Lexus Car ES, IS, LS 1998-06

Transmission Removal & Installation

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Click image to see an enlarged view

Fig. Exploded view of automatic transmission components-IS 250 and IS 350

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Drain transmission fluid.
  8.  
  9. Remove or disconnect the following:

    Cool air intake duct seal
     
    Left engine room side cover
     
    Engine under cover
     
    No. 2 engine under cover
     
    No. 1 rear floor panel brace
     
    Front center floor brace
     
    Oxygen sensor
     
    Front exhaust pipe assembly
     
    Right outside air guide plate
     
    Front floor No. 1 heat insulator
     
    Propeller shaft with center bearing assembly after matchmarking location
     
    Left exhaust manifold
     
    Starter motor
     
    Flywheel housing side cover
     
    6 torque converter clutch setting bolts while holding crankshaft pulley nut with wrench
     
    Floor shift gear shifting rod
     

  10.  
  11. Support the transmission unit with a transmission jack.

    Engine rear mounting member
     
    Ground wire
     
    Remaining wiring connectors
     
    Water by-pass hose from transmission oil cooler
     
    9 bolts and automatic transmission assembly
     

  12.  

To install:

  1. Install or connect the following:
    NOTE
    Make sure that the mark is as shown in the illustration.


    NOTE
    Stabilize the propeller shaft by rotating it several times by hand to stabilize the center support bearing.



    Transmission. Torque bolts A and B to 52 ft. lbs. (71 Nm) and bolt C to 27 ft. lbs. (37 Nm)
     



    Click image to see an enlarged view

    Fig. Automatic transmission mounting bolts-IS 250 and IS 350



    Water by-pass hose to transmission oil cooler. Torque the hose clamp bolt to 15 ft. lbs. (20 Nm)
     
    All wiring connectors
     
    Ground wire
     
    Engine rear mounting member. Torque the 4 nuts to the transmission to 10 ft. lbs. (13 Nm) and the 4 body bolts to 19 ft. lbs. (26 Nm)
     
    Floor shift gear shifting rod
     
    6 torque converter clutch setting bolts. Install the black colored bolt first. Torque to 30 ft. lbs. (41 Nm)
     
    Flywheel housing side cover
     
    Starter motor
     
    Left exhaust manifold
     
    Propeller shaft with center bearing assembly. Torque to 58 ft. lbs. (79 Nm)
     
    No. 1 center support bearing to the matchmark. Torque to 51 ft. lbs. (69 Nm)
     



    Front floor No. 1 heat insulator
     
    Right outside air guide plate
     
    Front exhaust pipe assembly
     
    Oxygen sensor
     
    Front center floor brace
     
    No. 1 rear floor panel brace
     
    Negative battery cable
     

  2.  
  3. Add transmission fluid and engine coolant.
  4.  
  5. Start engine and check for fluid and exhaust leaks.
  6.  
  7. Check shift lever position as follows:

    Remove the nut and disconnect the shifting rod.
     
    Turn the control shaft lever of the neutral start switch counterclockwise until it stops, and turn it clockwise 2 notches to set it to the N position.
     
    Move the shift lever to the N position and tighten the nut while lightly pushing the lever toward the R position.
     
    After adjustment, check that the shift lever moves smoothly and the shift lever and gear operate correctly.
     

  8.  
  9. Inspect shift lever position as follows:

    When shifting from the P to R position with the engine switch on (IG) and the brake pedal depressed, make sure that the shift lever moves smoothly and then moves correctly into the position.
     
    Start the engine and make sure that the vehicle moves forward when shifting from the N to D position and moves rearward when shifting to the R position. If operation cannot be done as specified, inspect the neutral start switch assembly and check the shift lever assembly installation condition.
     
    No. 2 engine under cover
     
    Engine under cover
     
    Left engine room side cover
     
    Cool air intake duct seal
     

  10.  
  11. Reset memory.
  12.  



Click image to see an enlarged view

Fig. Exploded view of automatic transmission components for removal-IS300 (1 of 2)



Click image to see an enlarged view

Fig. Exploded view of automatic transmission components for removal-IS300 (2 of 2)

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.

    Negative battery cable
     
    Transmission oil dipstick and tube
     
    Air cleaner
     
    Mass Air Flow (MAF) sensor
     
    Exhaust manifold
     
    Engine under covers
     
    Left front floor center cover
     
    No. 1 rear floor board
     
    Upper radiator hose
     
    Exhaust front pipe
     
    Exhaust center pipe
     
    Shift control rod
     
    Drive shaft
     
    Oil cooler lines
     
    Torque converter mounting bolts (through access hole)
     
    Rear transmission mount crossmember. Support the transmission with a jack.
     
    Transmission wiring harness connectors
     
    Starter motor
     
    Transmission flange bolts
     
    Transmission
     

  4.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    17mm transmission flange bolts: 53 ft. lbs. (72 Nm)
     
    14mm transmission flange bolts: 27 ft. lbs. (37 Nm)
     
    Starter motor bolts: 27 ft. lbs. (37 Nm)
     
    Rear transmission mount crossmember bolts: 19 ft. lbs. (25 Nm)
     
    Torque converter bolts: 35 ft. lbs. (48 Nm)
     
    Oil cooler lines: 33 ft. lbs. (44 Nm)
     
    Drive shaft center support bolts: 36 ft. lbs. (49 Nm)
     
    Drive shaft U-joint flange bolts: 54 ft. lbs. (74 Nm)
     
    Shift control rod nuts: 108 inch lbs. (13 Nm)
     
    Exhaust manifold nuts: 29 ft. lbs. (39 Nm)
     

  2.  



Click image to see an enlarged view

Fig. Exploded view of the transmission mounting-LS400

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable. Wait at least 90 seconds before performing any other work.
     
    Transmission dipstick and tube
     
    Throttle cable
     
    Driveshaft
     
    Engine undercover
     
    Shift control rod
     
    Exhaust pipe support bracket by removing the 2 bolts
     
    Catalytic converters by removing the 6 nuts
     
    Both side heat insulators
     
    Oil cooler tube clamps and disconnect the tubes
     
    Torque converter inspection plate by removing the 2 bolts
     
    Torque converter bolts
     

  4.  
  5. Support the transmission with a suitable jack.
  6.  
  7. Remove or disconnect the following:

    Rear transmission mount
     
    Overdrive direct clutch speed sensor connector
     
    Vehicle Speed Sensor (VSS) connector
     
    Park/Neutral Position (PNP) switch connector
     
    Solenoid connector
     
    3 wiring harness clamps from the bracket on the transmission.
     
    10 transmission mounting bolts and the transmission.
     

  8.  

To install:

  1. Install or connect the following:

    Transmission and tighten the bolts as follows: 14mm-27 ft. lbs. (37 Nm); 17mm-53 ft. lbs. (72 Nm)
     
    3 wiring harness clamp to the bracket on the transmission
     
    Solenoid connector
     
    PNP switch connector
     
    VSS connector
     
    Overdrive direct clutch speed sensor connector
     
    Rear transmission mount and tighten the bolts to 19 ft. lbs. (20 Nm) and the nuts to 10 ft. lbs. (13 Nm)
     
    Torque converter bolts to 30 ft. lbs. (41 Nm)
     
    Converter inspection plate
     
    Support from the transmission
     
    Oil cooler pipes and tighten the union nuts to 32 ft. lbs. (44 Nm)
     
    Side heat insulators
     
    Catalytic converters with new gaskets and new nuts. Tighten the nuts to 46 ft. lbs. (62 Nm).
     
    Exhaust pipe support bracket with the 2 bolts and tighten the bolts to 32 ft. lbs. (44 Nm)
     
    Shift control rod
     
    Engine undercover
     
    Driveshaft
     
    Throttle control cable
     
    Transmission tube and dipstick
     
    Negative battery cable
     

  2.  
  3. Fill the transmission to the proper level with recommended type fluid.
  4.  

42RE Transmission




NOTE
The transmission and torque converter must be removed as an assembly to avoid component damage. The converter drive plate, pump bushing, or oil seal can be damaged if the converter is left attached to the drive plate during removal. Be sure to remove the transmission and converter as an assembly.

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect battery negative cable.
  4.  
  5. Disconnect and lower or remove necessary exhaust components.
  6.  
  7. Disconnect fluid cooler lines at transmission.
  8.  
  9. Remove starter motor.
  10.  
  11. Disconnect and remove crankshaft position sensor. Retain sensor attaching bolts.
    NOTE
    The crankshaft position sensor will be damaged if the transmission is removed, or installed, while the sensor is still bolted to the engine block, or transmission (4.0L only). To avoid damage, be sure to remove the sensor before removing the transmission.

  12.  
  13. Remove the bolts holding the bell housing brace to the transmission.
  14.  
  15. Remove nut holding the bell housing brace to the engine to transmission bending brace.
  16.  
  17. Remove the bell housing brace from the transmission.
  18.  
  19. Remove the bolt holding the torque converter cover to the transmission.
  20.  
  21. Remove the torque converter cover from the transmission.
  22.  
  23. If transmission is being removed for overhaul, remove transmission oil pan, drain fluid and reinstall pan.
  24.  
  25. Remove fill tube bracket bolts and pull tube out of transmission. Retain fill tube seal. On 4 x 4 models, it will also be necessary to remove bolt attaching transfer case vent tube to converter housing.
  26.  
  27. Rotate crankshaft in clockwise direction until converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft with socket wrench on dampener bolt.
  28.  
  29. Mark propeller shaft and axle yokes for assembly alignment. Then disconnect and remove propeller shaft. On 4 x 4 models, remove both propeller shafts.
  30.  
  31. Disconnect wires from park/neutral position switch and transmission solenoid.
  32.  
  33. Disconnect gearshift cable from transmission manual valve lever.
  34.  
  35. Disconnect throttle valve cable from transmission bracket and throttle valve lever.
  36.  
  37. Disconnect transfer case shift cable from the transfer case shift lever.
  38.  
  39. Remove the clip securing the transfer case shift cable into the cable support bracket.
  40.  
  41. Disconnect transmission fluid cooler lines at transmission fittings and clips.
  42.  
  43. Support rear of engine with safety stand or jack.
  44.  
  45. Raise transmission slightly with service jack to relieve load on crossmember and supports.
  46.  
  47. Remove bolts securing rear support and cushion to transmission and crossmember.
  48.  
  49. Remove bolts attaching crossmember to frame and remove crossmember.
  50.  
  51. Remove transfer case.
  52.  

To install:

  1. Check torque converter hub and hub drive notches for sharp edges burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper and crocus cloth if necessary. The hub must be smooth to avoid damaging pump seal during installation.
  2.  
  3. Lubricate oil pump seal lip with transmission fluid.
  4.  
  5. Align converter and oil pump.
  6.  
  7. Carefully insert converter in oil pump. Then rotate converter back and forth until fully seated in pump gears.
  8.  
  9. Check converter seating with steel scale and straightedge. Surface of converter lugs should be 1 / 2 in. to rear of straightedge when converter is fully seated.
  10.  
  11. Temporarily secure converter with C-clamp.
  12.  
  13. Position transmission on jack and secure it with chains.
  14.  
  15. Check condition of converter drive plate. Replace the plate if cracked, distorted or damaged. Also be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment.
  16.  
  17. Apply a light coating of Mopar® High Temp grease to the torque converter hub pocket in the rear of the crankshaft.
  18.  
  19. Raise transmission and align converter with drive plate and converter housing with engine block.
  20.  
  21. Move transmission forward. Then raise, lower or tilt transmission to align converter housing with engine block dowels.
  22.  
  23. Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft.
  24.  
  25. Install two bolts to attach converter housing to engine.
  26.  
  27. Install the upper transmission bending braces to the torque converter housing and the overdrive unit. Tighten the bolts to 30 ft. lbs. (41 Nm).
  28.  
  29. Install remaining torque converter housing to engine bolts. Tighten to 50 ft. lbs. (68 Nm).
  30.  
  31. Install rear transmission crossmember. Tighten crossmember to frame bolts to 68 Nm (50 ft. lbs.).
  32.  
  33. Install rear support to transmission. Tighten bolts to 35 ft. lbs. (47 Nm).
  34.  
  35. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. Tighten clevis bracket to crossmember bolts to 35 ft. lbs. (47 Nm).Tighten the clevis bracket to rear support bolt to 50 ft. lbs. (68 Nm).
  36.  
  37. Remove engine support fixture.
  38.  
  39. Install crankshaft position sensor.
  40.  
  41. Install new plastic retainer grommet on any shift cable that was disconnected. Grommets should not be reused. Use pry tool to remove rod from grommet and cut away old grommet. Use pliers to snap new grommet into cable and to snap grommet onto lever.
  42.  
  43. Connect gearshift and throttle valve cable to transmission.
  44.  
  45. Connect wires to park/neutral position switch and transmission solenoid connector. Be sure transmission harnesses are properly routed.
    NOTE
    It is essential that correct length bolts be used to attach the converter to the drive plate. Bolts that are too long will damage the clutch surface inside the converter.

  46.  
  47. Install all torque converter-to-drive plate bolts by hand.
  48.  
  49. Verify that the torque converter is pulled flush to the drive plate. Tighten bolts to 270 inch lbs. (31 Nm).
  50.  
  51. Install converter housing access cover. Tighten bolt to 200 inch lbs. (23 Nm).
  52.  
  53. Install the bell housing brace to the torque converter cover and the engine to transmission bending brace. Tighten the bolts and nut to 30 ft. lbs. (41 Nm).
  54.  
  55. Install starter motor and cooler line bracket.
  56.  
  57. Connect cooler lines to transmission.
  58.  
  59. Install transmission fill tube. Install new seal on tube before installation.
  60.  
  61. Install exhaust components.
  62.  
  63. Install transfer case. Tighten transfer case nuts to 26 ft. lbs. (35 Nm).
  64.  
  65. Install the transfer case shift cable to the cable support bracket and the transfer case shift lever.
  66.  
  67. Align and connect propeller shaft(s).
  68.  
  69. Adjust gearshift linkage and throttle valve cable if necessary.
  70.  
  71. Lower vehicle.
  72.  
  73. Fill transmission with Mopar® ATF +4, type 9602, fluid.
  74.  

545RFE Transmission




NOTE
The transmission and torque converter must be removed as an assembly to avoid component damage. The converter drive plate, converter hub O-ring, or oil seal can be damaged if the converter is left attached to the drive plate during removal. Be sure to remove the transmission and converter as an assembly.

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle
  6.  
  7. Mark propeller shaft and axle yokes for assembly alignment.
  8.  
  9. Remove the rear propeller shaft
  10.  
  11. Remove the front propeller shaft.
  12.  
  13. Remove the engine to transmission collar.
  14.  
  15. Remove the exhaust support bracket from the rear of the transmission.
  16.  
  17. Disconnect and lower or remove any necessary exhaust components.
  18.  
  19. Remove the starter motor.
  20.  
  21. Rotate crankshaft in clockwise direction until converter bolts are accessible. Then remove bolts one at a time. Rotate crankshaft with socket wrench on dampener bolt.
  22.  
  23. Disconnect wires from solenoid and pressure switch assembly, input and output speed sensors, and line pressure sensor.
  24.  
  25. Disconnect gearshift cable from transmission manual valve lever.
  26.  
  27. Disconnect transfer case shift cable from the transfer case shift lever.
  28.  
  29. Remove the clip securing the transfer case shift cable into the cable support bracket.
  30.  
  31. Disconnect transmission fluid cooler lines at transmission fittings and clips.
  32.  
  33. Disconnect the transmission vent hose from the transmission.
  34.  
  35. Support rear of engine with safety stand or jack.
  36.  
  37. Raise transmission slightly with service jack to relieve load on crossmember and supports.
  38.  
  39. Remove bolts securing rear support and cushion to transmission and crossmember.
  40.  
  41. Remove bolts attaching crossmember to frame and remove crossmember.
  42.  
  43. Remove transfer case.
  44.  
  45. Remove all remaining converter housing bolts.
  46.  
  47. Carefully work transmission and torque converter assembly rearward off engine block dowels.
  48.  
  49. Hold torque converter in place during transmission removal.
  50.  
  51. Lower transmission and remove assembly from under the vehicle.
  52.  
  53. To remove torque converter, carefully slide torque converter out of the transmission. To install:
  54.  
  55. Check torque converter hub and hub drive flats for sharp edges burrs, scratches, or nicks. Polish the hub and flats with 320/400 grit paper and crocus cloth if necessary. Verify that the converter hub O-ring is properly installed and is free of any debris. The hub must be smooth to avoid damaging pump seal at installation.
  56.  
  57. If a replacement transmission is being installed, transfer any components necessary, such as the manual shift lever and shift cable bracket, from the original transmission onto the replacement transmission.
  58.  
  59. Lubricate oil pump seal lip with transmission fluid.
  60.  
  61. Align converter and oil pump.
  62.  
  63. Carefully insert converter in oil pump. Then rotate converter back and forth until fully seated in pump gears.
  64.  
  65. Check converter seating with steel scale and straightedge. Surface of converter lugs should be at least 13mm ( 1 / 2 in.) to rear of straightedge when converter is fully seated.
  66.  
  67. Temporarily secure converter with C-clamp.
  68.  
  69. Position transmission on jack and secure it with chains.
  70.  
  71. Check condition of converter drive plate. Replace the plate if cracked, distorted or damaged.
    NOTE
    Be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment.

  72.  
  73. Apply a light coating of Mopar® High Temp Grease to the torque converter hub pocket in the rear pocket of the engine-s crankshaft.
  74.  
  75. Raise transmission and align the torque converter with the drive plate and the transmission converter housing with the engine block.
  76.  
  77. Move transmission forward. Then raise, lower, or tilt transmission to align the converter housing with the engine block dowels.
  78.  
  79. Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft. Verify that no wires, or the transmission vent hose, have become trapped between the engine block and the transmission.
  80.  
  81. Install two bolts to attach the transmission to the engine.
  82.  
  83. Install remaining torque converter housing to engine bolts. Tighten to 50 ft. lbs. (68 Nm).
  84.  
  85. Install rear transmission crossmember. Tighten crossmember to frame bolts to 50 ft. lbs. (68 Nm).
  86.  
  87. Install rear support to transmission. Tighten bolts to 35 ft. lbs. (47 Nm).
  88.  
  89. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. Tighten clevis bracket to crossmember bolts to 35 ft. lbs. (47 Nm). Tighten the clevis bracket to rear support bolt to 50 ft. lbs. (68 Nm).
  90.  
  91. Install both the left and right side oil pan to transmission bolts, 5.7L only. Torque the bolts to 39 ft. lbs. (57 Nm).
  92.  
  93. Remove engine support fixture.
  94.  
  95. Install new plastic retainer grommet on any shift cable that was disconnected. Grommets should not be reused. Use pry tool to remove rod from grommet and cut away old grommet. Use pliers to snap new grommet into cable and to snap grommet onto lever.
  96.  
  97. Connect gearshift cable to transmission.
  98.  
  99. Connect wires to solenoid and pressure switch assembly connector, input and output speed sensors, and line pressure sensor. Be sure transmission harnesses are properly routed.
    NOTE
    It is essential that correct length bolts be used to attach the converter to the drive plate. Bolts that are too long will damage the clutch surface inside the converter.

  100.  
  101. Install all torque converter-to-drive plate bolts by hand.
  102.  
  103. Verify that the torque converter is pulled flush to the drive plate. Tighten bolts to 270 inch lbs. (31 Nm).
  104.  
  105. Install starter motor and cooler line bracket.
  106.  
  107. Connect cooler lines to transmission.
  108.  
  109. Install transmission fill tube.
  110.  
  111. Install exhaust components.
  112.  
  113. Install transfer case. Tighten transfer case nuts to 26 ft. lbs. (35 Nm).
  114.  
  115. Install the transfer case shift cable to the cable support bracket and the transfer case shift lever.
  116.  
  117. Install the structural dust cover onto the transmission and the engine.
  118.  
  119. Align and connect propeller shaft(s).
  120.  
  121. Adjust gearshift cable if necessary.
  122.  
  123. Lower vehicle.
  124.  
  125. Fill transmission with Mopar® ATF +4, Automatic Transmission fluid.
  126.  

 
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