Lexus IS250 · Service Manual TRANSMISSION

DISASSEMBLY

Removal / installation


1. FIX CLUTCH DRUM AND INPUT SHAFT

  1. D031375E02
    Place the oil pump onto the torque converter clutch, and then place the reverse clutch drum sub-assembly and input shaft onto the oil pump.


2. REMOVE REVERSE CLUTCH HUB SUB-ASSEMBLY

  1. D027996
    Using a screwdriver, remove the snap ring from the reverse clutch drum sub-assembly and input shaft.

  1. D027997
    Remove the reverse clutch hub sub-assembly with the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 5 rear clutch discs, and the 4 clutch plates from the forward clutch hub.


3. REMOVE REVERSE CLUTCH REACTION SLEEVE

  1. D027998
    Remove the reverse clutch reaction sleeve from the reverse clutch hub sub-assembly.


4. REMOVE NO. 3 CLUTCH DISC

  1. C122852
    Remove the clutch cushion plate, the reverse clutch flange, the 3 plates and the 4 discs from the reverse clutch hub.


5. INSPECT NO. 3 CLUTCH 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 even a part of the printed numbers is damaged, replace all discs.
    1. Before assembling new discs, soak them in ATF for at least 15 minutes.


6. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY

  1. Inspect the pack clearance of the reverse clutch hub sub-assembly.

    1. Using a dial indicator, measure the reverse clutch piston stroke (distance A) and the moving distance (distance B) of the reverse clutch flange at both ends across a diameter while blowing air (392 kPa, 4 kgf/cm2, 57 psi) from the oil hole as shown in the illustration, and calculate the average.

      D028538E02

      HINT:
      Piston stroke A = 1.62 to 2.68 mm (0.0638 to 0.1055 in.)
      Flange moving distance B = 1.22 to 1.67 mm (0.0480 to 0.0657 in.)
      Pack clearance = Piston stroke A - Flange moving distance B - 0.02 mm (0.0008 in.)

      Pack Clearance:
      0.4 to 0.7 mm (0.016 to 0.028 in.)

      NOTICE:
      Install a selective flange {t = 2.8 mm (0.110 in.)} when measuring the moving distance (shaded area in the illustration).

    2. If the pack clearance is outside the specified range, select and install a clutch flange that brings the pack clearance within the specified range.

      HINT:
      There are 12 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

      Flange thickness:
      No.
      		 Thickness
      0
      		 2.4 mm (0.094 in.)
      1
      		 2.5 mm (0.098 in.)
      2
      		 2.6 mm (0.102 in.)
      3
      		 2.7 mm (0.106 in.)
      4
      		 2.8 mm (0.110 in.)
      5
      		 2.9 mm (0.114 in.)
      6
      		 3.0 mm (0.118 in.)
      7
      		 3.1 mm (0.122 in.)
      8
      		 3.2 mm (0.126 in.)
      9
      		 3.3 mm (0.130 in.)
      A
      		 3.4 mm (0.134 in.)
      B
      		 3.5 mm (0.138 in.)


7. REMOVE CLUTCH HUB SUB-ASSEMBLY

  1. D031376
    Remove the clutch hub sub-assembly and thrust washer from the reverse clutch drum sub-assembly.

  1. C109367
    Remove the 2 thrust needle roller bearings and the thrust bearing race from the clutch hub sub-assembly.


8. INSPECT CLUTCH HUB SUB-ASSEMBLY

  1. D028501
    Using a dial indicator, measure the inside diameter of the clutch hub bushing.

    Standard inside diameter:
    23.037 to 23.062 mm (0.907 to 0.908 in.)

    If the inside diameter is greater than the standard inside diameter, replace the clutch hub.


9. REMOVE COAST CLUTCH HUB SUB-ASSEMBLY

  1. D031377
    Remove the coast clutch hub sub-assembly from the reverse clutch drum sub-assembly.


10. INSPECT NO. 4 ONE WAY CLUTCH ASSEMBLY

  1. C109337E01
    Hold the coast clutch hub and turn the one way clutch assembly.

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


11. REMOVE NO. 4 ONE WAY CLUTCH ASSEMBLY

  1. C109362
    Remove the No. 4 one way clutch assembly and the clutch hub thrust washer from the coast clutch hub.


12. REMOVE NO. 1 CLUTCH DISC

  1. D031378
    Using a screwdriver, remove the hole snap ring.

  1. D031379E03
    Remove the flange, cushion plate, 4 discs and 5 plates from the input shaft.


13. INSPECT NO. 1 CLUTCH 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 even a part of the printed numbers is damaged, replace all discs.
    1. Before assembling new discs, soak them in ATF for at least 15 minutes.


14. REMOVE COAST CLUTCH DISC

  1. D031380
    Using a screwdriver, remove the hole snap ring.

  1. C109336
    Remove the flange, the 4 discs and the 4 plates from the input shaft.


15. INSPECT COAST CLUTCH 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 even a part of the printed numbers is damaged, replace all discs.
    1. Before assembling new discs, soak them in ATF for at least 15 minutes.


16. REMOVE INPUT SHAFT

  1. C109352E02
    Remove the thrust needle roller bearing and the thrust bearing race from the input shaft.

  1. D031522
    Remove the input shaft from the reverse clutch drum sub-assembly.

  1. D031523
    Remove the thrust needle roller bearing and thrust bearing race from the reverse clutch drum sub-assembly.


17. REMOVE INPUT SHAFT OIL SEAL RING

  1. D031399
    Remove the 4 oil seal rings from the input shaft.


18. REMOVE NO. 1 CLUTCH BALANCER

  1. C109342E01
    Place SST on the No. 1 clutch balancer, and compress the return spring with a press.
    SST
    09350-30020   (09350-07040)
    09316-20011  

  1. Using the SST, remove the snap ring.

    SST
    09350-30020   (09350-07070)

  1. C109343
    Remove the No. 1 clutch balancer and the forward clutch return spring from the input shaft.

  1. C109344
    Remove the D-ring from the No. 1 clutch balancer.


19. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

  1. C059838
    Using vernier calipers, measure the free length of the spring together with the spring seat.

    Standard free length:
    26.29 mm (1.035 in.)

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


20. REMOVE FORWARD CLUTCH PISTON SUB-ASSEMBLY

  1. D031400
    Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the input shaft to remove the forward clutch piston.

  1. D031383
    Remove the coast clutch piston from the forward clutch piston.

  1. Remove the O-ring from the input shaft.


21. REMOVE REVERSE CLUTCH FLANGE

  1. D028506
    Remove the reverse clutch flange from the reverse clutch drum sub-assembly.


22. REMOVE NO. 2 DIRECT CLUTCH DISC

  1. D028507
    Using a screwdriver, remove the 2 hole snap rings from the reverse clutch drum sub-assembly.

  1. C109338
    Remove the direct clutch flange, the 5 plates and the 5 discs from the reverse clutch drum sub-assembly.


23. INSPECT NO. 2 DIRECT CLUTCH 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 even a part of the printed numbers is damaged, replace all discs.
    1. Before assembling new discs, soak them in ATF for at least 15 minutes.


24. REMOVE NO. 3 CLUTCH BALANCER

  1. D028509E02
    Place SST on the No. 3 clutch balancer, and compress the return spring with a press.
    SST
    09387-00070  

  1. Using SST, remove the snap ring.

    SST
    09350-30020   (09350-07070)

  1. Remove the No. 3 clutch balancer.


25. REMOVE REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY

  1. D028510
    Remove the reverse clutch return spring and the O-ring from the reverse clutch piston.


26. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY

  1. C059838
    Using vernier calipers, measure the free length of the spring together with the spring seat.

    Standard free length:
    21.03 mm (0.828 in.)

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


27. REMOVE REVERSE CLUTCH PISTON SUB-ASSEMBLY

  1. D028511
    Remove the reverse clutch piston sub-assembly from the reverse clutch drum sub-assembly.

  1. D028512
    Remove the O-ring from the reverse clutch piston sub-assembly.

  1. D028513
    Remove the O-ring from the reverse clutch drum sub-assembly.


28. REMOVE DIRECT CLUTCH PISTON SUB-ASSEMBLY

  1. C108589E01
    Place SST on the direct clutch piston, and compress the return spring with a press.
    SST
    09350-30020   (09350-07070)
    09518-36020  

  1. Using SST, remove the snap ring.

  1. C109370
    Remove the No. 2 clutch balancer and the direct clutch return spring sub-assembly.

  1. Remove the O-ring from the No. 2 clutch balancer.

  1. D028515
    Using 2 screwdrivers, remove the direct clutch piston sub-assembly from the reverse clutch drum sub-assembly.

  1. D028816
    Remove the 2 O-rings from the direct clutch piston sub-assembly.


29. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

  1. C059838
    Using vernier calipers, measure the free length of the spring together with the spring seat.

    Standard free length:
    20.02 mm (0.788 in.)

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

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