Part No.	Thickness: mm (in.)	Mark
90520-31026	2.65 to 2.70 (0.1043 to 0.1063)	A
90520-31027	2.70 to 2.75 (0.1063 to 0.1083)	B
90520-31028	2.75 to 2.80 (0.1083 to 0.1102)	C
90520-31029	2.80 to 2.85 (0.1102 to 0.1122)	D
90520-31030	2.85 to 2.90 (0.1122 to 0.1142)	E
90520-31031	2.90 to 2.95 (0.1142 to 0.1161)	F

Using a brass bar and hammer, install the snap ring onto the input shaft.

3. INSTALL NO. 2 TRANSMISSION CLUTCH HUB (for 3rd - 4th Gear)

Apply a light coat of gear oil to the sleeve and hub.

Install the clutch hub sleeve onto the No. 2 transmission clutch hub.

Install the 3 shifting keys, 3 shifting key springs, and 3 balls onto the clutch hub.

NOTICE:

Take care to prevent the ball from flying off.

HINT:

Make sure that the No. 2 transmission clutch hub faces the correct direction as shown in the illustration.

4. INSTALL NO. 2 TRANSMISSION CLUTCH HUB (for 5th - 6th Gear)

Apply a light coat of gear oil to the sleeve and hub.

Install the clutch hub sleeve onto the No. 3 transmission clutch hub.

Install the 3 shifting keys, 3 shifting key springs, and 3 balls onto the clutch hub.

NOTICE:

Take care to prevent the ball from flying off.

HINT:

Make sure that the No. 2 transmission clutch hub faces the correct direction as shown in the illustration.

5. INSTALL 4TH GEAR NEEDLE ROLLER BEARING

Coat the 4th gear needle roller bearing with gear oil, then install it onto the input shaft.

6. INSTALL 4TH GEAR

Coat the 4th gear and No. 3 synchronizer ring with gear oil, then install them onto the input shaft.

Using SST and a press, install the No. 2 transmission clutch hub onto the input shaft.

SST
09308-14010

HINT:

Align the convex portion of the synchronizer ring with the groove of the clutch hub.

Install the clutch hub and confirm that the gear and synchronizer ring move smoothly.

7. INSTALL NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING

Select a snap ring that will allow minimum axial play.

Standard clearance:
0.1 mm (0.004 in.) or less

Snap ring thickness:

Part No.	Thickness: mm (in.)	Mark
90520-42012	1.80 to 1.85 (0.0709 to 0.0728)	A
90520-42013	1.85 to 1.90 (0.0728 to 0.0748)	B
90520-42014	1.90 to 1.95 (0.0748 to 0.0768)	C
90520-42015	1.95 to 2.00 (0.0768 to 0.0787)	D
90520-42016	2.00 to 2.05 (0.0787 to 0.0807)	E
90520-42017	2.05 to 2.10 (0.0807 to 0.0827)	F
90520-42018	2.10 to 2.15 (0.0827 to 0.0846)	G

Using a snap ring expander, install the snap ring onto the input shaft.

8. INSTALL NO. 2 SYNCHRONIZER RING SET

Coat the No. 2 synchronizer ring set with gear oil, then install it onto the input shaft.

9. INSTALL SPACER

Coat the spacer with gear oil, and install it onto the input shaft.

10. INSTALL 3RD GEAR NEEDLE ROLLER BEARING

Coat the 3rd gear needle roller bearing with gear oil, and install it onto the input shaft.

11. INSTALL STRAIGHT PIN

Install the straight pin onto the input shaft.

12. INSTALL 3RD GEAR

Coat the 3rd gear with gear oil, and install it onto the input shaft.

13. INSTALL 3RD GEAR THRUST WASHER

Coat the 3rd gear thrust washer with gear oil, and install it onto the input shaft.

HINT:

Align the straight pin with the groove of the gear thrust washer and install it.

14. INSTALL GEAR THRUST WASHER SHAFT SNAP RING

Select a snap ring that will allow minimum axial play.

Standard clearance:
0.1 mm (0.004 in.) or less

Snap ring thickness:

Part No.	Thickness: mm (in.)	Mark
90520-39026	2.07 to 2.12 (0.0815 to 0.0835)	A
90520-39027	2.12 to 2.17 (0.0835 to 0.0854)	B
90520-39028	2.17 to 2.22 (0.0854 to 0.0874)	C
90520-39029	2.22 to 2.27 (0.0874 to 0.0894)	D
90520-39030	2.27 to 2.32 (0.0894 to 0.0913)	E
90520-39031	2.32 to 2.37 (0.0913 to 0.0933)	F

Using a snap ring expander, install the snap ring onto the input shaft.

15. INSTALL SPACER

Coat the spacer with gear oil, and install it onto the input shaft.

16. INSTALL 6TH GEAR NEEDLE ROLLER BEARING

Coat the 6th gear needle roller bearing with gear oil, and install it onto the input shaft.

17. INSTALL 6TH GEAR

Install the 6th gear onto the input shaft.

Install the synchronizer ring onto the input shaft.

Using SST and a press, install the clutch hub onto the input shaft.

SST
09309-37010
09950-00020

Install the clutch hub and confirm that the gear and synchronizer ring move smoothly.

18. INSTALL TRANSMISSION CLUTCH HUB NO. 3 SHAFT SNAP RING

Select a snap ring that will allow minimum axial play.

Standard clearance:
0.1 mm (0.004 in.) or less

Snap ring thickness:

Part No.	Thickness: mm (in.)	Mark
90520-33022	2.10 to 2.15 (0.0827 to 0.0847)	A
90520-33023	2.15 to 2.20 (0.0847 to 0.0866)	B
90520-33024	2.20 to 2.25 (0.0866 to 0.0886)	C
90520-33025	2.25 to 2.30 (0.0886 to 0.0906)	D
90520-33026	2.30 to 2.35 (0.0906 to 0.0925)	E
90520-33027	2.35 to 2.40 (0.0925 to 0.0945)	F
90520-33028	2.40 to 2.45 (0.0945 to 0.0965)	G

Using a brass bar and a hammer, install the snap ring onto the input shaft.

19. INSPECT 6TH GEAR THRUST CLEARANCE

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 not as specified, replace the defective gear, thrust washer, or shaft.

20. INSPECT 3RD GEAR THRUST CLEARANCE

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 not as specified, replace the defective gear, thrust washer, clutch hub, or shaft.

21. INSPECT 4TH GEAR THRUST CLEARANCE

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 not as specified, replace the defective gear, clutch hub, or shaft.

22. INSPECT 6TH GEAR RADIAL CLEARANCE

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 not as specified, replace the defective gear, needle roller bearing, or shaft.

23. INSPECT 3RD GEAR RADIAL CLEARANCE

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 not as specified, replace the defective gear, needle roller bearing, or shaft.

24. INSPECT 4TH GEAR RADIAL CLEARANCE

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 not as specified, replace the defective gear, needle roller bearing, or shaft.

LEXUS IS250, IS220d / GSE20 ALE20

RA63 MANUAL TRANSMISSION

Lexus IS250 IS220d GSE20 ALE20

INPUT SHAFT