standard inside diameter, replace the front planetary gear assembly.


40. INSPECT ONE WAY CLUTCH ASSEMBLY

  1. D028542E02
    Install the one way clutch assembly to the one way clutch inner race.

  1. Hold the one way clutch inner race and turn the one way clutch assembly.

  1. Check that the one way clutch assembly turns freely counterclockwise and locks clockwise.
    If there is a problem with the one way clutch, replace the one way clutch.

  1. Remove the one way clutch assembly from the one way clutch inner race.


41. REMOVE FRONT PLANETARY RING GEAR

  1. C108586
    Remove the front planetary ring gear from the transmission case.


42. REMOVE CENTER PLANETARY RING GEAR

  1. C108587
    Using a screwdriver, remove the snap ring.

  1. Remove the center planetary ring gear from the front planetary ring gear.

  1. C108585
    Using a screwdriver, remove the snap ring.

  1. Remove the center planetary ring gear flange from the center planetary ring gear.

  1. Remove the thrust needle roller bearing from the front planetary ring gear flange.


43. REMOVE NO. 1 BRAKE DISC

  1. D027933
    Remove the flange, the 3 discs and the 3 plates from the transmission case.


44. INSPECT NO. 1 BRAKE DISC

  1. D001216
    Check whether the sliding surfaces of the discs, the plates, or the flange are worn or burnt.
    If necessary, replace them.

    NOTICE:
    1. If the linings of the discs are peeled off or discolored, or if any part of the groove is damaged, replace all discs.
    2. Before assembling new discs, soak them in ATF for at least 15 minutes.


45. REMOVE BRAKE PISTON RETURN SPRING SNAP RING

  1. D027934
    Using a screwdriver, remove the brake piston return spring snap ring from the transmission case.


46. REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

  1. D027935
    Remove the brake piston return spring, the No. 1 brake piston and the No. 1 brake cylinder from the transmission case.


47. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

  1. D003830
    Using vernier calipers, measure the free length of the spring together with the spring seat.

    Standard free length:
    17.05 mm (0.671 in.)

    If the free length is shorter than the standard free length, replace the brake piston return spring sub-assembly.


48. REMOVE NO. 1 BRAKE PISTON

  1. D027936
    Hold the No. 1 brake cylinder and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to the No. 1 brake cylinder to remove the No. 1 brake piston.

    HINT:
    If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

  1. Remove the 2 O-rings from the No. 1 brake piston.


49. REMOVE NO. 2 BRAKE DISC

  1. D027937
    Using a screwdriver, remove the snap ring from the transmission case.

  1. D031547
    Remove the 2 flanges, the brake piston return spring, the 4 discs and the 3 plates from the transmission case.


50. INSPECT NO. 2 BRAKE DISC

  1. D001216
    Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.
    If necessary, replace them.

    NOTICE:
    1. If the linings of the discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all discs.
    2. Before assembling new discs, soak them in ATF for at least 15 minutes.


51. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

  1. D029829
    Using vernier calipers, measure the free length of the spring together with the spring seat.

    Standard free length:
    22.66 mm (0.8921 in.)

    If the free length is shorter than the standard free length, replace the No. 2 brake piston return spring sub-assembly.


52. REMOVE NO. 2 BRAKE PISTON

  1. D027939
    Hold the No. 2 brake piston and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to the transmission case to remove the No. 2 brake piston and the No. 2 brake cylinder.

    HINT:
    If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

  1. Remove the piston from the cylinder.

  1. Remove the 2 O-rings from the No. 2 brake piston.


53. REMOVE CENTER PLANETARY GEAR ASSEMBLY

  1. C109345
    Remove the center planetary gear assembly, the planetary sun gear and the No. 4 thrust bearing race from the transmission case.


54. INSPECT CENTER PLANETARY GEAR ASSEMBLY

  1. D028533
    Using a feeler gauge, measure the center planetary gear pinion thrust clearance.

    Standard clearance:
    0.12 to 0.68 mm (0.005 to 0.027 in.)

    If the clearance is greater than the standard clearance, replace the center planetary gear assembly.


55. REMOVE INTERMEDIATE SHAFT

  1. D031365E03
    Using SST, remove the snap ring from the transmission case.
    SST
    09350-30020   (09350-07060)

  1. D027942
    Remove the intermediate shaft with the No. 3 one way clutch assembly from the transmission case.


56. INSPECT NO. 3 ONE WAY CLUTCH ASSEMBLY

  1. D028532E02
    Hold the rear planetary ring gear flange sub-assembly and turn the one way clutch assembly.

  1. Check that the one way clutch assembly turns freely counterclockwise and locks clockwise.
    If there is a problem with the one way clutch, replace the one way clutch.


57. REMOVE NO. 3 ONE WAY CLUTCH ASSEMBLY

  1. D027964
    Remove the No. 3 one way clutch assembly and the one way clutch inner race from the intermediate shaft.


58. REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

  1. C108607E03
    Remove the No. 8 thrust bearing race, the thrust needle roller bearing, the No. 7 thrust bearing race and the planetary ring gear flange from the intermediate shaft.


59. INSPECT INTERMEDIATE SHAFT

  1. D028529E02
    Using a dial indicator, check the intermediate shaft runout.

    Standard runout:
    A:
    0.03 mm (0.0012 in.)
    B:
    0.03 mm (0.0012 in.)
    C:
    0.03 mm (0.0012 in.)
    D:
    0.03 mm (0.0012 in.)

    If the runout exceeds the specification, replace the intermediate shaft with a new one.

  1. D028530E02
    Using a micrometer, check the outer diameter of the intermediate shaft at each point shown in the illustration.

    Standard diameter:
    A:
    22.962 to 22.975 mm (0.904 to 0.905 in.)
    B:
    22.962 to 22.975 mm (0.904 to 0.905 in.)
    C:
    27.759 to 27.775 mm (1.0929 to 1.0935 in.)
    D:
    27.759 to 27.775 mm (1.0929 to 1.0935 in.)

    If the outer diameter is outside the standard range, replace the intermediate shaft with a new one.


60. REMOVE BRAKE PLATE STOPPER SPRING

  1. D027943
    Remove the brake plate stopper spring from the transmission case.


61. REMOVE NO. 4 BRAKE DISC

  1. C108590
    Remove the 4 plates, 5 discs and 2 flanges from the transmission case.


62. INSPECT NO. 4 BRAKE DISC

  1. D001216
    Check whether the sliding surfaces of the discs, the plates, and the flanges are worn or burnt.
    If necessary, replace them.

    NOTICE:
    1. If the linings of the discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all discs.
    2. Before assembling new discs, soak them in ATF for at least 15 minutes.


63. REMOVE REAR PLANETARY GEAR ASSEMBLY

  1. C109346
    Remove the rear planetary gear assembly from the transmission case.

  1. C109347E03
    Remove the No. 9 thrust bearing race, thrust bearing race and the thrust needle roller bearing from the rear planetary gear assembly.

  1. D027947
    Remove the thrust needle roller bearing from the transmission case.


64. INSPECT REAR PLANETARY GEAR ASSEMBLY

  1. C109349
    Using a feeler gauge, measure the rear planetary gear pinion thrust clearance.

    Standard clearance:
    0.2 to 0.6 mm (0.008 to 0.024 in.)

    If the clearance is greater than the standard clearance, replace the planetary gear assembly.

  1. C109350
    Using a dial indicator, measure the inside diameter of the rear planetary gear bushing.

    Standard inside diameter:
    18.025 mm (0.710 in.)

    If the inside diameter is greater than the standard inside diameter, replace the rear planetary gear assembly.


65. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

  1. C108601E02
    Place SST on the 1st and reverse brake return spring sub-assembly and compress the brake return spring.
    SST
    09350-30020   (09350-07050)

  1. Using the SST, remove the snap ring and the brake return spring.

    SST
    09350-30020   (09350-07070)


66. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

  1. D029830
    Using vernier calipers, measure the free length of the spring together with the spring seat.

    Standard free length:
    23.74 mm (0.94 in.)

    If the free length is shorter than the standard free length, replace the brake piston return spring sub-assembly.


67. REMOVE BRAKE APPLY TUBE

  1. C108599
    Remove the brake apply tube from the 1st and reverse brake piston.


68. REMOVE 1ST AND REVERSE BRAKE PISTON

  1. C108598
    Hold the 1st and reverse brake piston and blow compressed air (392 kPa, 4 kgf/cm2, 57 psi) into the transmission case to remove the brake piston.

    HINT:
    If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

  1. Remove the brake apply tube from the piston.

  1. Remove the O-ring from the brake piston.


69. REMOVE BRAKE REACTION SLEEVE

  1. C108602E01
    Using SST, remove the reaction sleeve.
    SST
    09350-30020   (09350-07080)

  1. Remove the 2 O-rings from the reaction sleeve.


70. REMOVE NO. 4 BRAKE PISTON

  1. C108603E01
    Using SST, remove the No. 4 brake piston.
    SST
    09350-30020   (09350-07080)

  1. Remove the 2 O-rings from the No. 4 brake piston.

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