Lexus IS250 IS220d GSE20 ALE20 - RA63 MANUAL TRANSMISSION
MANUAL TRANSMISSION UNIT - DISASSEMBLY
| 1. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY |
Remove the bolt and separate the wire harness clamp.
Using SST, remove the back-up light switch and gasket.
- SST
- 09817-16011
| 2. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY |
Remove the floor shift control shift lever retainer sub-assembly.
| 3. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER |
Pull up the locks of the shift lever pins, and remove the 2 shift lever pins.
Remove the floor shift control shift lever retainer.
| 4. REMOVE SHIFT AND SELECT LEVER BOOT |
Remove the shift and select lever boot.
| 5. REMOVE SHIFT LEVER RETAINER BUSHING |
Remove the 4 shift lever retainer bushings.
| 6. REMOVE CONTROL SHAFT |
Using a screwdriver, remove the E-ring and control shaft.
Remove the 2 collars from the floor shift control shaft.
| 7. REMOVE FLOOR SHIFT CONTROL SHAFT |
Using a hammer and a screwdriver, cut off the control shaft collar and remove it from the shaft.
Remove the shaft pin and floor shift control shaft.
Remove the shift lever damper from the floor shift control shaft.
| 8. REMOVE EXTENSION HOUSING DUST DEFLECTOR |
Using a plastic hammer, remove the extension housing dust deflector.
| 9. REMOVE OUTPUT SHAFT ADJUST NUT |
Using a belt and wooden block, fasten the transmission to the workbench.
Using SST and hammer, unstake the nut.
- SST
- 09930-00010
Place the gearshift into 5th gear, and then secure the input shaft using SST.
- SST
- 09556-16030
Using a deep socket wrench 30 mm, remove the nut from the output shaft.
Remove the belt and wooden block from the transmission.
| 10. REMOVE OUTPUT SHAFT COMPANION FLANGE |
Remove the companion flange from the output shaft.
Remove the O-ring from the companion flange.
| 11. REMOVE COMPANION FLANGE DUST DEFLECTOR |
- HINT:
- Perform this procedure only when the dust deflector is damaged.
Using SST and a press, remove the dust deflector.
- SST
- 09950-60010(09951-00410)
09950-00020
09950-70010(09951-07100)
| 12. REMOVE MANUAL TRANSMISSION EXTENSION HOUSING OIL SEAL |
Using SST, remove the extension housing oil seal.
- SST
- 09308-00010
| 13. REMOVE OUTPUT SHAFT REAR BEARING |
Remove the output shaft rear bearing and output shaft spacer.
| 14. REMOVE EXTENSION HOUSING SUB-ASSEMBLY |
Remove the 8 bolts.
Using a screwdriver, remove the extension housing.
- NOTICE:
- Be careful not to damage the contact surfaces of the extension housing and rear case.
- HINT:
- Tape the screwdriver tip before use.
Remove the extension housing.
| 15. REMOVE EXTENSION HOUSING REAR OIL SEAL |
Using SST and a hammer, remove the extension housing rear oil seal.
- SST
- 09201-31010
| 16. REMOVE OUTPUT SHAFT REAR BEARING OUTER RACE |
Using a brass bar and hammer, remove the output shaft bearing outer race.
| 17. REMOVE TRANSMISSION OIL SEPARATOR |
Using a brass bar and hammer, remove the transmission oil separator.
| 18. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE |
Remove the oil receiver pipe.
| 19. REMOVE SHIFT DETENT BALL PLUG |
Using a socket hexagon wrench (10 mm), remove the shift detent ball plug from the transmission rear case.
Remove the ball and compression spring from the transmission rear case.
| 20. REMOVE TRANSMISSION REAR CASE |
Remove the 10 bolts and bracket.
Using a plastic hammer, carefully tap out the rear case.
Remove the rear case.
| 21. REMOVE MANUAL TRANSMISSION FILLER PLUG |
Remove the 2 transmission filler plugs and 2 gaskets from the transmission rear case.
| 22. REMOVE EXTENSION HOUSING OIL RECEIVER PIPE |
Remove the extension housing oil receiver pipe from the transmission rear case.
| 23. REMOVE OIL SEPARATOR PACKING SEAL |
Remove the oil separator packing seal from the transmission rear case.
| 24. REMOVE OUTPUT SHAFT REAR BEARING OUTER RACE |
Using SST, remove the output shaft rear bearing outer race.
- SST
- 09308-00010
| 25. REMOVE COUNTER GEAR REAR CYLINDRICAL ROLLER BEARING |
Remove the bolt, then remove the bearing lock plate.
Using SST, remove the counter gear rear cylindrical roller bearing from the transmission rear case.
- SST
- 09387-00041
| 26. REMOVE TRANSMISSION REAR CASE BEARING |
Using SST and a press, remove the transmission rear case bearing from the transmission rear case.
- SST
- 09950-60010(09951-00230)
| 27. REMOVE TRANSMISSION OIL SEPARATOR |
Remove the 2 bolts, then remove the oil separator.
| 28. REMOVE REVERSE IDLER GEAR SHAFT BOLT |
Remove the reverse idler gear shaft bolt and gasket from the transmission middle case.
| 29. REMOVE NO. 2 OIL RECEIVER PIPE |
Remove the No. 2 oil receiver pipe from the transmission middle case.
| 30. REMOVE TRANSMISSION MIDDLE CASE |
Remove the 11 bolts, then remove the transmission middle case.
Using a plastic hammer, carefully tap out the transmission middle case.
| 31. REMOVE TRANSMISSION DRAIN PLUG |
Remove the drain plug and gasket from the transmission middle case.
| 32. REMOVE TRANSMISSION MIDDLE CASE BEARING |
Using SST and a press, remove the transmission middle case bearing from the transmission middle case.
- SST
- 09950-60010(09951-00230)
| 33. REMOVE OUTPUT SHAFT |
Remove the output shaft.
| 34. REMOVE SHIFT AND SELECT LEVER SHAFT |
Remove the shift and select lever shaft.
| 35. REMOVE SHIFT AND SELECT LEVER |
Remove the bolt, then remove the shift and select lever.
Remove the lock ball pin and spring from the shift and select lever.
| 36. REMOVE SHIFT AND SELECT LEVER CAM |
Using a screwdriver, remove the E-ring and the shift and select lever cam from the shift and select lever shaft.
| 37. INSPECT REVERSE IDLER GEAR THRUST CLEARANCE |
Using a feeler gauge, measure the thrust clearance.
- Standard clearance:
- 0.10 to 0.25 mm (0.0039 to 0.0098 in.)
- Maximum clearance:
- 0.25 mm (0.0098 in.)
If the clearance exceeds the maximum, replace the reverse idler gear shaft, reverse idler gear or transmission front case.
| 38. REMOVE REVERSE IDLER GEAR |
Remove the reverse idler gear shaft, reverse idler gear bearing and reverse idler gear.
| 39. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE |
Install the reverse idler gear and reverse idler gear bearing to the reverse idler gear shaft.
Using a dial indicator, measure the radial clearance.
- Standard clearance:
- 0.015 to 0.050 mm (0.0006 to 0.0020 in.)
- Maximum clearance:
- 0.050 mm (0.0020 in.)
If the clearance exceeds the maximum, replace the reverse idler gear bearing, reverse idler gear shaft or reverse idler gear.
| 40. REMOVE TRANSMISSION FRONT CASE |
Using a hexagon wrench (24 mm), remove the plug from the transmission front case.
Remove the 4 bolts from the shift interlock bracket.
Tie the input shaft, counter gear, and control assembly with a rope or string.
Expand the 2 snap rings, and lift up the output shaft, input shaft, counter gear, and control assembly.
Remove the output shaft, input shaft, counter gear shaft, and control assembly while gently tapping the front case with a plastic hammer.
- NOTICE:
- Take care not to subject the output shaft, input shaft, counter gear shaft, and control assembly to any impact. This may cause the shift detent ball and spring to come out.
Separate the output shaft, input shaft, counter gear shaft, and control assembly.
| 41. REMOVE NO. 1 OIL RECEIVER PIPE |
Remove the No. 1 oil receiver pipe from the transmission front case.
| 42. REMOVE FRONT BEARING SHAFT SNAP RING |
Using snap ring pliers, remove the 2 snap rings.
| 43. REMOVE TRANSMISSION CASE OIL SEAL |
Using SST, remove the transmission case oil seal from the transmission front case.
- SST
- 09308-00010
| 44. REMOVE NO. 3 GEAR SHIFT FORK |
Using 2 screwdrivers and a hammer, remove the 4 snap rings.
Remove the bolt, then remove the No. 3 gear shift fork.
| 45. REMOVE NO. 1 GEAR SHIFT HEAD |
Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.
| 46. REMOVE NO. 1 GEAR SHIFT FORK SHAFT |
Remove the No. 1 gear shift fork shaft, No. 1 gear shift head, shift detent ball, spring, No. 2 shift interlock pin and No. 3 shift interlock pin.
| 47. REMOVE NO. 2 GEAR SHIFT FORK |
Remove the bolt, then remove the No. 2 gear shift fork.
| 48. REMOVE NO. 2 GEAR SHIFT FORK SHAFT |
Remove the No. 2 gear shift fork shaft, shift detent ball, spring, No. 2 shift interlock pin, and No. 3 shift interlock pin.
| 49. REMOVE NO. 3 GEAR SHIFT HEAD |
Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.
| 50. REMOVE NO. 3 GEAR SHIFT FORK SHAFT |
Remove the No. 3 gear shift fork shaft, shift detent ball, spring, No. 3 gear shift head, and No. 1 shift interlock pin.
| 51. REMOVE NO. 1 GEAR SHIFT FORK |
Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.
Remove the No. 2 gear shift head and No. 1 gear shift fork.
| 52. REMOVE NO. 4 GEAR SHIFT FORK |
Using a pin punch (5 mm (0.20 in.)) and hammer, tap out the slotted spring pin.
Remove the No. 4 gear shift fork.
| 53. REMOVE NO. 4 GEAR SHIFT FORK SHAFT |
Remove the No. 4 gear shift fork shaft, shift detent ball, and spring.
| 54. REMOVE SHIFT ARM |
Using a screwdriver, remove the E-ring.
Remove the shift arm pivot and shift arm.