Comprehensive AR5 Swap Thread - Lexus IS Forum
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post #1 of 141 (permalink) Old 12-18-2015, 11:57 AM Thread Starter
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Comprehensive AR5 Swap Thread

The purpose of this thread will answer all your questions for a AR5 swap into a IS300. I will cover part lists, Questions and answers, and at the end a Installation. There is many options and variables to doing a transmission change on a IS300. We will start with the bare bones parts list, these will be the basic must have for doing the swap.



*NOTE, this part list may contain parts you already have ie; transmission bracket, islolator, 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, but 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 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 a all in one system, but may require the swap to a larger bore clutch master cylinder, similar to the size used on the solstice "3/4". If you chose 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 use a external slave and pull fork to engages the clutch by pulling on it. This system has many parts, but may be the most familiar. If you choose this option you can use R series Clutch components, this list is for you.



But wait thats not all then there is the aftermarket, where choices are endless, I will cover 2 that seem to be most popular

Option C. Spec and clutch masters, make a multiplate clutch system that both use a internal slave that is made for the r154 retainer. Spec is a very complete kit it comes with your clutch disc, flywheel, pressure plate, slave cylinder, and clutch master clynider. Make sure to special order for a correct clutch disk.!!!! Clutch masters kit comes with the same minus the clutch master clylinder. So this set will vary but all require the R154 retianer. 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 retianer. This kit coverts the r154 external slave movement into a push style. This 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 ideal of your parts list.

Now lets cover some questions about the AR5

Q. Do i need to buy a certian 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 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 slighty towards driver”. Or alternatively use a aftermarket w55 shifter.

Q Do I need “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 crossmember is the best option, you simply use the AR5 mount and isolator and it is direct bolt in. It can be found on a poplular auction site.

Q. I have a automatic transmission, what other parts do I need?
A. I have another thread that can help answer question for auto to manual swap.
https://my.is/forums/f88/auto-manual-...ged-ca-434112/

Q. I have a Manual transmission, what other parts do I need?
A. The main thing a manual car will need is to wire there speed from the abs instead of from the transmission. Here is a thread that can help you.
https://my.is/forums/f114/how-abs-spe...-5spds-412759/

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 peice driveshaft, or get a one piece telescoping driveshaft. 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 greatly reduced cost. Shipping can be a killer, so try to get it in all in one order!

Installation

Here a 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 a ID 15mm and OD 32mm





Good time to do your rear seal!


Install your flywheel, torque bolts to your hardware specs, ie arp will be different than stock.



Insert alignment tool and install clutch disks and cover plate



Install transmision to 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, crossmember.






Install Driveshaft, clutch slave line to master cylinder





Install shifter

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Last edited by Curran; 04-18-2018 at 01:18 PM.
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post #2 of 141 (permalink) Old 12-21-2015, 12:02 PM
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Sticky! Awesome write-up Brandon.

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post #3 of 141 (permalink) Old 12-28-2015, 11:24 AM
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Thank you brandon for taking the time to make such a list

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post #4 of 141 (permalink) Old 12-28-2015, 01:50 PM
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Awesome write up!

However, with the link to your old thread, all of the pictures are broken, just so you know.
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post #5 of 141 (permalink) Old 12-30-2015, 09:12 PM
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Are there any particular year models of the ar5 to stay away from?
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post #6 of 141 (permalink) Old 12-31-2015, 01:25 PM Thread Starter
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Quote:
Originally Posted by dcharms View Post
Sticky! Awesome write-up Brandon.
Thank you Sir.

Quote:
Originally Posted by 02gita View Post
Thank you brandon for taking the time to make such a list
The original progress thread was so long, we needed a clean start with well documented information.

Quote:
Originally Posted by TheLost View Post
Awesome write up!

However, with the link to your old thread, all of the pictures are broken, just so you know.
Yes, my old image hosting stopped supporting free hosting. so I needed some time to update the thread with my current hosting site. It is now up!

Quote:
Originally Posted by RAJJis300 View Post
Are there any particular year models of the ar5 to stay away from?
YES!!!!! do not get any side mount! 07 and newer changed to a side mount system that connects to the Solstice differential. This would only further complicate your swap. Purchase a 06 or older for a traditional bottom mount.
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post #7 of 141 (permalink) Old 01-04-2016, 09:01 AM
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Quote:
Originally Posted by RAJJis300 View Post
Are there any particular year models of the ar5 to stay away from?
The AR5 you want, like Brandon already clarified, is a 2006 or older. I just wanted to add that the correct transmissions are called "without interim design change."

And Brandon, have you seen that sometimes they are labeled 2006/2007 without interim design change? Weird because a straight 2007 has the side mount like you said.

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post #8 of 141 (permalink) Old 01-04-2016, 10:12 AM
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So what kind of power can you expect to hold, being you use the r154 retainer clip isn't that normally the first part to fail?

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post #9 of 141 (permalink) Old 01-04-2016, 12:52 PM Thread Starter
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Quote:
Originally Posted by dcharms View Post
The AR5 you want, like Brandon already clarified, is a 2006 or older. I just wanted to add that the correct transmissions are called "without interim design change."

And Brandon, have you seen that sometimes they are labeled 2006/2007 without interim design change? Weird because a straight 2007 has the side mount like you said.
Correct it is often called "without interm change" Sometimes parts can be mislabeled, thats why its imperative that it must be clear that it is a bottom mount. To be exact there where 3 different mounting options.
1. The tradional bottom mount, 06 and older without interm change.
2. side mount to bottom mount, this was used on ZOK club sport. Impossible to find even a part number.
3. the side mount to differential, 07 and newer with interm change.

Quote:
Originally Posted by bastafari View Post
So what kind of power can you expect to hold, being you use the r154 retainer clip isn't that normally the first part to fail?

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Can you clarify your statement further? im using a traditional r154 retianer, but no clips as you mentioned.

I do not want to speculate power levels, because as you may already know it greatly depends on the driver. but i will say that i expect it to be on par with a R154.

13 J8A FR-S Series 10
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post #10 of 141 (permalink) Old 01-04-2016, 01:35 PM
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I can't say from experience only from what I've read in threads on this forum in regards to the r154 and how much power they can hold and if memory serves which it may not I believe it was the retainer that typically failed first in higher power situations. I'll try to dig up the thread.

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post #11 of 141 (permalink) Old 01-04-2016, 10:03 PM Thread Starter
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I think I see where you are coming from now, your talking about the bearing plate retainer. Yes I see that there is a upgraded part from Marlin crawler. I can't say if the AR5 unit is the same or different than the R154 because I haven't personally opened the two transmissions to compare. I have not seen mention of it either.

The point of using the AR5 for me at least is to have a alternative to the old, overpriced R154. If it ends up needing to be "built" I think I will have still made the right choice, seeing how I basically got the transmission for free, can't say I see that happening much with the R154.

13 J8A FR-S Series 10
02 CW Sportcross rebuild in progress
02 BO Sportcross 2jzgte build in progress
11 SW Tundra DC TRD supercharged

02 MSM L-tuned Sportcross 5 Speed Sold
01 DWP IS300 Sold

Sportcross owners group on facebook

My Story: https://my.is/forums/f219/sportcross-...8/#post7991882


My For Sale: https://my.is/forums/f99/sportcross-s...hifter-438917/
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post #12 of 141 (permalink) Old 02-14-2016, 08:55 PM
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Nice write up! Few quick questions for you about option A:

1 - Any specific year land cruiser for the master cylinder?

2 - What clutch? Having a hard time finding one with those measurements. Every 240mm 26 spline I come across is 1.375 in. input shaft diameter.

3 - Just to confirm, the bell housing you have listed, is a 1JZ bell housing?

4 - If I were to use, say, a B&M or Ralcorz short shifter I wouldn't need the JZX shifter lever right?

Lastly, not concerning option A, any input on using an AR5 from the Colorado or H3 instead of the Solstice?

Last edited by SAM1990; 02-14-2016 at 09:26 PM.
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post #13 of 141 (permalink) Old 02-15-2016, 05:17 AM
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Quote:
Lastly, not concerning option A, any input on using an AR5 from the Colorado or H3 instead of the Solstice?
Anything can be made to work. The Solstice transmission is just the easiest one to fit. You'd have to figure out the mounts and determine where the shifter will come out on the transmission tunnel. Using the Solstice transmissions makes this swap pretty close to an R154 swap.

Any IS300 compatible shift lever will work once you put the proper housing on the transmission to convert from solstice to Toyota style shifters.
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post #14 of 141 (permalink) Old 02-15-2016, 03:37 PM
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Originally Posted by Ek9B18 View Post
Anything can be made to work. The Solstice transmission is just the easiest one to fit. You'd have to figure out the mounts and determine where the shifter will come out on the transmission tunnel. Using the Solstice transmissions makes this swap pretty close to an R154 swap.

Any IS300 compatible shift lever will work once you put the proper housing on the transmission to convert from solstice to Toyota style shifters.
The 4x2 Colorado AR5 looks identical to the Solstice AR5 except for the shifter assembly. Since you're swapping that out for a Toyota one it shouldn't make a difference. But that's just going off pictures I was able to find online so I'm trying to get a 100% confirmation before buying a trans I can't use lol.
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post #15 of 141 (permalink) Old 02-15-2016, 05:09 PM
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Quote:
The 4x2 Colorado AR5 looks identical to the Solstice AR5 except for the shifter assembly. Since you're swapping that out for a Toyota one it shouldn't make a difference. But that's just going off pictures I was able to find online so I'm trying to get a 100% confirmation before buying a trans I can't use lol.
Looks like there's at least 5" or more difference between the shifter positions. I think you're making incorrect assumptions that are going to cost you some serious cash. You can see the colorado shifter connects right on top of the housing that the toyota housing extends. You can't mount the toyota adapter on the colorado housing too. Wrong number of bolts and wrong size.




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