Lexus IS250 · Service Manual TRANSMISSION

DISASSEMBLY

Removal / installation


1. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY

  1. C126553
    Remove the bolt and separate the wire harness clamp.

  1. C125921E01
    Using SST, remove the back-up light switch and gasket.
    SST
    09817-16011  


2. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY

  1. C123471
    Remove the floor shift control shift lever retainer sub-assembly.


3. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER

  1. C123472
    Pull up the locks of the shift lever pins, and remove the 2 shift lever pins.

  1. Remove the floor shift control shift lever retainer.


4. REMOVE SHIFT AND SELECT LEVER BOOT

  1. Remove the shift and select lever boot.


5. REMOVE SHIFT LEVER RETAINER BUSHING

  1. C123470
    Remove the 4 shift lever retainer bushings.


6. REMOVE CONTROL SHAFT

  1. C126526
    Using a screwdriver, remove the E-ring and control shaft.

  1. Remove the 2 collars from the floor shift control shaft.


7. REMOVE FLOOR SHIFT CONTROL SHAFT

  1. C126523E01
    Using a hammer and a screwdriver, cut off the control shaft collar and remove it from the shaft.

  1. Remove the shaft pin and floor shift control shaft.

  1. Remove the shift lever damper from the floor shift control shaft.


8. REMOVE EXTENSION HOUSING DUST DEFLECTOR

  1. Using a plastic hammer, remove the extension housing dust deflector.


9. REMOVE EXTENSION HOUSING SUB-ASSEMBLY

  1. C123474
    Remove the 8 bolts.

  1. D033731
    Using a plastic hammer, carefully tap out the extension housing.

  1. Remove the extension housing.


10. REMOVE EXTENSION HOUSING REAR OIL SEAL

  1. C125942E01
    Using SST, remove the extension housing rear oil seal.
    SST
    09612-70100   (09612-07210)


11. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL

  1. D033744E02
    Using SST, remove the extension housing oil seal.
    SST
    09308-00010  


12. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE

  1. D033732
    Using a snap ring expander, remove the snap ring.

  1. C126543
    Remove the oil receiver pipe.


13. REMOVE SHIFT DETENT BALL PLUG

  1. F051570
    Using a socket hexagon wrench (10 mm), remove the shift detent ball plug from the transmission rear case.

  1. Remove the ball and compression spring from the transmission rear case.


14. REMOVE OUTPUT SHAFT ADJUST NUT

  1. D033734
    Using a belt and wooden block, fasten the transmission to the workbench.

  1. Using a chisel and hammer, unstake the nut.

  1. D033631E02
    Place the gearshift into 5th gear, and then fix the input shaft using SST.
    SST
    09556-16030  

  1. D033735E02
    Using SST, remove the nut from the output shaft.
    SST
    09922-10010  

  1. Remove the belt and wooden block from the transmission.

  1. D033736
    Remove the No. 2 taper roller bearing and spacer.


15. REMOVE TRANSMISSION REAR CASE

  1. C123481E01
    Remove the 10 bolts and bracket.

  1. D033739
    Using a plastic hammer, carefully tap out the rear case.

  1. Remove the rear case.


16. REMOVE MANUAL TRANSMISSION FILLER PLUG

  1. C123478
    Remove the 2 transmission filler plugs and 2 gaskets from the transmission rear case.


17. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE

  1. F051573
    Remove the extension housing oil receiver pipe from the transmission rear case.


18. REMOVE OIL SEPARATOR PACKING SEAL

  1. F051828
    Remove the oil separator packing seal from the transmission rear case.


19. REMOVE OUTPUT SHAFT REAR BEARING OUTER RACE

  1. D033748E02
    Using SST, remove the 2 bearing outer races.
    SST
    09308-00010  


20. REMOVE COUNTER GEAR REAR CYLINDRICAL ROLLER BEARING

  1. D033746
    Remove the bolt, then remove the bearing lock plate.

  1. F051574E02
    Using SST, remove the counter gear rear cylindrical roller bearing from the transmission rear case.
    SST
    09308-00010  


21. REMOVE TRANSMISSION REAR CASE BEARING

  1. C125944E01
    Using SST and a press, remove the transmission rear case bearing from the transmission rear case.
    SST
    09950-60010   (09951-00230)


22. REMOVE TRANSMISSION OIL SEPARATOR

  1. F051575
    Remove the 2 bolts, then remove the oil separator.


23. REMOVE REVERSE IDLER GEAR SHAFT BOLT

  1. D033649
    Remove the reverse idler gear shaft bolt and gasket from the transmission middle case.


24. REMOVE TRANSMISSION MIDDLE CASE

  1. D033740
    Remove the 11 bolts, then remove the transmission middle case.

  1. D033741
    Using a plastic hammer, carefully tap out the transmission middle case.


25. REMOVE TRANSMISSION DRAIN PLUG

  1. F051576
    Remove the drain plug and gasket from the transmission middle case.


26. REMOVE NO. 2 OIL RECEIVER PIPE

  1. F051577
    Remove the No. 2 oil receiver pipe from the transmission middle case.


27. REMOVE TRANSMISSION MIDDLE CASE BEARING

  1. C125946E01
    Using SST and a press, remove the transmission middle case bearing from the transmission middle case.
    SST
    09950-60010   (09951-00230)


28. REMOVE SHIFT AND SELECT LEVER SHAFT

  1. F051578
    Remove the shift and select lever shaft.


29. REMOVE SHIFT AND SELECT LEVER

  1. F051579
    Remove the bolt, then remove the shift and select lever.

  1. Remove the lock ball pin and spring from the shift and select lever.


30. REMOVE SHIFT AND SELECT LEVER CAM

  1. C126552
    Using a screwdriver, remove the E-ring and the shift and select lever cam from the shift and select lever shaft.


31. INSPECT REVERSE IDLER GEAR THRUST CLEARANCE

  1. D033776
    Using a feeler gauge, measure the thrust clearance.

    Standard clearance:
    0.10 to 0.25 mm (0.0039 to 0.0098 in.)

    Maximum clearance:
    0.25 (0.0098 in.)

    If the clearance exceeds the maximum, replace the reverse idler gear shaft, reverse idler gear or transmission front case.


32. REMOVE REVERSE IDLER GEAR

  1. D033634
    Remove the reverse idle gear shaft, reverse idler gear bearing and reverse idler gear.


33. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE

  1. D033777
    Install the reverse idler gear and reverse idler gear bearing to the reverse idler gear shaft.

  1. Using a dial indicator, measure the radial clearance.

    Standard clearance:
    0.015 to 0.050 mm (0.0006 to 0.0020 in.)

    Maximum clearance:
    0.050 mm (0.0020 in.)

    If the clearance exceeds the maximum, replace the reverse idler gear bearing, reverse idler gear shaft or reverse idler gear.


34. REMOVE TRANSMISSION FRONT CASE

  1. F051583
    Using a hexagon wrench (24 mm), remove the plug from the transmission front case.

  1. F051582
    Remove the 4 bolts from the shift interlock bracket.

  1. D033636
    Tie the input shaft, counter gear and control assembly with a rope or string.

  1. D033637
    Expand the 2 snap rings, and lift up the output shaft, input shaft, counter gear and control assembly.

  1. D033638
    Remove the output shaft, input shaft, counter gear shaft and control assembly while gently tapping the front case with a plastic hammer.

    NOTICE:
    Take care not to subject the output shaft, input shaft, counter gear shaft and control assembly to any impact. This may cause the ball and spring to come out.

  1. Separate the output shaft, input shaft, counter gear shaft and control assembly.


35. REMOVE NO. 1 OIL RECEIVER PIPE

  1. F051585
    Remove the No. 1 oil receiver pipe from the transmission front case.


36. REMOVE FRONT BEARING SHAFT SNAP RING

  1. D033639
    Using snap ring pliers, remove the 2 snap rings.


37. REMOVE TRANSMISSION CASE OIL SEAL

  1. F051587E02
    Using SST, remove the transmission case oil seal from the transmission front case.
    SST
    09308-00010  


38. REMOVE NO. 3 GEAR SHIFT FORK

  1. C126518
    Using 2 screwdrivers, remove the 4 snap rings.

  1. C126522
    Remove the bolt, then remove the No. 3 gear shift fork.


39. REMOVE NO. 1 GEAR SHIFT HEAD

  1. C126521
    Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.


40. REMOVE NO. 1 GEAR SHIFT FORK SHAFT

  1. C126504
    Remove the No. 1 gear shift fork shaft, No. 1 gear shift head, ball, spring, No. 2 shift interlock pin and No. 3 shift interlock pin.


41. REMOVE NO. 2 GEAR SHIFT FORK

  1. C126505
    Remove the bolt, then remove the No. 2 gear shift fork.


42. REMOVE NO. 2 GEAR SHIFT FORK SHAFT

  1. C126506
    Remove the No. 2 gear shift fork shaft, ball, spring, No. 2 shift interlock pin and No. 3 shift interlock pin.


43. REMOVE NO. 3 GEAR SHIFT HEAD

  1. C126508
    Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.


44. REMOVE NO. 3 GEAR SHIFT FORK SHAFT

  1. C126509
    Remove the No. 3 gear shift fork shaft, ball, spring, No. 3 gear shift head and No. 1 shift interlock pin.


45. REMOVE NO. 1 GEAR SHIFT FORK

  1. C126511
    Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.

  1. C126512
    Remove the No. 2 gear shift head and No. 1 gear shift fork.


46. REMOVE NO. 4 GEAR SHIFT FORK

  1. C126514
    Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.

  1. Remove the No. 4 gear shift fork.


47. REMOVE NO. 4 GEAR SHIFT FORK SHAFT

  1. C126515
    Remove the No. 4 gear shift fork shaft, ball and spring.


48. REMOVE SHIFT ARM

  1. C126516
    Using a screwdriver, remove the E-ring.

  1. C126517
    Remove the shift arm pivot and shift arm.

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