Check the contact surface between the engine and transmission, knock pins, and knock pin holes for foreign objects or burrs. If either is present, remove them using a shop rag, a piece of cloth, or compressed air.

When installing the transmission, do not allow the input shaft to hit the clutch disc plate.

Make sure that the knock pins are fully engaged and install the bolts with the transmission attached firmly to the engine.

Temporarily tighten bolt *1, fully tighten bolt *2, lift the rear end of the transmission, and fully tighten bolt *1 and the other bolts. Make sure that excessive force is not applied to the knock pins when lifting the rear end of the transmission.

4. INSTALL ENGINE REAR MOUNTING MEMBER

Install the engine rear mounting member with the 4 bolts and 4 nuts.

Torque:
Nut:
13 N*m{ 130 kgf*cm, 10 ft.*lbf}
Bolt:
26 N*m{ 265 kgf*cm, 19 ft.*lbf}

5. INSTALL FLOOR SHIFT LEVER ASSEMBLY

Install the 2 bushings to the shift lever assembly.

Install the washer to the floor shift lever assembly.

Install the shift lever assembly with a new E-ring.

Install the shift and select lever boot.

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

Install the floor shift control shift lever retainer sub-assembly with the 2 nuts.

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

7. CONNECT WIRE HARNESS

Install the wire harness bracket with the bolt.

Torque:
10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Connect the back-up light switch connector and install the wire harness.

8. CONNECT GROUND CABLE

Connect the ground cable with the bolt.

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

9. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY

10. INSTALL CLUTCH ACCUMULATOR ASSEMBLY

11. INSTALL STARTER ASSEMBLY

Install the starter assembly with the bolt and nut.

Torque:
64 N*m{ 650 kgf*cm, 47 ft.*lbf}

Connect the wire harness to terminal 30 and install the nut, and then attach the terminal cap.

Torque:
9.8 N*m{ 100 kgf*cm, 87 in.*lbf}

Connect the terminal 50 connector to the starter assembly.

Install the wire harness clamp bracket with the bolt.

Torque:
10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Connect the 2 wire harness clamps.

12. INSTALL ENGINE UNDER COVER AIR GUIDE BRACKET

Install the engine under cover air guide bracket with the 2 bolts.

Torque:
26 N*m{ 260 kgf*cm, 19 ft.*lbf}

13. INSTALL EXHAUST PIPE NO. 1 SUPPORT BRACKET SUB-ASSEMBLY

Install the exhaust pipe No. 1 support bracket sub-assembly with the 2 nuts.

Torque:
22 N*m{ 224 kgf*cm, 16 ft.*lbf}

14. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

Apply grease to the flexible coupling centering bushings.

Grease:
Molybdenum disulphide lithium base NLGI No. 2 or equivalent

Align the matchmarks on the transmission companion flange and flexible coupling.

Install and tighten the 3 bolts, 3 washers and 3 nuts.

Torque:
79 N*m{ 805 kgf*cm, 58 ft.*lbf}

NOTICE:

Be careful not to damage the flexible coupling centering bushing.

HINT:

The bolts should be installed from the propeller shaft side.

Align the matchmarks on the differential companion flange and flexible coupling.

Install and torque the 3 bolts, 3 washers and 3 nuts.

Torque:
79 N*m{ 805 kgf*cm, 58 ft.*lbf}

NOTICE:

Be careful not to damage the flexible coupling centering bushing.

HINT:

The bolts should be installed from the propeller shaft side.

Temporarily install the 2 center support bearing washers, 2 bolts and 2 center support bearing dampers.

NOTICE:

Install the center support bearing damper with the pink area facing downwards.

15. FULLY TIGHTEN NO. 1 CENTER SUPPORT BEARING

Adjust the dimension between the edge surface of the center support bearing and the edge surface of the cushion to 11.5 to 13.5 mm (0.4528 to 0.5315 in.) respectively as shown in the illustration.

Check that the center line of the bracket is perpendicular to the shaft axial direction.

Tighten the 2 bolts.

Torque:
49 N*m{ 500 kgf*cm, 36 ft.*lbf}

Using SST, tighten the adjusting nut.

SST
09922-10010

Torque:
When not using SST:
69 N*m{ 700 kgf*cm, 51 ft.*lbf}
When using SST:
51 N*m{ 520 kgf*cm, 38 ft.*lbf}

HINT:

Use a torque wrench with a fulcrum length of 345 mm (13.5 in.).

Use 2 of the same type of SST.

16. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE

Stabilize the propeller shaft and differential.

Turn the propeller shaft several times by hand to stabilize the center support bearing.

Check both the No. 2 and No. 3 joint angles.

Using SST, measure the installation angle of the intermediate shaft and propeller shaft.

SST
09370-50010

HINT:

The SST should be set directly on the bottom of the shaft.

Using SST, measure the installation angle of the differential.

Manual Transmission Assembly - Installation. RA63 MANUAL TRANSMISSION. Lexus IS250 IS220d GSE20 ALE20

SST
09370-50010

HINT:

Measure the installation angle by placing the SST in the positions shown in the illustration.

Calculate the No. 2 joint angle.

No. 2 joint angle:
A - B = -0°49' to -1°49'

A:
Intermediate shaft installation angle

B:
Propeller shaft installation angle

Calculate the No. 3 joint angle.

No. 3 joint angle:
B - C = 0°70' to 2°10'

B:
Propeller shaft installation angle

C:
Differential installation angle

HINT:

If the measured angle is not within the specified range, adjust it with the center support bearing washers.

Adjust the No. 2 joint angle.

Select the center support bearing washers for adjustment.

Adjustment washer
thickness mm (in.)
2 (0.0787)
4.5 (0.1772)
6.5 (0.2559)
9.0 (0.3543)
11.0 (0.4331)

NOTICE:

The 2 washers should be the same thickness.

17. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR

Install the front No. 1 floor heat insulator with the 4 nuts.

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

18. INSTALL OUTSIDE AIR GUIDE PLATE RH

Install the outside air guide plate RH with the 4 nuts.

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

19. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

Temporarily install the No. 1 manifold stay.

Temporarily install a new turbine outlet elbow gasket and exhaust manifold converter with the 3 nuts.

Temporarily install the 2 bolts and nut.

Tighten the 3 nuts (Pushing the manifold converter against the No. 1 manifold stay).

Torque:
25 N*m{ 255 kgf*cm, 18 ft.*lbf}

Tighten the 2 bolts and nut.

Torque:
56 N*m{ 571 kgf*cm, 41 ft.*lbf}

Temporarily install the No. 2 exhaust manifold stay with the 2 bolts and nut.

Tighten the 2 bolts (Pushing the No. 2 exhaust manifold stay against the manual transmission).

Torque:
56 N*m{ 571 kgf*cm, 41 ft.*lbf}

Tighten the nut.

Torque:
56 N*m{ 571 kgf*cm, 41 ft.*lbf}

Using pliers, slide the clip to install the No. 1 and No. 2 vacuum transmitting hose assembly.

HINT:

Make sure that the paint marks on the No. 1 and No. 2 vacuum transmitting hose assemblies and No. 1 and No. 2 vacuum pipes are aligned.

20. INSTALL FRONT EXHAUST PIPE ASSEMBLY

Using vernier calipers, measure the free length of the compression springs.

Minimum length:
38.5 mm (1.516 in.)

If the free length is less than the minimum, replace the compression spring.

Fully insert 2 new gaskets to the exhaust manifold converter and front exhaust pipe assembly by hand.

NOTICE:

Be careful with the installation direction of the gasket.

Do not reuse the gasket.

Do not damage the gasket.

To ensure a proper seal, do not use the tail exhaust pipe to force the gasket onto the front exhaust pipe.

HINT:

Using a plastic hammer, uniformly strike the gasket so that the gasket and front exhaust pipe are properly fit.

Install the front exhaust pipe assembly.

Install the 2 bolts and 2 compression springs.

Torque:
43 N*m{ 439 kgf*cm, 32 ft.*lbf}

NOTICE:

After installation, check that the clearance is almost the same at any point between the flanges of the tail exhaust pipe assembly and front exhaust pipe assembly.

Install the 2 bolts and 2 compression springs.

Torque:
43 N*m{ 439 kgf*cm, 32 ft.*lbf}

NOTICE:

After installation, check that the clearance is almost the same at any point between the flanges of the exhaust manifold converter and front exhaust pipe assembly.

21. INSTALL AIR FUEL RATIO SENSOR

Before installing the air fuel ratio sensor, twist the sensor wire counterclockwise 4 turns.

Using SST, install the air fuel ratio sensor to the front exhaust pipe.

SST
09224-00010

Torque:
44 N*m{ 449 kgf*cm, 33 ft.*lbf}

22. INSTALL FRONT CENTER FLOOR BRACE

Install the front center floor brace with the 4 bolts.

Torque:
7.4 N*m{ 75 kgf*cm, 65 in.*lbf}

23. INSTALL REAR NO. 1 FLOOR PANEL BRACE

Install the rear No. 1 floor panel brace with the 4 bolts.

Torque:
19 N*m{ 195 kgf*cm, 14 ft.*lbf}

24. INSTALL NO. 1 FLOOR UNDER COVER

25. INSTALL FRONT FLOOR COVER RH

26. INSTALL NO. 2 ENGINE UNDER COVER

27. INSTALL SHIFT LEVER CAP

Temporarily install the shift lever cap with the 4 bolts.

Move the shift lever to the 2nd gear position. Adjust the guide plate so that dimension A is as shown in the illustration with the shift lever cap pushed toward neutral (select direction).

Fully tighten the 4 bolts.

Torque:
10 N*m{ 102 kgf*cm, 7 ft.*lbf}

28. INSTALL NO. 1 SHIFT AND SELECT LEVER BOOT

Install the shift lever boot with the 4 bolts.

29. INSTALL NO. 2 CONSOLE BOX DUCT

Install the No. 2 console box duct with the clip.

30. INSTALL CONSOLE BOX

Engage the 2 claws and 2 clips.

Install the 2 bolts <C-.

Connect the connector.

Connect the connectors.

Engage the 2 clamps.

Install the 2 bolts <C-.

31. INSTALL CONSOLE BOX REGISTER ASSEMBLY

Engage the 2 claws and 4 clips, and then install the console box register assembly.

Install the rear ash receptacle assembly.

32. INSTALL FRONT ASH RECEPTACLE SUB-ASSEMBLY

Connect the connectors.

Insert the protruding parts of the front ash receptacle sub-assembly into the 2 guide holes as shown in the illustration.

Install the front ash receptacle sub-assembly with the 2 screws <F-.

33. INSTALL FRONT CONSOLE PANEL SUB-ASSEMBLY

Engage the 6 clips.

Close the snap.

34. INSTALL REAR CONSOLE PANEL SUB-ASSEMBLY

Engage the 7 claws and 2 clips.

Close the snap.

35. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY

36. INSTALL BATTERY TRAY

37. INSTALL POWER STEERING ECU ASSEMBLY

38. INSTALL ENGINE ROOM SIDE COVER RH

Install the side cover with the 2 clips.

39. INSTALL COOL AIR INTAKE DUCT SEAL

Install the intake duct seal with the 11 clips.

40. REMOVE NO. 1 ENGINE COVER

Install the No. 1 engine cover.

41. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

42. ADD MANUAL TRANSMISSION OIL

Park the vehicle on a level surface.

Remove the transmission filler plug and gasket.

Check that the oil surface is within 5 mm (0.20 in.) below the lowest point of the transmission filler plug opening.

Oil grade:
API GL-4 or GL-5

Viscosity:
SAE 75W-90

NOTICE:

Problems may occur if the oil level is too high or too low.

After replacing the oil, drive the vehicle and check the oil level again.

Check for oil leakage if the oil level is low.

Install the transmission filler plug and a new gasket.

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

43. CHECK FOR EXHAUST GAS LEAKS

If exhaust gas is leaking, tighten the related parts to stop the leak. Replace damaged parts as necessary.

44. INSPECT AND ADJUST MANUAL TRANSMISSION OIL LEVEL

Park the vehicle on a level surface.

Remove the transmission filler plug and gasket.

Check that the oil surface is within 5 mm (0.20 in.) of the lowest point of the transmission filler plug opening.

NOTICE:

Problems may occur if the oil level is too high or low.

After replacing the oil, drive the vehicle and check the oil level again.

Check for oil leakage if the oil level is low.

Install a new gasket and the transmission filler plug.

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

45. PERFORM INITIALIZATION

Perform initialization procedure .

HINT:

Some vehicle systems require initialization after reconnecting the negative battery cable.

LEXUS IS250, IS220d / GSE20 ALE20

RA63 MANUAL TRANSMISSION

Lexus IS250 IS220d GSE20 ALE20

MANUAL TRANSMISSION ASSEMBLY