Lexus IS250 · Service Manual TRANSMISSION

INSTALLATION

Removal / installation


1. INSTALL TRANSMISSION UPPER COVER SUB-ASSEMBLY

  1. C123480
    Install the transmission upper cover sub-assembly with the 2 bolts.

    Torque:
    12 N*m{ 120 kgf*cm , 9 ft.*lbf }


2. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

  1. C123442
    Install the rear No. 1 engine mounting insulator to the manual transmission with the 4 bolts.

    Torque:
    25 N*m{ 255 kgf*cm , 18 ft.*lbf }


3. INSTALL CLUTCH COVER ASSEMBLY

  1. Apply clutch spline grease to the input shaft spline.

    Sealant:
    Part No. 08887-01706, CLUTCH SPLINE GREASE or equivalent

  1. Install the clutch cover assembly to the input shaft.


4. INSTALL CLUTCH DISC ASSEMBLY

  1. C123490E01
    Install the clutch disc assembly to the transmission unit.

    NOTICE:
    Take care not to insert the clutch disc assembly in the wrong direction.


5. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

  1. D033847
    Apply release hub grease to the contact surface between, the release fork and release bearing hub, the contact surface between the release fork and push rod, and release fork pivot points as shown in the illustration.

    Sealant:
    Part No. 08887-01806, RELEASE HUB GREASE or equivalent

  1. Install the clutch release fork sub-assembly to the release fork support.

    NOTICE:
    1. Do not use excess force to install the clutch release fork sub-assembly.
    2. After installation, move the fork back and forth to check that the clutch release bearing hub slides smoothly.


6. INSTALL MANUAL TRANSMISSION ASSEMBLY

  1. C116473E01
    Install the manual transmission to the engine with the 9 bolts.

    Torque:
    Bolt A:
    72 N*m{ 730 kgf*cm , 53 ft.*lbf }
    Bolt B:
    37 N*m{ 380 kgf*cm , 28 ft.*lbf }

    NOTICE:
    Temporarily tighten bolt *1, fully tighten bolt *2, lift the rear end of the transmission, and fully tighten bolt *1 and the other bolts. Make sure that excessive force is not applied to the knock pins when lifting the rear end of the transmission.


7. INSTALL ENGINE REAR MOUNTING MEMBER

  1. C116481
    Install the engine rear mounting member with the 4 bolts and 4 nuts.

    Torque:
    Nut:
    13 N*m{ 130 kgf*cm , 10 ft.*lbf }
    Bolt:
    26 N*m{ 265 kgf*cm , 19 ft.*lbf }


8. INSTALL FLOOR SHIFT LEVER ASSEMBLY

  1. C123473
    Install the 2 bushings to the shift lever assembly.

  1. Install the washer to the floor shift lever assembly.

  1. C123475
    Install the shift lever assembly with a new E-ring.

  1. Install the shift and select lever boot.


9. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY

  1. C123444
    Install the floor shift control shift lever retainer sub-assembly with the 2 nuts.

    Torque:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }


10. INSTALL CLUTCH COVER ASSEMBLY

  1. C123443E01
    Align the matchmarks on the clutch cover assembly and the flywheel sub-assembly.

  1. Install the clutch cover to the flywheel sub-assembly with the new 6 bolts.

    Torque:
    19 N*m{ 195 kgf*cm , 14 ft.*lbf }

    NOTICE:
    Tighten the bolts a little at a time in a diagonal pattern until they are all tightened.


11. INSTALL NO. 1 CLUTCH HOUSING COVER

  1. C123446
    Install the No. 1 clutch housing cover with the 4 bolts.

    Torque:
    18 N*m{ 184 kgf*cm , 13 ft.*lbf }

    Bolt length:
    20 mm (0.79 in.)


12. INSTALL NO. 2 CLUTCH HOUSING COVER

  1. C123445
    Install the No. 2 clutch housing cover with the 4 bolts.

    Torque:
    18 N*m{ 184 kgf*cm , 13 ft.*lbf }

    Bolt length:
    16 mm (0.63 in.)


13. CONNECT WIRE HARNESS

  1. C116462
    Connect the back-up light switch connector and install the wire harness.


14. CONNECT GROUND CABLE

  1. C116459
    Connect the ground cable with the bolt.

    Torque:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }


15. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY

  1. C116479
    Install the clutch release cylinder assembly with the 2 bolts.

    Torque:
    12 N*m{ 120 kgf*cm , 9 ft.*lbf }


16. INSTALL CLUTCH ACCUMULATOR ASSEMBLY

  1. C116478
    Install the clutch accumulator assembly with the 2 bolts and 2 nuts.

    Torque:
    Bolt:
    12 N*m{ 120 kgf*cm , 9 ft.*lbf }
    Nut:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }


17. INSTALL STARTER ASSEMBLY
(Click here)

18. INSTALL ENGINE UNDER COVER AIR GUIDE BRACKET

  1. C123447
    Install the engine under cover air guide bracket with the 2 bolts.

    Torque:
    26 N*m{ 260 kgf*cm , 19 ft.*lbf }


19. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

  1. C109590E02
    Remove the SST from the transmission.
    SST
    09325-40010  

  1. Insert the yoke of the intermediate shaft into the transmission.

    HINT:
    Be careful not to damage the oil seal.

  1. F048233
    Install the 2 center support bearing washers and center support bearing. (for automatic transmission)

  1. Install the 2 center support bearing washers, center support bearing and 2 center support bearing dampers. (for manual transmission)

  1. Temporarily tighten the 2 bolts.

  1. C104521E02
    Align the matchmarks on the propeller shaft flange and differential companion flange, and connect the shaft with the 4 bolts, washers and nuts.

    Torque:
    74 N*m{ 750 kgf*cm , 54 ft.*lbf }

  1. C127022E01
    Adjust the dimension between the edge surface of the center support bearing and the edge surface of the cushion to 11.5 to 13.5 mm (0.4528 to 0.5315 in.) as shown in illustration.

  1. C109375E01
    Check that the center line of the bracket is perpendicular to the shaft axial direction.

  1. F048233
    Tighten the 2 bolts.

    Torque:
    49 N*m{ 500 kgf*cm , 36 ft.*lbf }


20. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE

  1. Stabilize the propeller shaft and differential.

    1. Turn the propeller shaft several times by hand to stabilize the center support bearing.

  1. Check both the No. 2 and No. 3 joint angles.

    1. Using SST, measure the installation angle of the intermediate shaft and propeller shaft.

      SST
      09370-50010  

      HINT:
      The SST should be set directly on the bottom of the shaft.

    2. Using SST, measure the installation angle of the differential.

      C109596E01

      SST
      09370-50010  

      HINT:
      Measure the installation angle by placing the SST in the positions shown in the illustration.

    3. Calculate the No. 2 joint angle.

      No. 2 joint angle:
      A - B = -1°13' to -0°13'

      A:
      Intermediate shaft installation angle

      B:
      Propeller shaft installation angle

    4. Calculate the No. 3 joint angle.

      No. 3 joint angle:
      B - C = 1°30' to 2°30'

      B:
      Propeller shaft installation angle

      C:
      Differential installation angle

      HINT:
      If the measured angle is not within the specified range, adjust it with the center support bearing washers.

  1. Adjust the No. 2 joint angle .

    1. Select the center support bearing washers for adjustment.

      Adjustment washer (for manual transmission) 
      Thickness mm (in)
      2 (0.078)
      4.5 (0.1772)
      6.5 (0.2559)
      9.0 (0.3543)
      11 (0.4331)
      Adjustment washer (for automatic transmission) 
      Thickness mm (in)
      2 (0.078)
      4.5 (0.1772)
      6.5 (0.2559)
      9.0 (0.3543)
      11 (0.4331)
      13.5 (0.5315)

      NOTICE:
      The 2 washers should be the same thickness.


21. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR

  1. C125771E01
    Install the No. 1 heat insulator with the 4 nuts.

    Torque:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }


22. INSTALL OUTSIDE AIR GUIDE PLATE RH

  1. C126031
    Install the air guide plate outside RH with the 4 nuts.

    Torque:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }


23. INSTALL FRONT EXHAUST PIPE ASSEMBLY

  1. A077857
    Using a vernier caliper, measure the free length of the compression springs.

    Minimum length:
    38.5 mm (1.516 in.)

    If the free length is less than the minimum, replace the compression spring.

  1. A109513E09
    Install a new gasket to the rear end of the front exhaust pipe.

    NOTICE:
    1. Be careful with the installation direction of the gasket.
    1. Do not reuse the gasket.
    1. To ensure a proper seal, do not use the tail exhaust pipe to force the gasket onto the front exhaust pipe.

      HINT:
      Using a plastic hammer, uniformly strike the gasket so that the gasket and front exhaust pipe are properly fit.

  1. Install 3 new gaskets and front exhaust pipe assembly.

    CAUTION:
    Do not reuse the gaskets.

  1. A125008
    Install the 2 bolts and 2 compression springs.

    Torque:
    43 N*m{ 438 kgf*cm , 32 ft.*lbf }

  1. A127822E01
    Install 4 new nuts and 4 bolts.

    Torque:
    62 N*m{ 632 kgf*cm , 46 ft.*lbf }

    NOTICE:
    Do not reuse the nuts.


24. INSTALL HEATED OXYGEN SENSOR

  1. A119092
    Before installing the heated oxygen sensors, twist the sensor wires counterclockwise 4 turns.

  1. A123663E02
    Using the SST, install the heated oxygen sensors to the front exhaust pipe.
    SST
    09224-00010  

    Torque:
    44 N*m{ 449 kgf*cm , 33 ft.*lbf }

  1. After installing the sensors, check that the sensor wires are not twisted.
    If the sensor wires are twisted, reinstall them.

  1. A120539E05
    Install the grommets of the heated oxygen sensors.


25. INSTALL FRONT CENTER FLOOR BRACE

  1. C104834
    Install the front center floor brace with the 4 bolts.

    Torque:
    7.4 N*m{ 75 kgf*cm , 65 in.*lbf }


26. INSTALL NO. 1 REAR FLOOR PANEL BRACE

  1. A121036
    Install the rear No. 1 floor panel brace with the 4 bolts.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }


27. INSTALL NO. 2 ENGINE UNDER COVER

28. INSTALL ENGINE UNDER COVER

29. INSTALL SHIFT LEVER CAP

  1. C126541E01
    Move the shift lever to the 2nd gear position. Adjust the guide plate so that dimension A is as shown in the illustration with the shift lever cap pushed toward neutral (select direction).

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }


30. INSTALL NO. 1 SHIFT AND SELECT LEVER BOOT

  1. C116460
    Install the shift lever boot with the 4 bolts.


31. INSTALL NO. 2 CONSOLE BOX DUCT

  1. B123361
    Install the No. 2 console box duct with the clip.


32. INSTALL CONSOLE BOX

  1. B123342
    Engage the 2 claws and 2 clips.

  1. B116791
    Install the 2 bolts <C>.

  1. B123339
    Install the 2 bolts <C>.

  1. Connect the connector.

  1. B123341E01
    Connect the connectors.

  1. Engage the 2 clamps.

  1. Install the 2 bolts <C>.


33. INSTALL CONSOLE BOX REGISTER ASSEMBLY

  1. B123605
    Engage the 2 claws and 4 clips, and then install the console box register assembly.

  1. Install the rear ash receptacle assembly.


34. INSTALL FRONT ASH RECEPTACLE SUB-ASSEMBLY

  1. B116700E01
    Connect the connectors.

  1. Insert the protruding parts of the front ash receptacle sub-assembly into the 2 guide holes as shown in the illustration.

  1. B116698
    Install the front ash receptacle sub-assembly with the 2 screws <F>.


35. INSTALL FRONT CONSOLE PANEL SUB-ASSEMBLY

  1. B123400
    Engage the 6 clips.

  1. B123395
    Close the snap.


36. INSTALL REAR CONSOLE PANEL SUB-ASSEMBLY

  1. B123398
    Engage the 7 claws and 2 clips.

  1. B123396
    Close the snap.


37. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY

38. ADD MANUAL TRANSMISSION OIL

  1. D025304E01
    Park the vehicle in a level place.

  1. Remove the transmission filler plug and gasket.

  1. Check that the oil surface is within 5 mm (0.20 in.) below the lowest point of the transmission filler plug opening.

    Oil grade:
    API GL-4 or GL-5

    Viscosity:
    SAE 75W-90

    NOTICE:
    1. Problems may occur when the oil level is too high or too low.
    2. After replacing the oil, drive the vehicle and check the oil level again.

  1. Check for oil leakage if the oil level is low.

  1. Install the transmission filler plug and a new gasket.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }


39. CHECK FOR EXHAUST GAS LEAKS
If exhaust gas is leaking, tighten the related parts to stop the leak. Replace damaged parts as necessary.

40. INSPECT AND ADJUST MANUAL TRANSMISSION OIL LEVEL

  1. D025304E03
    Park the vehicle on a level surface.

  1. Remove the transmission filler plug and gasket.

  1. Check that the oil surface is within 5 mm (0.20 in.) of the lowest point of the transmission filler plug opening.

    NOTICE:
    1. Problems may occur if the oil level is too high or low.
    2. After replacing the oil, drive the vehicle and check the oil level again.

  1. Check for oil leakage when the oil level is low.

  1. Install the transmission filler plug and a new gasket.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }

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