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IS200 / Altezza 6th gear replacement (J160 gearbox)

1. Remove gearbox from the car.
2. Remove gear lever retainer assembly (one 12mm bolt on each side of the gearbox, two 12mm bolts on top). Not the exact position of the
assembly, as this gearbox has 2 positions of it – forward for IS200 (1G-FE) and rearward for Altezza RS200 (3S-GE). It should lift right out.

3. Peel back the rubber grommet on the end of the gear linkage to reveal
the gear lever holder. Note how it’s positioned and then remove the
12mm bolt and lock pin holding it in place. It should pull right off the
rod. You should be left with a bare gear select rod (pictured on the
right).
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4. Remove the lock ball pin near the top mounting point for the gear lever linkage assembly (8mm allen key). It consists of 3 parts, pictured,
place them somewhere safe.

5. Remove the reverse lock bolt near the seam between the rear and
middle casing, 18mm in size.
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6. You can also remove the speed sensor (12mm bolt) if it pulls out easily. If you struggle with
it, don’t break it trying to pull it out, just leave it in and be extra careful when removing and
reinstalling the rear gearbox housing.
7. Remove all nine 12mm bolts, holding the rear housing to the main gearbox housing. Note
the position of the wire clamp. Using a rubber mallet break the seal between the two and
pull out the rear housing, minding the seal of the gear select rod.

8. You’re presented with a view where 6th gear lives:

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9. Remove the clip holding the speed sensor worm gear in place. Be careful not to break it. It goes through
a slot in the worm gear and is held in place via 2 holes in the shaft on both sides of the worm gear.
There should be no extra tension, the worm gear is floating between the 2 parts of this clip. Remove the
worm gear, leaving the shaft smooth.

10. Tap out the two lock pins holding the engagement mechanism in place.
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11. Remove the snap ring, holding the torsion spring in place. Remove the spring
(noting the position it sits in, as it is NOT symmetrical).

12. Pull out the engagement mechanism trying not to lose anything in the process.
13. Remove the two snap rings holding the main and counter gears in place (it’s easiest to use two screwdrivers and a hammer).
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<<< From here on you’ll need good gear pullers and a hydraulic press. Make sure you’re prepared!!! >>>

14. Using a gear puller remove the 6th counter gear clutch hub (held in the puller via 3x M8 threaded holes).

15. Pull 6th counter gear by hand.

16. Remove the cover around main 6th gear (4x T45 torx screws).
17. Using a LONG gear puller, pull main 6th gear off the shaft.
18. Using a hydraulic press, press the new main gear in. Reassemble in reverse order.
19. Done!