The purpose of this thread will answer all your questions about an AR5 swap into an IS300. I will cover part lists, Questions and answers, and at the end, an Installation. There are many options and variables to doing a transmission change on an IS300. We will start with the bare-bones parts list, and these will be the basic must-have for doing the swap.
NOTE, this part list may contain parts you already have, i.e., transmission bracket, isolator, bolts, etc. You will need to look at what came with your donor AR5 transmission and use some common sense to order what you need.
The highlighted gaskets I could not find them, but they are part of the original installation for the inspection plates, so I left the part numbers in the list
Now that you have the basic must have a list, now you have some choices to make. The AR5 and the R154 engage the clutch very. Differently, you need to choose which system you are going to use because it will directly affect which clutch you will need to buy.
Option A. The AR5 comes with a bearing retainer that uses a bolt-on internal slave that engages the clutch by pushing on it. This is an all in one system, but it may require the swap to a larger bore clutch master cylinder, similar to the size used on the solstice "3/4". If you choose this option, you can use the W series clutch components; this list is for you.
Option B. The R154 comes with a bearing retainer that uses an external slave and pulls a fork to engage the clutch by pulling on it. This system has many parts, but it may be the most familiar. If you choose this option, you can use R series Clutch components, and this list is for you.
But wait, that's not all. Then there is the aftermarket, where choices are endless. I will cover 2 that seem to be the most popular.
Option C. Spec and clutch masters make a multiplate clutch system that both use an internal slave that is made for the r154 retainer. Spec is a complete kit. It comes with your clutch disc, flywheel, pressure plate, slave cylinder, and clutch master cylinder. Make sure to special order for a correct clutch disk.!!!! The Clutch masters kit comes with the same minus the clutch master cylinder. So this set will vary, but all require the R154 retainer. This is a light list since there are too many variables to make it complete.
Option D. OS Giken makes a movement alteration kit that is compatible with the r154 bearing retainer. This kit covers the r154 external slave movement into a push style. I would consider a middle ground between the above choices, you still have your external slave, but you do not have to buy a lot of small parts. This is a light list since there are too many variables to make it complete.
Now that we covered the part options, you should have a much clearer idea of your parts list.
Now let's cover some questions about the AR5.
Q. Do I need to buy a certain year AR5?
A. Yes! the 06 and older use a traditional bottom mount. 07 and newer use a side mount system that connects to the solstice differential. This would not be ideal for the IS300 and will require additional work.
Q. Do I need to trim the input shaft?
A. No, there is sufficient room to fit.
Q. Do I need a custom pilot bearing?
A. Yes, ID 15mm and OD 32mm Driftmotion sells one.
Q. Do I need to buy the shifter JZX shifter cover plate?
A. Yes! If you want to have your shifter line up correctly for the IS300 application
Q. Do I need to buy the JZX Shifter?
A. No, you can buy a JZX shifter “more straight” or a W55 shifter “slanted slightly towards the driver”. Or alternatively, use an aftermarket w55 shifter.
Q Do I need a “special” clutch disk for the AR5 Spline?
A. Yes R154 flywheel Clutch Disc Diameter (mm): 240 Input Shaft Size (In): 1-1/8 Inch Number Of Splines: 26.
W55/58 flywheel Clutch Disc Diameter (mm): 236 Input Shaft Size (In): 1-1/8 Inch Number Of Splines: 26.
Q. Do I need A custom crossmember?
A. Yes, for a no compromise solution, the custom cross member is the best option, you simply use the AR5 mount and isolator, and it is a direct bolt-in. It can be found on a popular auction site.
Q. I have an automatic transmission. What other parts do I need?
A. I have another thread that can help answer questions for auto to manual swap.
Auto to Manual Swap, Wiring, Ecu, CC, NSS, CLSW, Trac...
Q. I have a Manual transmission. What other parts do I need?
A. The main thing a manual car will need is to wire their speed from the abs instead of from the transmission. Here is a thread that can help you.
How-To: ABS to Speedo Rewire for V160 swapped IS's...
Q. Do I need a custom driveshaft?
A. Yes, AR5 does not use a slip yoke. It mates to a 100mm cv joint. Driftmotion and driveshaft shop both make adapters to convert to 4 bolt flange. You can modify your two-piece driveshaft or get a one-piece telescoping driveshaft. The transmission output flange to diff flange is 51,” but you should always measure yours to verify!
Q. Lots of parts seem to be discontinued. Where do I find them?
A. Amyama trading company is a good site to find parts, often times at a greatly reduced cost. Shipping can be a killer, so try to get it all in one order!
Installation
Here is an installation guide for my setup “option D” Many steps will be the same for all other options.
Remove AR5 bellhousing, slave cylinder, and shifter cover,
Install 2jz bellhousing, and jzx shifter cover
Install breather plug
Install R154 retianer seal
Clean up, and apply fipg
Install movement alteration kit
Install pilot Bearing, I got mine from driftmotion, but all you need is a pilot bearing with an ID 15mm and OD 32mm.
Good time to do your rear seal!
Install your flywheel and torque bolts to your hardware specs, i.e., the arp will be different than stock.
Insert alignment tool and install clutch disks and cover plate
Install transmission to the engine
Used some spare connectors for the reverse light.
Swap slave shaft for movement kit shaft
Install cover plates
Install slave
Trim AR5 Isolator bolts. Always have the bolt on before cutting,
Install AR5 Metal Mount, isolator, and crossmember.
Install Driveshaft, clutch slave line to master cylinder
Install shifter
NOTE, this part list may contain parts you already have, i.e., transmission bracket, isolator, bolts, etc. You will need to look at what came with your donor AR5 transmission and use some common sense to order what you need.
The highlighted gaskets I could not find them, but they are part of the original installation for the inspection plates, so I left the part numbers in the list
Now that you have the basic must have a list, now you have some choices to make. The AR5 and the R154 engage the clutch very. Differently, you need to choose which system you are going to use because it will directly affect which clutch you will need to buy.
Option A. The AR5 comes with a bearing retainer that uses a bolt-on internal slave that engages the clutch by pushing on it. This is an all in one system, but it may require the swap to a larger bore clutch master cylinder, similar to the size used on the solstice "3/4". If you choose this option, you can use the W series clutch components; this list is for you.
Option B. The R154 comes with a bearing retainer that uses an external slave and pulls a fork to engage the clutch by pulling on it. This system has many parts, but it may be the most familiar. If you choose this option, you can use R series Clutch components, and this list is for you.
But wait, that's not all. Then there is the aftermarket, where choices are endless. I will cover 2 that seem to be the most popular.
Option C. Spec and clutch masters make a multiplate clutch system that both use an internal slave that is made for the r154 retainer. Spec is a complete kit. It comes with your clutch disc, flywheel, pressure plate, slave cylinder, and clutch master cylinder. Make sure to special order for a correct clutch disk.!!!! The Clutch masters kit comes with the same minus the clutch master cylinder. So this set will vary, but all require the R154 retainer. This is a light list since there are too many variables to make it complete.
Option D. OS Giken makes a movement alteration kit that is compatible with the r154 bearing retainer. This kit covers the r154 external slave movement into a push style. I would consider a middle ground between the above choices, you still have your external slave, but you do not have to buy a lot of small parts. This is a light list since there are too many variables to make it complete.
Now that we covered the part options, you should have a much clearer idea of your parts list.
Now let's cover some questions about the AR5.
Q. Do I need to buy a certain year AR5?
A. Yes! the 06 and older use a traditional bottom mount. 07 and newer use a side mount system that connects to the solstice differential. This would not be ideal for the IS300 and will require additional work.
Q. Do I need to trim the input shaft?
A. No, there is sufficient room to fit.
Q. Do I need a custom pilot bearing?
A. Yes, ID 15mm and OD 32mm Driftmotion sells one.
Q. Do I need to buy the shifter JZX shifter cover plate?
A. Yes! If you want to have your shifter line up correctly for the IS300 application
Q. Do I need to buy the JZX Shifter?
A. No, you can buy a JZX shifter “more straight” or a W55 shifter “slanted slightly towards the driver”. Or alternatively, use an aftermarket w55 shifter.
Q Do I need a “special” clutch disk for the AR5 Spline?
A. Yes R154 flywheel Clutch Disc Diameter (mm): 240 Input Shaft Size (In): 1-1/8 Inch Number Of Splines: 26.
W55/58 flywheel Clutch Disc Diameter (mm): 236 Input Shaft Size (In): 1-1/8 Inch Number Of Splines: 26.
Q. Do I need A custom crossmember?
A. Yes, for a no compromise solution, the custom cross member is the best option, you simply use the AR5 mount and isolator, and it is a direct bolt-in. It can be found on a popular auction site.
Q. I have an automatic transmission. What other parts do I need?
A. I have another thread that can help answer questions for auto to manual swap.
Auto to Manual Swap, Wiring, Ecu, CC, NSS, CLSW, Trac...
Q. I have a Manual transmission. What other parts do I need?
A. The main thing a manual car will need is to wire their speed from the abs instead of from the transmission. Here is a thread that can help you.
How-To: ABS to Speedo Rewire for V160 swapped IS's...
Q. Do I need a custom driveshaft?
A. Yes, AR5 does not use a slip yoke. It mates to a 100mm cv joint. Driftmotion and driveshaft shop both make adapters to convert to 4 bolt flange. You can modify your two-piece driveshaft or get a one-piece telescoping driveshaft. The transmission output flange to diff flange is 51,” but you should always measure yours to verify!
Q. Lots of parts seem to be discontinued. Where do I find them?
A. Amyama trading company is a good site to find parts, often times at a greatly reduced cost. Shipping can be a killer, so try to get it all in one order!
Installation
Here is an installation guide for my setup “option D” Many steps will be the same for all other options.
Remove AR5 bellhousing, slave cylinder, and shifter cover,
Install 2jz bellhousing, and jzx shifter cover
Install breather plug
Install R154 retianer seal
Clean up, and apply fipg
Install movement alteration kit
Install pilot Bearing, I got mine from driftmotion, but all you need is a pilot bearing with an ID 15mm and OD 32mm.
Good time to do your rear seal!
Install your flywheel and torque bolts to your hardware specs, i.e., the arp will be different than stock.
Insert alignment tool and install clutch disks and cover plate
Install transmission to the engine
Used some spare connectors for the reverse light.
Swap slave shaft for movement kit shaft
Install cover plates
Install slave
Trim AR5 Isolator bolts. Always have the bolt on before cutting,
Install AR5 Metal Mount, isolator, and crossmember.
Install Driveshaft, clutch slave line to master cylinder
Install shifter