Lexus IS250 · Service Manual TRANSMISSION

REASSEMBLY

Removal / installation


1. INSTALL SHIFT ARM

  1. C126517
    Install the shift arm and shift arm pivot onto the shift interlock bracket.

  1. C126516
    Install a new E-ring onto the shift arm pivot.


2. INSTALL NO. 4 GEAR SHIFT FORK SHAFT

  1. C126515
    Install the spring and ball into the shift interlock bracket.

  1. Install the No. 4 gear shift fork shaft.


3. INSTALL NO. 4 GEAR SHIFT FORK

  1. C126513
    Install the No. 4 gear shift fork onto the No. 4 gear shift fork shaft.

  1. Using a pin punch (5 mm (0.20 in.)) and hammer, tap a new slotted spring pin to install the No. 4 shift fork and No. 4 gear shift fork shaft.

    Installation depth:
    0 to 0.5 mm (0 to 0.020 in.)


4. INSTALL NO. 1 GEAR SHIFT FORK

  1. C126512
    Install the No. 1 gear shift fork and No. 2 gear shift head onto the No. 4 gear shift fork shaft.

  1. C126510
    Using a pin punch (5 mm (0.20 in.)) and hammer, tap a new slotted spring pin to install the No. 2 gear shift head and No. 4 gear shift fork shaft.

    Installation depth:
    0 to 0.5 mm (0 to 0.020 in.)


5. INSTALL NO. 3 GEAR SHIFT FORK SHAFT

  1. C126509
    Apply MP grease to the No. 1 shift interlock pin and install it onto the shift interlock bracket.

  1. Install the spring and ball onto the shift interlock bracket.

  1. Install the No. 3 gear shift head and No. 3 gear shift fork shaft into the shift interlock bracket.

    HINT:
    Place the No. 4 gear shift fork shaft in the neutral position.


6. INSTALL NO. 3 GEAR SHIFT HEAD

  1. C126507
    Using a pin punch (5 mm (0.20 in.)) and hammer, tap a new slotted spring pin to install the No. 3 gear shift head and No. 3 gear shift fork shaft.

    Installation depth:
    0 to 0.5 mm (0 to 0.020 in.)


7. INSTALL NO. 2 GEAR SHIFT FORK SHAFT

  1. C126506
    Apply MP grease to the No. 2 and No. 3 shift interlock pins, then install them into the shift interlock bracket.

  1. Install the spring and ball into the shift interlock bracket.

  1. Install the No. 2 gear shift fork shaft onto the shift interlock bracket.

    HINT:
    Place the No. 3 and No. 4 gear shift fork shafts in the neutral position.


8. INSTALL NO. 2 GEAR SHIFT FORK

  1. C126505
    Install the No. 2 gear shift fork with the bolt.

    Torque:
    20 N*m{ 200 kgf*cm , 14 ft.*lbf }


9. INSTALL NO. 1 GEAR SHIFT FORK SHAFT

  1. C126504
    Apply MP grease to the No. 2 and No. 3 shift interlock pins, then install them into the shift interlock bracket.

  1. Install the spring and ball into the shift interlock bracket.

  1. Install the No. 1 gear shift head and No. 1 gear shift fork shaft onto the shift interlock bracket.

    HINT:
    Place the No. 4, No. 3 and No. 2 gear shift fork shafts in the neutral position.


10. INSTALL NO. 1 GEAR SHIFT HEAD

  1. C126520
    Using a pin punch (5 mm (0.20 in.)) and hammer, tap a new slotted spring pin to install the No. 1 gear shift head and No. 1 gear shift fork shaft.

    Installation depth:
    0 to 0.5 mm (0 to 0.020 in.)


11. INSTALL NO. 3 GEAR SHIFT FORK

  1. C126522
    Install the No. 3 gear shift fork with the bolt.

    Torque:
    20 N*m{ 200 kgf*cm , 14 ft.*lbf }

  1. C126519
    Install 4 new snap rings.


12. INSTALL TRANSMISSION CASE OIL SEAL

  1. D033643E02
    Using SST and a hammer, tap a new oil seal into the front case in accordance with the dimension specified in the illustration.
    SST
    09950-70010   (09951-07100)
    09950-60010   (09951-00470)

    Dimension A:
    60.0 to 60.8 mm (2.362 to 2.394 in.)

  1. Apply gear oil to the lip of the oil seal.


13. INSTALL FRONT BEARING SHAFT SNAP RING

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


14. INSTALL NO. 1 OIL RECEIVER PIPE

  1. D033642
    Install the No. 1 oil receiver pipe onto the transmission front case.

    HINT:
    Align the convex portion of the oil receiver pipe with the cutout of the front case and install the oil receiver pipe onto the front case.


15. INSTALL TRANSMISSION FRONT CASE

  1. D033644
    Apply gear oil to all sliding and rotating parts.

  1. Provisionally install the output shaft, input shaft, counter gear shaft and control assembly, and tie them with a rope or string.

  1. D033637
    Using a snap ring expander, extend the 2 snap rings and install the output shaft, input shaft, counter gear shaft and control assembly.

    HINT:
    Make sure that the snap ring is fully engaged into the grooves of the input shaft and front bearing of the counter gear shaft.

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

  1. F051583
    Using a hexagonal wrench (24 mm), install the plug onto the front case.

    Torque:
    39 N*m{ 400 kgf*cm , 29 ft.*lbf }

  1. D033635
    Install the 4 bolts onto the shift interlock bracket.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }


16. INSTALL REVERSE IDLER GEAR

  1. C116297
    Install the reverse idler gear, reverse idler gear bearing and reverse idler gear shaft.

    HINT:
    Make sure that the reverse idler gear faces the correct direction as shown in the illustration.

    NOTICE:
    Make sure that the tapped hole portion of the reverse idler shaft is in the position shown in the illustration.


17. INSTALL SHIFT AND SELECT LEVER CAM

  1. C126552
    Install the shift and select lever cam onto the shaft and install a new E-ring.


18. INSTALL SHIFT AND SELECT LEVER

  1. F051579
    Install the lock ball pin and spring into the shift and select lever.

  1. Install the shift and select lever onto the shift and select lever shaft.

  1. Install a new bolt onto the shift and select lever.

    Torque:
    33 N*m{ 340 kgf*cm , 25 ft.*lbf }


19. INSTALL SHIFT AND SELECT LEVER SHAFT

  1. D033647
    Align the groove of the shift and select cam with the reverse idler gear shaft, and the claw with the groove of the control assembly, and install them.


20. INSTALL TRANSMISSION MIDDLE CASE BEARING

  1. C125945E01
    Using SST and a press, install the transmission middle case bearing to the transmission middle case.
    SST
    09950-60010   (09951-00230)

    Installation depth:
    0.5 to 1.5 mm (0.0197 to 0.0591 in.)


21. INSTALL NO. 2 OIL RECEIVER PIPE

  1. F051577
    Install the No. 2 oil receiver pipe into the transmission middle case.


22. INSTALL TRANSMISSION DRAIN PLUG

  1. F051576
    Install the drain plug with a new gasket onto the transmission middle case.

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


23. INSTALL TRANSMISSION MIDDLE CASE

  1. Clean the seal packing attached on the transmission middle case and transmission front case using a scraper and wire brush. Then remove the oil with non-residue type solvent or equivalent.

    NOTICE:
    Do not scratch the fitting surface.

  1. D033756E02
    Apply FIPG to the transmission middle case, as shown in the illustration.

    FIPG:
    Part No. 08826-00090, THREE BOND 1281 or equivalent

    NOTICE:
    Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

  1. D033740E02
    Install the transmission middle case with the 11 bolts onto the transmission front case.

    Torque:
    40 N*m{ 408 kgf*cm , 30 ft.*lbf }

    Bolt length:
    Bolt A:
    40 mm (1.57 in.)
    Bolt B:
    80 mm (3.15 in.)


24. INSTALL REVERSE IDLER GEAR SHAFT BOLT

  1. D033649
    Install a new gasket and the reverse idler gear shaft bolt onto the reverse idler gear shaft.

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }


25. INSTALL TRANSMISSION OIL SEPARATOR

  1. F051575
    Install the transmission oil separator with the 2 bolts.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }


26. INSTALL TRANSMISSION REAR CASE BEARING

  1. C125943E01
    Using SST and a press, install the transmission rear case bearing to the transmission rear case.
    SST
    09950-60010   (09951-00230)

    Installation depth:
    1.0 to 2.0 mm (0.0394 to 0.0787 in.)


27. INSTALL COUNTER GEAR REAR CYLINDRICAL ROLLER BEARING

  1. D033750E02
    Coat a new counter gear rear cylindrical roller bearing with gear oil, and using SST and a press, install it into the transmission rear case.
    SST
    09950-70010   (09951-07360)
    09950-60010   (09951-00650)

  1. D033746
    Install the bearing lock plate with the bolt.

    Torque:
    11 N*m{ 115 kgf*cm , 8.3 ft.*lbf }


28. INSTALL OUTPUT SHAFT REAR BEARING OUTER RACE

  1. D033749E02
    Using SST and a press, press in 2 new bearing outer races.
    SST
    09950-70010   (09951-07100, 09951-07360)
    09950-60020   (09951-00790)


29. INSTALL OIL SEPARATOR PACKING SEAL

  1. D033752
    Install the oil separator packing seal onto the transmission rear case.

    HINT:
    Insert the protruding part of the oil separator packing seal into the groove on the transmission rear case.


30. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE

  1. F051573
    Install the extension housing oil receiver pipe onto the transmission rear case.


31. INSTALL MANUAL TRANSMISSION FILLER PLUG

  1. C123478
    Install the 2 transmission filler plugs with 2 new gaskets onto the transmission rear case.

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


32. INSTALL TRANSMISSION REAR CASE

  1. Clean the seal packing attached on the transmission rear case and transmission middle case using a scraper and wire brush. Then remove the oil with non-residue type solvent or equivalent.

    NOTICE:
    Do not scratch the fitting surface.

  1. D033757E02
    Apply FIPG to the transmission rear case, as shown in the illustration.

    FIPG:
    Part No. 08826-00090, THREE BOND 1281 or equivalent

    NOTICE:
    Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

  1. C123481E01
    Install the transmission rear case with the 10 bolts and bracket onto the transmission middle case.

    Torque:
    40 N*m{ 408 kgf*cm , 30 ft.*lbf }


33. INSTALL SHIFT DETENT BALL PLUG

  1. F051570
    Install the ball and compression spring onto the transmission rear case.

  1. Install a new shift detent ball plug onto the transmission rear case.

    Torque:
    25 N*m{ 250 kgf*cm , 18 ft.*lbf }


34. INSTALL OUTPUT SHAFT ADJUST NUT

  1. D033736
    Using a belt and wooden block, fasten the transmission to the workbench.

  1. Install a new spacer and a new No. 2 taper roller bearing.

  1. D033758E02
    Using SST, provisionally tighten a new nut until there is no slack in the output shaft.
    SST
    09922-10010  

    HINT:
    No preload should be applied to the nut.

  1. Fit the bearing into the output shaft by turning the output shaft 15 times.

  1. D033759
    Place the gearshift into 5th gear and check the initial torque of the input shaft.

  1. Using SST, tighten the nut.

    SST
    09922-10010  

  1. Place the gearshift into 5th gear and check the initial torque of the input shaft.

  1. Confirm that the difference between (d) and (f) is within the specified values.

    Preload (at starting):
    0.45 to 1.35 N*m (4.59 to 13.77 kgf*cm, 3.98 to 11.95 in.*lbf)

    If the result is not as specified, tighten and adjust the output shaft adjusting nut.

    NOTICE:
    If the output shaft adjusting nut is loose or removed due to a large preload, always replace the spacer with a new one.

  1. D033734
    Using a chisel and hammer, stake the output shaft adjust nut.


35. INSTALL EXTENSION HOUSING OIL RECEIVER PIPE

  1. C126543
    Install the oil receiver pipe.

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


36. INSTALL MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL

  1. F051839E02
    Using SST and a hammer, install a new oil seal into the extension housing in accordance with the dimension specified in the illustration.
    SST
    09950-60020   (09951-00640)
    09950-70010   (09951-07100)

    Dimension A:
    -0.5 to 0.5 mm (-00.197 to 0.0197 in.)

  1. Apply gear oil to the lip of the oil seal.


37. INSTALL EXTENSION HOUSING REAR OIL SEAL

  1. C125941E01
    Using SST and a hammer, install a new extension housing rear oil seal.
    SST
    09612-70100   (09612-07210)

    Installation depth:
    4.6 to 5.4 mm (0.1811 to 0.2126 in.)


38. INSTALL EXTENSION HOUSING DUST DEFLECTOR

  1. Using a plastic hammer, install a new extension housing dust deflector.


39. INSTALL EXTENSION HOUSING SUB-ASSEMBLY

  1. Clean the seal packing attached on the transmission middle case and extension housing using a scraper and wire brush. Then remove the oil with non-residue type solvent or equivalent.

    NOTICE:
    Do not scratch the fitting surface.

  1. D033760E02
    Apply FIPG to the extension housing, as shown in the illustration.

    FIPG:
    Part No. 08826-00090, THREE BOND 1281 or equivalent

    NOTICE:
    Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

  1. C123474
    Install the extension housing with the 8 bolts.

    Torque:
    29 N*m{ 296 kgf*cm , 21 ft.*lbf }


40. INSTALL FLOOR SHIFT CONTROL SHAFT

  1. C126524E01
    Install the control shaft collar onto the shift and select lever.

  1. Install the shift lever damper onto the floor shift control shaft, align the holes to allow the pin to be installed to the floor shift control shaft and shift and select lever shaft, and insert the shaft pin from above.

  1. Install the shaft collar to the floor shift control shaft, and stake the both sides.

    NOTICE:
    Be careful to install the floor shift control shaft in the proper direction.


41. INSTALL CONTROL SHAFT

  1. C126527
    Install the 2 collars to the floor shift control shaft.

  1. Install the control shaft with a new E-ring.


42. INSTALL SHIFT LEVER RETAINER BUSHING

  1. C123470
    Install the 4 shift lever bushings.


43. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER RETAINER

  1. C126539
    Install the floor shift control shift lever retainer with the 2 shift lever pins.

  1. Secure the shift lever pins to the extension housing.


44. INSTALL SHIFT AND SELECT LEVER BOOT

  1. Install the shift and select lever boot.


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

  1. C126525E01
    Install the floor shift lever retainer sub-assembly to the control shift lever retainer in accordance with the dimension specified in the illustration.

    Dimension A:
    18 mm (0.7087 in.)


46. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY

  1. C125921E01
    Using SST, install the back-up light switch with a new gasket onto the transmission middle case.
    SST
    09817-16011  

    Torque:
    44 N*m{ 450 kgf*cm , 33 ft.*lbf }

  1. C126553
    Install the wire harness with the clamp and bolt.

    Torque:
    13 N*m{ 130 kgf*cm , 9 ft.*lbf }

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