Manual Transmission Assembly Removal

Transmission. Lexus Is250, Is220D. Gse20 Ale20
Ra63 Manual Transmission. Lexus Is250, Is220D. Gse20 Ale20

  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. REMOVE NO. 1 ENGINE COVER

  3. REMOVE COOL AIR INTAKE DUCT SEAL

  4. REMOVE ENGINE ROOM SIDE COVER RH

  5. REMOVE POWER STEERING ECU ASSEMBLY

  6. REMOVE BATTERY TRAY

  7. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY

  8. REMOVE REAR CONSOLE PANEL SUB-ASSEMBLY

  9. REMOVE FRONT CONSOLE PANEL SUB-ASSEMBLY

  10. REMOVE FRONT ASH RECEPTACLE SUB-ASSEMBLY

  11. REMOVE CONSOLE BOX REGISTER ASSEMBLY

  12. REMOVE CONSOLE BOX

  13. REMOVE NO. 2 CONSOLE BOX DUCT

  14. REMOVE NO. 1 SHIFT AND SELECT LEVER BOOT

  15. REMOVE SHIFT LEVER CAP

  16. REMOVE NO. 2 ENGINE UNDER COVER

  17. DRAIN MANUAL TRANSMISSION OIL

  18. REMOVE NO. 1 FLOOR UNDER COVER

  19. REMOVE FRONT FLOOR COVER RH

  20. REMOVE REAR NO. 1 FLOOR PANEL BRACE

  21. REMOVE FRONT CENTER FLOOR BRACE

  22. DISCONNECT AIR FUEL RATIO SENSOR

  23. REMOVE FRONT EXHAUST PIPE ASSEMBLY

  24. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

  25. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR

  26. REMOVE OUTSIDE AIR GUIDE PLATE RH

  27. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

  28. REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET SUB-ASSEMBLY

  29. REMOVE ENGINE UNDER COVER AIR GUIDE BRACKET

  30. REMOVE STARTER ASSEMBLY

  31. REMOVE CLUTCH ACCUMULATOR ASSEMBLY

  32. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY

  33. DISCONNECT GROUND CABLE

  34. SEPARATE WIRE HARNESS

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

  36. REMOVE FLOOR SHIFT LEVER ASSEMBLY

  37. SUPPORT MANUAL TRANSMISSION ASSEMBLY

  38. REMOVE ENGINE REAR MOUNTING MEMBER

  39. REMOVE MANUAL TRANSMISSION ASSEMBLY

  40. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

  41. REMOVE WIRE HARNESS CLAMP BRACKET

Manual Transmission Assembly -- Removal



1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL


2. REMOVE NO. 1 ENGINE COVER


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the No. 1 engine cover.



3. REMOVE COOL AIR INTAKE DUCT SEAL


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 11 clips and intake duct seal.



4. REMOVE ENGINE ROOM SIDE COVER RH


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 clips and side cover.



5. REMOVE POWER STEERING ECU ASSEMBLY
(Click here)


6. REMOVE BATTERY TRAY


7. 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.



8. 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.



9. 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.



10. 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.



11. 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.



12. REMOVE CONSOLE BOX


    Lexus Is250, Is220D. Gse20 Ale20.Ra63 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.



13. REMOVE NO. 2 CONSOLE BOX DUCT


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



14. 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.



15. 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.



16. REMOVE NO. 2 ENGINE UNDER COVER


17. 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}


18. REMOVE NO. 1 FLOOR UNDER COVER


19. REMOVE FRONT FLOOR COVER RH


20. REMOVE REAR NO. 1 FLOOR PANEL BRACE


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



21. REMOVE FRONT CENTER FLOOR BRACE


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



22. DISCONNECT AIR FUEL RATIO SENSOR


    Lexus Is250, Is220D. Gse20 Ale20.Ra63 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Using SST, remove the air fuel ratio sensor.

    SST
    09224-00010


23. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20.Ra63 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Remove the 2 bolts and 2 compression springs.



    Lexus Is250, Is220D. Gse20 Ale20.Ra63 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Remove the 2 bolts, 2 compression springs, front exhaust pipe assembly and 2 gaskets.



24. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20.Ra63 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Disconnect the 2 exhaust gas temperature sensor connectors.



    Lexus Is250, Is220D. Gse20 Ale20.Ra63 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Remove the 2 bolts and nut from the No. 1 manifold stay.



    Lexus Is250, Is220D. Gse20 Ale20.Ra63 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Remove the 2 bolts, nut and No. 2 manifold stay.



    Lexus Is250, Is220D. Gse20 Ale20.Ra63 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Using pliers, slide the clip to disconnect the No. 1 and No. 2 vacuum transmitting hose.



    Lexus Is250, Is220D. Gse20 Ale20.Ra63 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Remove the 3 nuts.

  1. Remove the manifold converter sub-assembly and turbine outlet elbow gasket.

  1. Remove the No. 1 manifold stay.



25. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR


    Lexus Is250, Is220D. Gse20 Ale20.Ra63 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Remove the 4 nuts and front No. 1 floor heat insulator.



26. REMOVE OUTSIDE AIR GUIDE PLATE RH


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



27. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20.Ra63 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Using SST, loosen the adjusting nut until it can be turned by hand.

    SST
    09922-10010
    HINT:
    Use 2 of the same type of SST.


    Lexus Is250, Is220D. Gse20 Ale20.Ra63 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Put matchmarks on the transmission companion flange, flexible coupling and intermediate shaft.

  1. Remove the 3 bolts, 3 washers and 3 nuts.

    NOTICE:
    The propeller shaft and flexible coupling should not be separated.


    Lexus Is250, Is220D. Gse20 Ale20.Ra63 Manual Transmission.Manual Transmission System.Manual Transmission Assembly  Removal
  1. Put matchmarks on the differential companion flange, flexible coupling and propeller shaft.

  1. Remove the 3 bolts, 3 washers and 3 nuts.

    NOTICE:
    The propeller shaft and flexible coupling should not be separated.


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 bolts, 2 center support bearing washers and 2 center support bearing dampers.

    HINT:
    Some vehicles are not equipped with the center support bearing washers.


    Lexus Is250, Is220D. Gse20 Ale20
  1. Push the rear propeller shaft straight ahead to compress and pull out the propeller shaft from the centering pin of the differential.

    NOTICE:
    Press the propeller shaft straight ahead to keep the transmission and intermediate shaft aligned straight.
    HINT:
    If it is difficult to separate the flange from the flexible coupling, pry it using a screwdriver.
  1. Pull the propeller shaft outward from the rear of the vehicle.

    NOTICE:
    The intermediate shaft and propeller shaft should not be separated.


28. REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 nuts and exhaust pipe No. 1 support bracket sub-assembly.



29. REMOVE ENGINE UNDER COVER AIR GUIDE BRACKET


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



30. REMOVE STARTER ASSEMBLY
(Click here)


31. REMOVE CLUTCH ACCUMULATOR ASSEMBLY
(Click here)


32. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY
(Click here)


33. DISCONNECT GROUND CABLE


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



34. SEPARATE WIRE HARNESS


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the bolt and separate the wire harness bracket.

  1. Disconnect the back-up light switch connector and separate the wire harness.



35. 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.



36. 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.



37. SUPPORT MANUAL TRANSMISSION ASSEMBLY


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



38. REMOVE ENGINE REAR MOUNTING MEMBER


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



39. REMOVE MANUAL TRANSMISSION ASSEMBLY


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



40. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR


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



41. REMOVE WIRE HARNESS CLAMP BRACKET


    Lexus Is250, Is220D. Gse20 Ale20
  1. Remove the 2 bolts and 2 wire harness clamp brackets.