Lexus Car ES, IS, LS 1998-06

Transmission Removal & Installation

Print



Click image to see an enlarged view

Fig. Exploded view of manual transmission components-IS 250

  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 manual transmission fluid.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Loosen each bolt one turn at a time until spring tension is released.



    Shift lever knob
     
    Front and rear console panel sub-assemblies
     
    Front ashtray
     
    Console box register assembly
     
    Console box
     
    No. 2 console box duct
     
    Shift lever boot
     
    4 bolts and shift lever cap
     
    Engine under cover
     
    No. 2 engine under cover
     
    No. 1 rear floor panel brace
     
    Front center floor brace
     
    Oxygen sensor
     
    Front exhaust pipe assembly
     
    Front floor No. 1 heat insulator
     
    Right outside air guide plate
     
    Propeller shaft with center bearing assembly after matchmarking location
     
    Engine under cover air guide bracket
     
    Starter motor
     
    2 bolts, 2 nuts and clutch accumulator assembly
     
    2 bolts and clutch release cylinder
     
    Ground wire
     
    Remaining wiring connectors
     
    No. 1 and 2 clutch housing covers
     
    6 bolts and clutch cover assembly. Matchmark clutch cover to the flywheel.
     



    Floor shift control shift lever retainer
     
    E-ring and floor shift lever assembly
     

  8.  
  9. Support the transmission unit with a transmission jack.

    Engine rear mounting member
     
    9 bolts and manual transmission assembly
     

  10.  

To install:

  1. Install or connect the following:
    NOTE
    Temporarily tighten bolt *1, fully tighten bolt *2, lift the rear end of the transmission, and fully tighten bolt *1 and the other bolts.


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



    Manual transmission. Torque bolt A to 53 ft. lbs. (72 Nm) and bolt B to 28 ft. lbs. (37 Nm)
     



    Click image to see an enlarged view

    Fig. Manual transmission mounting bolts-IS 250



    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 lever assembly with a new E-ring
     
    Shift lever boot
     
    Floor shift control shift lever retainer. Torque the 2 nuts to 15 ft. lbs. (20 Nm).
     
    Align matchmarks of the clutch cover to the flywheel. Install 6 new bolts and torque them to 14 ft. lbs. (19 Nm) a little at a time in a diagonal pattern.
     
    No. 1 and 2 clutch housing covers. Torque to 13 ft. lbs. (18 Nm)
     
    Wiring connectors
     
    Ground wire
     
    Clutch release cylinder. Torque to 9 ft. lbs. (12 Nm)
     
    Clutch accumulator assembly. Torque the bolts to 9 ft. lbs. (12 Nm) and the nuts to 48 inch lbs. (5 Nm).
     
    Starter motor
     
    Engine under cover air guide bracket. Torque to 19 ft. lbs. (26 Nm).
     
    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
     
    No. 2 engine under cover
     
    Engine under cover
     

  2.  
  3. Install the shift lever cap as follows:
    1. Move the shift lever to the second gear position.
    2.  
    3. Adjust the guide plate so that dimension A is as shown in the illustration with the shift lever cap pushed toward neutral.
    4.  
    5. Torque the bolts to 7 ft. lbs. (10 Nm).

      Click image to see an enlarged view

      Fig. Adjusting the shift lever guide plate-IS 250



      No. 1 shift and select lever boot
       
      No. 2 console box duct
       
      Console box
       
      Console box register assembly
       
      Front ashtray
       
      Front and rear console panel sub-assemblies
       
      Shift lever knob
       
      Negative battery cable
       

    6.  

  4.  
  5. Add manual transmission fluid.
  6.  
  7. Start engine and check for fluid and exhaust leaks.
  8.  



Click image to see an enlarged view

Fig. Exploded view of console assembly and related components.-IS 300



Click image to see an enlarged view

Fig. Exploded view of the manual transmission and related components.-IS 300

  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 manual transmission fluid and engine coolant.
  6.  
  7. Remove upper console panel and console box.
  8.  
  9. Disconnect the 2 wire harness clamps, remove the 4 bolts and shift boot retainer.
  10.  
  11. Remove the shift boot.
  12.  
  13. Remove the 4 bolts, transmission shift lever and washer.
  14.  
  15. Remove engine cover No. 1.
  16.  
  17. Remove No. 1 and No. 2 engine under covers.
  18.  
  19. Disconnect the upper radiator hose.
  20.  
  21. Disconnect the MAF meter connector.
  22.  
  23. Disconnect the engine wire harness clamp from the air cleaner case.
  24.  
  25. Loosen the 2 hose clamp bolts, remove the intake air connector from the throttle body.
  26.  
  27. Remove the exhaust manifold.
  28.  
  29. Raise and safely support the vehicle securely on jackstands.
  30.  
  31. Remove the left front floor center cover.
  32.  
  33. Remove the No. 1 rear floor board.
  34.  
  35. Remove the front and center exhaust pipes.
  36.  
  37. Remove the propeller shaft.
  38.  
  39. Remove the 2 bolts and disconnect the clutch release cylinder.
  40.  
  41. Remove the bolt and disconnect the clutch line bracket and earth wire.
  42.  
  43. Disconnect the back-up light switch connector.
  44.  
  45. Disconnect the speed sensor connector and wire harness.
  46.  
  47. Remove the starter.
  48.  
  49. Using a transmission jack, support the transmission.
  50.  
  51. Remove the 4 bolts, 4 nuts and rear engine mounting member.
  52.  
  53. Remove the 4 bolts and engine rear mounting.
  54.  
  55. Remove the 8 bolts, wire harness clamp and transmission.
  56.  
  57. After separating the transmission from the engine, turn the transmission a little in clockwise. At the condition that the transmission housing does not contact the body, lower the jack.
  58.  

To install:

  1. Raise the engine front side.
  2.  
  3. Align the input spline with a clutch disc and install the transmission to the engine. Turn the transmission a little in the clockwise and jack up until just before the transmission housing touches the body.

    Click image to see an enlarged view

    Fig. Manual transmission mounting bolts.-IS 300

  4.  
  5. Install the transmission and wire harness clamp with the 8 bolts. Torque the bolts to the following values:


    1. Bolt A (12mm head bolt): 53 ft. lbs. (71.6 Nm)
    2.  
    3. Bolt B (10mm head bolt): 28 ft. lbs. (37.3 Nm)
    4.  

  6.  
  7. Install the engine rear mounting with the 4 bolts and tighten to 19 ft. lbs. (25.5 Nm).
  8.  
  9. Install the rear engine mounting member with the 4 bolts and 4 nuts. Tighten the bolts to 18 ft. lbs. (25 Nm), and the nuts to 10 ft. lbs. (13.5 Nm).
  10.  
  11. Install the starter.
  12.  
  13. Connect the speed sensor connector and wire harness.
  14.  
  15. Connect the back-up light switch connector.

    Click image to see an enlarged view

    Fig. Tighten clutch line bracket and earth wire bolt (A) and clutch release cylinder bolts (B).-IS 300

  16.  
  17. Connect the clutch line bracket and earth wire with the bolt. Tighten bolt A to 28 ft. lbs. (37.3 Nm).
  18.  
  19. Connect the clutch release cylinder with the 2 bolts. Tighten bolts B to 9 ft. lbs. (11.7 Nm).
  20.  
  21. Install the propeller shaft.
  22.  
  23. Install the front and center exhaust pipes.
  24.  
  25. Refill the transmission with the correct type and amount of manual transmission fluid.
  26.  
  27. Install the No. 1 rear floor board.
  28.  
  29. Install the left front floor center cover.
  30.  
  31. Lower the vehicle.
  32.  
  33. Install the exhaust manifold.
  34.  
  35. Install the intake air resonator to the throttle body, tighten the 2 hose clamp bolts.
  36.  
  37. Connect the PCV hose to the No. 2 cylinder head cover.
  38.  
  39. Connect the engine wire harness clamp to the air cleaner case.
  40.  
  41. Connect the MAF meter connector.
  42.  
  43. Connect the upper radiator hose.
  44.  
  45. Refill the engine cooling system.
  46.  
  47. Install engine cover No. 1.
  48.  
  49. Install No. 1 and No. 2 engine under covers.
  50.  
  51. Install the transmission shift lever as follows:


    1. Install the washer.
    2.  
    3. Apply MP grease to the tip of shift lever.
    4.  
    5. Install the shift lever with the 4 bolts. Tighten the bolts to 71 inch lbs. (8 Nm).
    6.  

  52.  
  53. Install the shift boot.
  54.  
  55. Install the shift boot retainer with the 4 bolts and connect the 2 wire harness clamps.
  56.  
  57. Install upper console panel and console box.
  58.  
  59. Connect the negative battery cable.
  60.  
  61. Perform road test to check for abnormal noises and smooth shifting.
  62.  

 
label.common.footer.alt.autozoneLogo