Lexus IS250 · Service Manual TRANSMISSION

DISASSEMBLY

Removal / installation


1. INSPECT 6TH GEAR THRUST CLEARANCE

  1. F051109
    Using a dial indicator, measure the 6th gear thrust clearance.

    Standard clearance:
    0.20 to 0.48 mm (0.0079 to 0.0189 in.)

    If the clearance is outside the specification, replace the defective gear, thrust washer or shaft.


2. INSPECT 3RD GEAR THRUST CLEARANCE

  1. F051110
    Using a feeler gauge, measure the 3rd gear thrust clearance.

    Standard clearance:
    0.19 to 0.51 mm (0.0075 to 0.0201 in.)

    If the clearance is outside the specification, replace the defective gear, thrust washer, clutch hub or shaft.


3. REMOVE 4TH GEAR THRUST CLEARANCE

  1. F051111
    Using a dial indicator, measure the 4th gear thrust clearance.

    Standard clearance:
    0.12 to 0.38 mm (0.0047 to 0.0150 in.)

    If the clearance is outside the specification, replace the defective gear, clutch hub or shaft.


4. INSPECT 6TH GEAR RADIAL CLEARANCE

  1. F051106
    Using a dial indicator, measure the 6th gear radial clearance.

    Standard clearance:
    0.015 to 0.065 mm (0.0006 to 0.0026 in.)

    If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.


5. INSPECT 3RD GEAR RADIAL CLEARANCE

  1. F051107
    Using a dial indicator, measure the 3rd gear radial clearance.

    Standard clearance:
    0.015 to 0.067 mm (0.0006 to 0.0026 in.)

    If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.


6. INSPECT 4TH GEAR RADIAL CLEARANCE

  1. F051108
    Using a dial indicator, measure the 4th gear radial clearance.

    Standard clearance:
    0.015 to 0.067 mm (0.0006 to 0.0026 in.)

    If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.


7. REMOVE NO. 3 TRANSMISSION CLUTCH HUB SHAFT SNAP RING

  1. D033652
    Using 2 screwdrivers and a hammer, tap out the snap ring.

    HINT:
    Use a shop rag or a piece of cloth to prevent the snap ring from flying off.


8. REMOVE 6TH GEAR

  1. D033653E02
    Using SST and a press, remove the No. 3 transmission clutch hub, hub sleeve, synchronizer ring and 6th gear from the input shaft.
    SST
    09950-00020  
    09950-70010   (09951-07200)
    09950-60010   (09951-00300)

    NOTICE:
    1. Do not tighten SST excessively.
    2. Support the input shaft by hand so that it does not fall off.


9. REMOVE 6TH GEAR NEEDLE ROLLER BEARING

  1. F051087
    Remove the 6th gear needle roller bearing from the input shaft.


10. REMOVE SPACER

  1. F051088
    Remove the spacer from the input shaft.


11. REMOVE GEAR THRUST WASHER SHAFT SNAP RING

  1. D033654
    Using a snap ring expander, remove the snap ring from the input shaft.


12. REMOVE 3RD GEAR THRUST WASHER

  1. F051090
    Remove the 3rd gear thrust washer from the input shaft.


13. REMOVE 3RD GEAR

  1. F051091
    Remove the 3rd gear from the input shaft.


14. REMOVE STRAIGHT PIN

  1. C126548
    Remove the straight pin from the input shaft.


15. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

  1. F051093
    Remove the 3rd gear needle roller bearing from the input shaft.


16. REMOVE SPACER

  1. F051094
    Remove the spacer from the input shaft.


17. REMOVE NO. 2 SYNCHRONIZER RING SET

  1. F051095
    Remove the No. 2 synchronizer ring set from the input shaft.


18. REMOVE NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING

  1. D033657
    Using a snap ring expander, remove the snap ring from the input shaft.


19. REMOVE 4TH GEAR

  1. D033658E02
    Using SST and a press, remove the No. 2 transmission clutch hub, hub sleeve, synchronizer ring and 4th gear from the input shaft.
    SST
    09950-00020  

    NOTICE:
    Support the input shaft by hand so that it does not fall off.


20. REMOVE 4TH GEAR NEEDLE ROLLER BEARING

  1. F051098
    Remove the 4th gear needle roller bearing from the input shaft.


21. REMOVE INPUT SHAFT FRONT BEARING SNAP RING

  1. D033659
    Using 2 screwdrivers and a hammer, tap out the snap ring.

    HINT:
    Use a shop rag or a piece of cloth to prevent the snap ring from flying off.


22. REMOVE INPUT SHAFT FRONT BEARING

  1. D033660E02
    Using SST and a press, remove the input shaft front bearing from the input shaft.
    SST
    09950-00020  

    NOTICE:
    Support the input shaft by hand so that it does not fall off.


23. REMOVE NO. 2 TRANSMISSION CLUTCH HUB

  1. C126549E01
    Remove the clutch hub, 3 synchromesh shifting keys, 3 balls and 3 springs from the hub sleeve.

    HINT:
    Use a shop rag or a piece of cloth to prevent the ball and spring from flying off.


24. REMOVE NO. 3 TRANSMISSION CLUTCH HUB

  1. Perform the same procedures as for the No. 2 transmission clutch hub.

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