FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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Home >> Lexus >> 2008 >> IS 250 RWD V6-2.5L (4GR-FSE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Service and Repair >> Removal and Replacement >> Installation

Installation








RA62 MANUAL TRANSMISSION: MANUAL TRANSMISSION ASSEMBLY:

INSTALLATION

1. INSTALL TRANSMISSION UPPER COVER SUB-ASSEMBLY






(a) Install the transmission upper cover sub-assembly with the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft-lbf)
2. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR






(a) Install the rear No. 1 engine mounting insulator to the manual transmission with the 4 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
3. INSTALL CLUTCH COVER ASSEMBLY Installation

4. INSTALL CLUTCH DISC ASSEMBLY Installation

5. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY






(a) Apply release hub grease to the contact surface between, the release fork and release bearing hub, the contact surface between the release fork and push rod, and release fork pivot points as shown in the illustration.
Sealant:
Part No. 08887-01806, RELEASE HUB GREASE or equivalent
(b) Install the clutch release fork sub-assembly to the release fork support.
NOTICE:
- Do not use excess force to install the clutch release fork sub-assembly.
- After installation, move the fork back and forth to check that the clutch release bearing hub slides smoothly.

6. INSTALL MANUAL TRANSMISSION ASSEMBLY






(a) Install the manual transmission to the engine with the 9 bolts.
Bolt A - Torque: 72 Nm (730 kgf-cm, 53 ft-lbf)
Bolt B - Torque: 37 Nm (380 kgf-cm, 28 ft-lbf)
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. Make sure that excessive force is not applied to the knock pins when lifting the rear end of the transmission.

7. INSTALL ENGINE REAR MOUNTING MEMBER






(a) Install the engine rear mounting member with the 4 bolts and 4 nuts.
Nut - Torque: 13 Nm (130 kgf-cm, 10 ft-lbf)
Bolt - Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)
8. INSTALL FLOOR SHIFT LEVER ASSEMBLY






(a) Install the 2 bushings to the shift lever assembly.
(b) Install the washer to the floor shift lever assembly.






(c) Install the shift lever assembly with a new E-ring.
(d) Install the shift and select lever boot.
9. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY






(a) Install the floor shift control shift lever retainer sub-assembly with the 2 nuts.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
10. INSTALL CLUTCH COVER ASSEMBLY






(a) Align the matchmarks on the clutch cover assembly and the flywheel sub-assembly.
(b) Install the clutch cover to the flywheel sub-assembly with the new 6 bolts.
Torque: 19 Nm (195 kgf-cm, 14 ft-lbf)
NOTE: Tighten the bolts a little at a time in a diagonal pattern until they are all tightened.

11. INSTALL NO. 1 CLUTCH HOUSING COVER






(a) Install the No. 1 clutch housing cover with the 4 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
Bolt length:
20 mm (0.79 in.)
12. INSTALL NO. 2 CLUTCH HOUSING COVER






(a) Install the No. 2 clutch housing cover with the 4 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
Bolt length:
16 mm (0.63 in.)
13. CONNECT WIRE HARNESS






(a) Connect the back-up light switch connector and install the wire harness.
14. CONNECT GROUND CABLE






(a) Connect the ground cable with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
15. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY






(a) Install the clutch release cylinder assembly with the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft-lbf)
16. INSTALL CLUTCH ACCUMULATOR ASSEMBLY






(a) Install the clutch accumulator assembly with the 2 bolts and 2 nuts.
Bolt - Torque: 12 Nm (120 kgf-cm, 9 ft-lbf)
Nut - Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
17. INSTALL STARTER ASSEMBLY
Installation
18. INSTALL ENGINE UNDER COVER AIR GUIDE BRACKET






(a) Install the engine under cover air guide bracket with the 2 bolts.
Torque: 26 Nm (260 kgf-cm, 19 ft-lbf)
19. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY Installation

20. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE Installation

21. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR Installation

22. INSTALL OUTSIDE AIR GUIDE PLATE RH Installation

23. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

24. INSTALL HEATED OXYGEN SENSOR Installation

25. INSTALL FRONT CENTER FLOOR BRACE Installation

26. INSTALL NO. 1 REAR FLOOR PANEL BRACE Installation

27. INSTALL NO. 2 ENGINE UNDER COVER
28. INSTALL ENGINE UNDER COVER
29. INSTALL SHIFT LEVER CAP






(a) 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).
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
30. INSTALL NO. 1 SHIFT AND SELECT LEVER BOOT






(a) Install the shift lever boot with the 4 bolts.
31. INSTALL NO. 2 CONSOLE BOX DUCT Installation

32. INSTALL CONSOLE BOX Installation

33. INSTALL CONSOLE BOX REGISTER ASSEMBLY Installation

34. INSTALL FRONT ASH RECEPTACLE SUB-ASSEMBLY Installation

35. INSTALL FRONT CONSOLE PANEL SUB-ASSEMBLY Installation

36. INSTALL REAR CONSOLE PANEL SUB-ASSEMBLY Installation

37. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY
38. ADD MANUAL TRANSMISSION OIL Replacement

39. INSPECT AND ADJUST MANUAL TRANSMISSION OIL LEVEL Testing and Inspection

40. CHECK FOR EXHAUST GAS LEAKS Installation
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