Lexus IS250 IS220d GSE20 ALE20 - A960E AUTOMATIC TRANSMISSION

AUTOMATIC TRANSMISSION UNIT - REASSEMBLY

1. BEARING POSITION

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

MarkFront Race Diameter
Inside/Outside
Thrust Bearing Diameter
Inside/Outside
Rear Race Diameter
Inside/Outside
A74.2 mm (2.921 in.) /87.7 mm (3.453 in.)71.9 mm (2.831 in.) /85.6 mm (3.370 in.)-
B34.9 mm (1.374 in.) /50.8 mm (2.0 in.)38.6 mm (1.520 in.) /53.1 mm (2.091 in.)-
C-58.5 mm (2.303 in.) /73.5 mm (2.894 in.)-
D--55.2 mm (2.173 in.) /71.2 mm (2.803 in.)
E29.6 mm (1.165 in.) /44.9 mm (1.768 in.)27.8 mm (1.095 in.) /43.85 mm (1.726 in.)27.8 mm (1.095 in.) /43.7 mm (1.721 in.)
F19.0 mm (0.748 in.) /35.0 mm (1.378 in.)20.8 mm (0.819 in.) /38.5 mm (1.516 in.)-
G43.3 mm (1.705 in.) /56.7 mm (2.232 in.)40.6 mm (1.598 in.) /58.0 mm (2.284 in.)-
H37.0 mm (1.457 in.) /51.2 mm (2.016 in.)33.5 mm (1.319 in.) /48.0 mm (1.890 in.)-
I37.0 mm (1.457 in.) /51.2 mm (2.016 in.)36.1 mm (1.421 in.) /52.5 mm (2.067 in.)36.1 mm (1.421 in.) /51.0 mm (2.007 in.)
2. INSTALL NO. 4 BRAKE PISTON
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Coat 2 new O-rings with ATF, and install them to the brake reaction sleeve.

Coat 2 new O-rings with ATF, and install them to the No. 4 brake piston.

Install the No. 4 brake piston to the reaction sleeve.

  • NOTICE:
  • Be careful not to damage the 4 O-rings.
3. INSTALL BRAKE REACTION SLEEVE
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

With the No. 4 brake piston underneath (the rear side), install the brake reaction sleeve and the No. 4 brake piston to the transmission case.

  • NOTICE:
  • Be careful not to damage the O-rings.
4. INSTALL 1ST AND REVERSE BRAKE PISTON
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Coat a new O-ring with ATF.

Install the O-ring on the 1st and reverse brake piston.

With the spring seat of the piston facing upwards (the front side), place the piston in the transmission case.

  • NOTICE:
  • Be careful not to damage the O-ring.
5. INSTALL 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

Place the brake return spring onto the brake piston.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Place SST on the brake return spring, and compress the return spring.

  • SST
  • 09350-30020(09350-07050)

Using the SST, install the snap ring.

  • SST
  • 09350-30020(09350-07070)
6. INSTALL BRAKE APPLY TUBE
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the brake apply tube with its protruding part fitting into the groove of the transmission case as shown in the illustration.

7. INSTALL REAR PLANETARY GEAR ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the thrust needle roller bearing.

  • Thrust needle roller bearing diameter:
  • InsideOutside
    Thrust needle roller bearing40.6 mm (1.598 in.)58.0 mm (2.284 in.)
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the thrust needle roller bearing.

Coat the No. 9 thrust bearing race and thrust bearing race with petroleum jelly, and install them onto the rear planetary gear.

  • Bearing and race diameter:
  • InsideOutside
    Bearing20.8 mm (0.819 in.)38.5 mm (1.516 in.)
    Thrust bearing Race19.0 mm (0.748 in.)35.0 mm (1.378 in.)
    No. 9 thrust bearing Race43.3 mm (1.705 in.)56.7 mm (2.232 in.)
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the rear planetary gear assembly.

8. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Make sure that the 1st and reverse brake piston moves smoothly when pulling and releasing the compressed air gun lever while applying compressed air into the transmission case.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using vernier calipers, measure the level difference (dimension A) between the upper surface of the brake apply tube and the hitting surface of the No. 4 brake flange at both ends across the 1st and reverse brake piston diameter, and calculate the average.

  • NOTICE:
  • The 1st and reverse brake piston must be securely installed to the end face of the transmission case.
  • HINT:
  • Dimension A = 23.32 to 24.18 mm (0.9181 to 0.952 in.)
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using vernier calipers, measure the thickness (dimension B) of the brake flanges, the 4 No. 4 brake plates and the 5 No. 4 brake discs altogether the both ends across a diameter, and calculate the average.

  • HINT:
  • Dimension B = 23.64 to 26.00 mm (0.9307 to 1.0236 in.)
  • Pack Clearance = Dimension A - Dimension B - 0.18 mm (0.0071 in.) + 1.8 mm (0.071 in.)
  • Pack Clearance:
  • 0.5 to 0.8 mm (0.0197 to 0.0315 in.)

If the pack clearance is outside the standard range, select and install a brake flange that brings the pack clearance to be within the standard range.

  • HINT:
  • There are 8 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.
  • Thickness H:
  • NO.Thickness HNO.Thickness H
    00 mm (0 in.)80.8 mm (0.03150 in.)
    20.2 mm (0.00787 in.)101.0 mm (0.03937 in.)
    40.4 mm (0.01575 in.)121.2 mm (0.04724 in.)
    60.6 mm (0.02362 in.)141.4 mm (0.05512 in.)
9. INSTALL NO. 4 BRAKE DISC
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the 4 plates, the 5 discs and the 2 flanges.

  • Install in order:
  • P = Plate, D = Disc, F = Flange
  • F - D - P - D - P - D - P - D - P - D - F
10. INSTALL BRAKE PLATE STOPPER SPRING
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the brake plate stopper spring.

11. INSTALL REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the No. 8 thrust bearing race, the thrust needle roller bearing, the No. 7 thrust bearing race and the planetary ring gear flange to the intermediate shaft.

  • Bearing and race diameter:
  • InsideOutside
    No. 7 thrust bearing race29.6 mm (1.165 in.)44.9 mm (1.768 in.)
    Thrust needle roller bearing27.8 mm (1.095 in.)43.85 mm (1.726 in.)
    No. 8 thrust bearing race27.8 mm (1.095 in.)43.7 mm (1.721 in.)
12. INSTALL NO. 3 ONE WAY CLUTCH ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the No. 3 one way clutch assembly and the one way clutch inner race to the intermediate shaft.

13. INSTALL INTERMEDIATE SHAFT
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the intermediate shaft with the No. 3 one way clutch assembly to the case.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using SST, install the snap ring.

  • SST
  • 09350-30020(09350-07050,09350-07060)
14. INSTALL CENTER PLANETARY GEAR ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the center planetary gear assembly and the planetary sun gear to the case.

Coat the thrust bearing race with petroleum jelly, and install it onto the center planetary gear assembly.

  • Race diameter:
  • InsideOutside
    Race55.2 mm (2.173 in.)71.2 mm (2.803 in.)
15. INSTALL NO. 2 BRAKE PISTON
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Coat 2 new O-rings with ATF, and install them to the No. 2 brake piston.

Press the No. 2 brake piston into the No. 2 brake cylinder.

  • NOTICE:
  • Be careful not to damage the 2 O-rings.

Install the No. 2 brake piston to the case.

  • HINT:
  • Install the No. 2 brake cylinder so that the projection protrudes from the upside of the transmission case.
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Check that the oil pressure apply hole of the No. 2 brake cylinder aligns with the oil pressure apply hole of the transmission case.

16. INSTALL NO. 2 BRAKE DISC
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the 2 flanges, 3 plates, 4 discs and brake piston return spring.

  • Install in order:
  • P = Plate, D = Disc, F = Flange
  • F -D - P - D - P - D - P - D - F
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using SST, a screwdriver and a press, install the No. 2 brake spring snap ring.

  • SST
  • 09351-40010(09351-04010,09351-04020,09351-04040,09351-04050)
17. INSPECT PISTON STROKE OF NO. 2 BRAKE PISTON

Inspect piston stroke of the No. 2 brake piston.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Make sure that the No. 2 brake piston moves smoothly when pulling and releasing the compressed air gun lever while applying compressed air into the transmission case.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using SST and a dial indicator, measure the moving distance (dimension A) of the clutch disc at both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.

  • SST
  • 09350-30020(09350-06120)
  • Piston stroke:
  • 0.6 to 0.9 mm (0.024 to 0.035 in.)

If the piston stroke is outside the standard range, select and install a brake flange that brings the piston stroke within the standard range.

  • HINT:
  • There are 8 types of flanges that can be used to adjust the piston stroke. Select one with the most appropriate thickness.
  • Flange thickness:
  • No.Thickness
    02.0 mm (0.079 in.)
    12.1 mm (0.083 in.)
    22.2 mm (0.087 in.)
    32.3 mm (0.091 in.)
    42.4 mm (0.094 in.)
    52.5 mm (0.098 in.)
    62.6 mm (0.102 in.)
    72.7 mm (0.106 in.)
18. INSTALL NO. 1 BRAKE PISTON
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Coat 2 new O-rings with ATF, and install them on the No. 1 brake piston.

Press the No. 1 brake piston into the No. 1 brake cylinder.

  • NOTICE:
  • Be careful not to damage the 2 O-rings.
19. INSTALL BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the brake piston return spring and the No. 1 brake piston with the No. 1 brake cylinder to the transmission case.

  • HINT:
  • Install the No. 1 brake cylinder so that the projection protrudes from the upside of the transmission case.
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Check that the oil pressure apply hole of the No. 2 brake cylinder aligns with the oil pressure apply hole of the transmission case.

20. INSTALL BRAKE PISTON RETURN SPRING SNAP RING
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using SST, a screwdriver and a press, install the brake piston return spring snap ring.

  • SST
  • 09351-40010(09351-04010,09351-04030,09351-04040,09351-04050)
21. INSTALL CENTER PLANETARY RING GEAR

Install the thrust needle roller bearing to the front planetary ring gear flange.

  • Thrust needle roller bearing diameter:
  • InsideOutside
    Thrust needle roller bearing58.5 mm (2.303 in.)73.5 mm (2.894 in.)
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the center planetary ring gear flange to the center planetary ring gear.

Using a screwdriver, install the snap ring.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the center planetary ring gear to the front planetary ring gear.

Using a screwdriver, install the snap ring.

  • NOTICE:
  • Install the snap ring to the ring gear so that the both ends of the snap ring come to the center of a protrusion on the ring gear.
22. INSTALL FRONT PLANETARY RING GEAR
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the front planetary ring gear to the case.

23. INSTALL FRONT PLANETARY GEAR ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the thrust needle roller bearing and the thrust washer.

Coat the thrust bearing race with petroleum jelly, and install it onto the front planetary ring gear.

  • Thrust needle roller bearing and race diameter:
  • InsideOutside
    Bearing 38.6 mm (1.520 in.)53.1 mm (2.091 in.)
    Race34.9 mm (1.374 in.)50.8 mm (2.0 in.)
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the front planetary gear assembly and the one way clutch inner race to the case.

24. INSPECT PISTON STROKE OF BRAKE PISTON

Inspect piston stroke of the No. 1 brake piston.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Make sure the No. 1 brake piston moves smoothly when pulling and releasing the compressed air gun lever while applying compressed air into the transmission case.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using vernier calipers, measure the level difference (dimension A) between the upper surface of the No. 1 brake piston and the hitting surface of the No. 1 brake flange at both ends across the No. 1 brake piston diameter.

Using vernier calipers, measure the thickness (dimension B) of the brake flange, the No. 1 brake plates and the 3 No. 1 brake discs altogether at the both ends across a diameter, and calculate the average.

  • HINT:
  • Dimension A = 15.27 to 15.92 mm (0.60118 to 0.62677 in.)
  • Dimension B = 14.50 to 15.54 mm (0.57087 to 0.61180 in.)
  • Piston stroke = Dimension A - Dimension B
  • Piston stroke:
  • 0.42 to 0.72 mm (0.017 to 0.028 in.)

If the piston stroke is outside the specified range, parts may have been assembled incorrectly, so check and reassemble them again.


If the piston stroke is not still outside the specified range, select another flange that brings the piston stroke within the specified range.


  • HINT:
  • There are 4 different thicknesses for the flange.
  • Flange thickness:
  • No.Thickness
    02.0 mm (0.079 in.)
    12.2 mm (0.087 in.)
    22.4 mm (0.094 in.)
    32.6 mm (0.102 in.)
25. INSTALL NO. 1 BRAKE DISC
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the 3 plates, the 3 discs and the flange.

  • Install in order:
  • P = Plate, D = Disc, F = Flange
  • F - D - P - D - P - D - P
26. INSTALL 2ND BRAKE CYLINDER
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the 2nd brake cylinder to the case.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Check that the oil pressure apply hole of the 2nd brake cylinder aligns with the oil pressure apply hole of the transmission case.

27. INSTALL ONE WAY CLUTCH ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the one way clutch assembly and the thrust washer to the case.

28. INSTALL 2ND BRAKE PISTON HOLE SNAP RING
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using SST, install the snap ring.

  • SST
  • 09350-30020(09350-07060)
29. INSTALL 2ND BRAKE DISC SET
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the flange, the 3 discs and the 3 plates to the case.

  • Install in order:
  • P = Plate, D = Disc, F = Flange
  • F - D - P - D - P - D - P
30. INSTALL NO. 3 BRAKE SNAP RING
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using a screwdriver, install the snap ring.

  • SST
  • 09350-30020(09350-07060)
31. INSTALL NO. 2 ONE WAY CLUTCH ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the No. 2 one way clutch assembly and No. 2 washer to the clutch drum and input shaft.

32. INSPECT NO. 2 ONE WAY CLUTCH ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Hold the reverse clutch hub and turn the No. 2 one way clutch assembly.

Check that the No. 2 one way clutch assembly turns freely clockwise and locks counterclockwise.


If there is a problem with the one way clutch, replace the one way clutch.

33. INSTALL CLUTCH DRUM AND INPUT SHAFT
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the 2 thrust needle roller bearings and thrust washer.

Coat the race and washer with petroleum jelly and install them onto the clutch drum and input shaft assembly.

  • Thrust needle roller bearing and diameter:
  • InsideOutside
    Thrust needle roller bearing A71.9 mm (2.831 in.)85.6 mm (3.370 in.)
    Bearing Race37.0 mm (1.457 in.)51.2 mm (2.016 in.)
    Thrust needle roller bearing B33.5 mm (1.319 in.)48.0 mm (1.890 in.)
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the clutch drum and input shaft into the transmission case.

34. INSTALL OIL PUMP ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the No. 1 thrust bearing race to the front oil pump.

InsideOutside
Race74.2 mm (2.921 in.)87.7 mm (3.453 in.)

Coat a new O-ring with ATF, and install it around the oil pump assembly.

Place the oil pump through the input shaft, and align the bolt holes of the oil pump assembly with the transmission case.

Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings into the overdrive direct clutch drum.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the 9 bolts.

  • Torque:
  • 21 N*m{ 214 kgf*cm, 15 ft.*lbf}
35. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using SST and a hammer, drive in 2 new oil seals.

  • SST
  • 09350-30020(09350-07110)

Coat the oil seal lips with MP grease.

36. INSPECT INDIVIDUAL PISTON OPERATION
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Check the operating sound while applying compressed air into the oil holes indicated in the illustration.

  • HINT:
  • When inspecting the O/D direct clutch, check the operating sound with the C3 accumulator piston hole closed.
  • If there is no sound, disassemble and check the installation condition of the parts.

No. 2 Clutch (C2)

No. 4 Clutch (C4)

No. 3 Clutch (C3)

No. 1 Clutch (C1)

No. 3 Brake (B3)

No. 1 Brake (B1)

No. 2 Brake (B2)

No. 4 Brake (B4)

37. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install a new spacer to the manual valve lever.

Install the manual valve lever shaft to the transmission case through the manual valve lever.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using a hammer, drive in a new spring pin.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Align the manual valve lever indentation with the spacer hole, and stake them together with the punch.

Make sure that the shaft rotates smoothly.

38. INSTALL PARKING LOCK PAWL SHAFT
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install a new E-ring to the shaft.

Install a new parking lock pawl, the shaft and the spring.

39. INSTALL PARKING LOCK ROD SUB-ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Connect the parking lock rod to the manual valve lever.

40. INSTALL PARKING LOCK PAWL BRACKET
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Place the parking lock pawl bracket onto the transmission case and tighten the 3 bolts.

  • Torque:
  • 7.3 N*m{ 74 kgf*cm, 65 in.*lbf}
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Shift the manual valve lever to the P position, and confirm that the planetary gear is correctly locked up by the lock pawl.

41. INSTALL B-1 ACCUMULATOR VALVE
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the spring and the accumulator valve to the hole.

  • B-1 accumulator spring:
  • Free lengthOuter diameterColor
    46.36 mm (1.8252 in.)17.10 mm (0.6732 in.)Natural
42. INSTALL C-3 ACCUMULATOR PISTON
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Coat 2 new O-rings with ATF, and install them to the piston.

Install the 2 springs and the accumulator piston to the hole.

  • C-3 accumulator spring:
  • Inner spring:
    Free lengthOuter diameterColor
    44.0 mm (1.732 in.)14.0 mm (0.551 in.)Yellow
  • Outer spring:
    Free lengthOuter diameterColor
    76.65 mm (3.0178 in.)20.10 mm (0.7913 in.)White
43. INSTALL B-3 ACCUMULATOR PISTON
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Coat 2 new O-rings with ATF, and install them to the piston.

Install the spring and the accumulator piston to the hole.

  • Accumulator spring:
  • Free lengthOuter diameterColor
    64.5 mm (2.539 in.)19.5 mm (0.768 in.)Orange
44. INSTALL C-2 ACCUMULATOR PISTON
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Coat 2 new O-rings with ATF, and install them to the piston.

Install the spring and the accumulator piston to the hole.

  • Accumulator spring:
  • Free lengthOuter diameterColor
    65.07 mm (2.5618 in.)16.2 mm (0.6378 in.)Pink
45. INSTALL CHECK BALL BODY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the check ball body and the spring.

46. INSTALL BRAKE DRUM GASKET
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the 3 new brake drum gaskets.

47. INSTALL TRANSAXLE CASE GASKET
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the 3 new transaxle case gaskets.

48. INSTALL TRANSMISSION VALVE BODY ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Align the groove of the manual valve lever with the pin of the manual valve.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the 19 bolts.

  • Torque:
  • 11 N*m{ 110 kgf*cm, 8 ft.*lbf}
  • HINT:
  • Each bolt length is indicated below.
  • Bolt length:
  • Bolt A:
  • 25 mm (0.98 in.)
  • Bolt B:
  • 36 mm (1.42 in.)
  • Bolt C:
  • 45 mm (1.77 in.)
  • Bolt D:
  • 50 mm (1.97 in.)
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the detent spring and the detent spring cover with the bolt.

  • Torque:
  • 10 N*m{ 102 kgf*cm, 7 ft.*lbf}
49. INSTALL TRANSMISSION WIRE
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Coat a new O-ring with ATF.

Install the O-ring to the transmission wire.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the transmission wire harness.

Install the bolt.

  • Torque:
  • 5.4 N*m{ 55 kgf*cm, 48 in.*lbf}
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Connect the 9 solenoid connectors.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the ATF temperature sensor.

  • Torque:
  • 10 N*m{ 102 kgf*cm, 7 ft.*lbf}
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the clamp and the 2 bolts.

  • Torque:
  • Bolt A:
  • 6.4 N*m{ 65 kgf*cm, 57 in.*lbf}
  • Bolt B:
  • 10 N*m{ 102 kgf*cm, 7 ft.*lbf}
50. INSTALL VALVE BODY OIL STRAINER ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Coat a new O-ring with ATF, and install it to the valve body oil strainer assembly.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the oil strainer with the 4 bolts.

  • Torque:
  • 10 N*m{ 102 kgf*cm, 7 ft.*lbf}
51. INSTALL TRANSMISSION OIL CLEANER MAGNET
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the 3 transmission oil cleaner magnets.

52. INSTALL AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

Install a new gasket on the oil pan.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install and tighten the 20 bolts.

  • Torque:
  • 4.4 N*m{ 45 kgf*cm, 39 in.*lbf}

Install a new gasket and the drain plug.

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

Install a new gasket and the overflow plug.

  • Torque:
  • 20 N*m{ 204 kgf*cm, 15 ft.*lbf}
53. INSTALL AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL

Coat the lip of a new oil seal with MP grease.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using SST and a hammer, install a new oil seal until it fits with the extension housing.

  • SST
  • 09325-40010
  • Oil seal drive in depth:
  • 5.4 to 5.8 mm (0.213 to 0.228 in.)
54. INSTALL EXTENSION HOUSING DUST DEFLECTOR
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using SST and a press, install a new extension housing dust deflector.

  • SST
  • 09950-60020(09951-01030)
55. INSTALL EXTENSION (ATM) HOUSING SUB-ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the transmission case adapter radial ball bearing to the extension housing.

Using a snap ring pliers, install the snap ring.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the thrust needle roller bearing and the 2 bearing races.

Using a snap ring expander, install the snap ring.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using a feeler gauge, measure the clearance between the snap ring and the race.

  • Clearance:
  • 0.02 to 0.12 mm (0.0008 to 0.0047 in.)

If the clearance is outside the specified range, select another race that brings the clearance within the specified range.


  • HINT:
  • There are 12 different thicknesses for the race.
  • Flange thickness:
  • NO.ThicknessNO.Thickness
    13.80 mm (0.1496 in.)74.10 mm (0.1614 in.)
    23.85 mm (0.1516 in.)84.15 mm (0.1634 in.)
    33.90 mm (0.1535 in.)94.20 mm (0.1653 in.)
    43.95 mm (0.1555 in.)104.25 mm (0.1673 in.)
    54.00 mm (0.1575 in.)114.30 mm (0.1693 in.)
    64.05 mm (0.1594 in.)124.35 mm (0.1713 in.)

Clean the threads of the bolts and the case with white gasoline.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Apply FIPG to the extension housing as shown in the illustration.

  • FIPG:
  • Seal Packing 1281, THREE BOND 1281 or equivalent
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the extension housing with 6 new bolts.

  • Torque:
  • 34 N*m{ 345 kgf*cm, 25 ft.*lbf}
  • HINT:
  • Each bolt length is indicated below.
  • Bolt length:
  • Bolt A:
  • 45 mm (1.772 in.)
  • Bolt B:
  • 35 mm (1.378 in.)
56. INSTALL AUTOMATIC TRANSMISSION HOUSING
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Clean the threads of the bolts and the case with white gasoline.

Install the transmission housing with the 10 bolts.

  • Torque:
  • A {14 mm (0.551 in.) bolt}:
  • 34 N*m{ 347 kgf*cm, 25 ft.*lbf}
  • B {17 mm (0.669 in.) bolt}:
  • 57 N*m{ 581 kgf*cm, 42 ft.*lbf}
57. INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the breather tube.

Install the 2 bolts.

  • Torque:
  • 5.4 N*m{ 55 kgf*cm, 48 in.*lbf}
58. INSTALL TRANSMISSION REVOLUTION SENSOR
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Coat 2 new O-rings with ATF, and install them to the transmission revolution sensors.

Install the 2 transmission revolution sensors.

Install the 2 bolts.

  • Torque:
  • 5.4 N*m{ 55 kgf*cm, 48 in.*lbf}
59. INSTALL TRANSMISSION OIL COOLER
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Coat 2 new O-rings with ATF, and install them to the transmission oil cooler.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the transmission oil cooler with the 3 bolts.

  • Torque:
  • 21 N*m{ 214 kgf*cm, 16 ft.*lbf}
60. INSTALL PARK/NEUTRAL POSITION SWITCH ASSEMBLY
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the park/neutral position switch onto the manual valve lever shaft, and temporarily install the adjusting bolt.

Install a new lock washer. Install and tighten the nut.

  • Torque:
  • 6.9 N*m{ 70 kgf*cm, 61 in.*lbf}
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using the control shaft lever, turn the manual lever shaft back all the way and then forward 2 notches. It is now in neutral.

Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Align the neutral basic line with the switch groove as shown in the illustration, and tighten the adjusting bolt.

  • Torque:
  • 13 N*m{ 130 kgf*cm, 9 ft.*lbf}
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Using a screwdriver, bend the tabs of the lock washer.

  • HINT:
  • Bend at least 2 of the lock washer tabs.
61. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the control shaft lever RH, washer and the nut.

  • Torque:
  • 16 N*m{ 163 kgf*cm, 12 ft.*lbf}
62. INSTALL TRANSMISSION CASE COVER
Automatic Transmission Unit - Reassembly. A960E AUTOMATIC TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

Install the transmission case cover with the 2 bolts.

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