Manual Transmission Assembly Removal

Transmission. Lexus Is250, Is220D. Gse20 Ale20
Ra62 Manual Transmission. Lexus Is250, Is220D. Gse20 Ale20

  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY

  3. REMOVE REAR CONSOLE PANEL SUB-ASSEMBLY

  4. REMOVE FRONT CONSOLE PANEL SUB-ASSEMBLY

  5. REMOVE FRONT ASH RECEPTACLE SUB-ASSEMBLY

  6. REMOVE CONSOLE BOX REGISTER ASSEMBLY

  7. REMOVE CONSOLE BOX

  8. REMOVE NO. 2 CONSOLE BOX DUCT

  9. REMOVE NO. 1 SHIFT AND SELECT LEVER BOOT

  10. REMOVE SHIFT LEVER CAP

  11. REMOVE ENGINE UNDER COVER

  12. REMOVE NO. 2 ENGINE UNDER COVER

  13. DRAIN MANUAL TRANSMISSION OIL

  14. REMOVE NO. 1 REAR FLOOR PANEL BRACE

  15. REMOVE FRONT CENTER FLOOR BRACE

  16. DISCONNECT HEATED OXYGEN SENSOR

  17. REMOVE FRONT EXHAUST PIPE ASSEMBLY

  18. REMOVE FRONT FLOOR NO. 1 HEAT INSULATOR

  19. REMOVE OUTSIDE AIR GUIDE PLATE RH

  20. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

  21. REMOVE ENGINE UNDER COVER AIR GUIDE BRACKET

  22. REMOVE STARTER ASSEMBLY

  23. SEPARATE CLUTCH ACCUMULATOR ASSEMBLY

  24. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY

  25. DISCONNECT GROUND CABLE

  26. SEPARATE WIRE HARNESS

  27. REMOVE NO. 1 CLUTCH HOUSING COVER

  28. REMOVE NO. 2 CLUTCH HOUSING COVER

  29. SEPARATE CLUTCH COVER ASSEMBLY

  30. SEPARATE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY

  31. REMOVE FLOOR SHIFT LEVER ASSEMBLY

  32. SUPPORT MANUAL TRANSMISSION ASSEMBLY

  33. REMOVE ENGINE REAR MOUNTING MEMBER

  34. REMOVE MANUAL TRANSMISSION ASSEMBLY

  35. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

  36. REMOVE CLUTCH DISC ASSEMBLY

  37. REMOVE CLUTCH COVER ASSEMBLY

  38. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

  39. REMOVE TRANSMISSION UPPER COVER SUB-ASSEMBLY

Manual Transmission Assembly -- Removal



1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL


2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Turn the shift lever knob counterclockwise and remove the shift lever knob sub-assembly.



3. REMOVE REAR CONSOLE PANEL SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Open the snap.



    Lexus Is250, Is220D. Gse20 Ale20
  1. Disengage the 7 claws and 2 clips, and then remove the rear console panel sub-assembly.



4. REMOVE FRONT CONSOLE PANEL SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Open the snap.



    Lexus Is250, Is220D. Gse20 Ale20
  1. Pull the front console panel sub-assembly in the direction indicated by the arrow to disengage the 6 clips and remove it.



5. REMOVE FRONT ASH RECEPTACLE SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 screws <F>.



    Lexus Is250, Is220D. Gse20 Ale20
  1. Pull the front ash receptacle sub-assembly in the direction indicated by the arrow to disconnect the connectors and remove it.



6. REMOVE CONSOLE BOX REGISTER ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the rear ash receptacle assembly.

  1. Disengage the 2 claws and 4 clips, and then remove the console box register assembly.



7. REMOVE CONSOLE BOX


    Lexus Is250, Is220D. Gse20 Ale20.Ra62 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Remove the 2 bolts <C>.

  1. Disconnect the 2 connectors.

  1. Disengage the 2 clamps.



    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 bolts <C>.

  1. Disconnect the connector.



    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 bolts <C>.



    Lexus Is250, Is220D. Gse20 Ale20
  1. Disengage the 2 claws and 2 clips, and then remove the console box.



8. REMOVE NO. 2 CONSOLE BOX DUCT


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the clip and No. 2 console box duct.



9. REMOVE NO. 1 SHIFT AND SELECT LEVER BOOT


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 4 bolts and No. 1 shift and select lever boot.



10. REMOVE SHIFT LEVER CAP


    Lexus Is250, Is220D. Gse20 Ale20
  1. Turn over the shift lever dust cover.

  1. Remove the 4 bolts and shift lever cap.



11. REMOVE ENGINE UNDER COVER


12. REMOVE NO. 2 ENGINE UNDER COVER


13. DRAIN MANUAL TRANSMISSION OIL


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the drain plug and gasket, and drain the transmission oil.

  1. Install a new gasket and the drain plug.

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


14. REMOVE NO. 1 REAR FLOOR PANEL BRACE


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 4 bolts and rear No. 1 floor panel brace.



15. REMOVE FRONT CENTER FLOOR BRACE


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 4 bolts and front center floor brace .



16. DISCONNECT HEATED OXYGEN SENSOR


    Lexus Is250, Is220D. Gse20 Ale20.Ra62 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Remove the grommets of the heated oxygen sensors (BANK 1, BANK 2).



    Lexus Is250, Is220D. Gse20 Ale20.Ra62 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Using the SST, remove a oxygen sensors (BANK 1, BANK 2).

    SST
    09224-00010


17. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20.Ra62 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Remove the 4 bolts and 4 nuts.



    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 bolts and 2 compression springs from the tail exhaust pipe assembly.

  1. Remove the front exhaust pipe assembly and 3 gaskets.



18. REMOVE FRONT FLOOR NO. 1 HEAT INSULATOR


    Lexus Is250, Is220D. Gse20 Ale20.Ra62 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Remove the 4 nuts and front No. 1 floor heat insulator.



19. REMOVE OUTSIDE AIR GUIDE PLATE RH


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 4 nuts and outside air guide plate RH.



20. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20.Ra62 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Put matchmarks on both flanges.

  1. Remove the 4 nuts, bolts and washers.

    HINT:
    If the flange connection is hard to separate, temporarily tighten one nut only and evenly tap the flange with a brass bar and hammer to separate the propeller shaft assembly from the differential companion flange.


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 bolts and 2 center support bearing washers. (for automatic transmission)

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

  1. Separate the center support bearing.



    Lexus Is250, Is220D. Gse20 Ale20.Ra62 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Insert SST in the transmission to prevent oil leakage.

    SST
    09325-40010
    NOTICE:
    Be careful not to damage the oil seal.


21. REMOVE ENGINE UNDER COVER AIR GUIDE BRACKET


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 bolts and engine under cover air guide bracket.



22. REMOVE STARTER ASSEMBLY
(Click here)


23. SEPARATE CLUTCH ACCUMULATOR ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 bolts and 2 nuts, and separate the clutch accumulator assembly.



24. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 bolts and separate the clutch release cylinder assembly.



25. DISCONNECT GROUND CABLE


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the bolt and disconnect the ground cable.



26. SEPARATE WIRE HARNESS


    Lexus Is250, Is220D. Gse20 Ale20
  1. Disconnect the back-up lamp switch connector and separate the wire harness.



27. REMOVE NO. 1 CLUTCH HOUSING COVER


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 4 bolts and No. 1 clutch housing cover.



28. REMOVE NO. 2 CLUTCH HOUSING COVER


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 4 bolts and No. 2 clutch housing cover.



29. SEPARATE CLUTCH COVER ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20.Ra62 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Put matchmarks on the clutch cover assembly and the flywheel sub-assembly.

  1. Loosen each set bolt one turn at a time until spring tension is released.

  1. Remove the 6 bolts and separate the clutch cover assembly.



30. SEPARATE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 nuts and separate the floor shift control shift lever retainer sub-assembly.



31. REMOVE FLOOR SHIFT LEVER ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Turn over the shift and select lever boot.

  1. Using a screwdriver, remove the E-ring and floor shift lever assembly.

  1. Remove the washer from the floor shift lever assembly.



    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 bushings from the floor shift lever assembly.



32. SUPPORT MANUAL TRANSMISSION ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Support the manual transmission with a transmission jack.



33. REMOVE ENGINE REAR MOUNTING MEMBER


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 4 bolts, 4 nuts and engine rear mounting member.



34. REMOVE MANUAL TRANSMISSION ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 9 bolts and manual transmission assembly.



35. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY
  1. Remove the clutch release fork sub-assembly from the transmission unit.



36. REMOVE CLUTCH DISC ASSEMBLY
NOTICE:
Keep the lining part of the clutch disc assembly, the pressure plate and surface of the flywheel sub-assembly away from oil and foreign matter.


37. REMOVE CLUTCH COVER ASSEMBLY


38. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 4 bolts and rear No. 1 engine mounting insulator.



39. REMOVE TRANSMISSION UPPER COVER SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 bolts and transmission upper cover sub-assembly.