Lexus RX (RX 350L, RX450h) 2016-2024 Repair Manual: Reassembly

Lexus RX (RX 350L, RX450h) 2016-2024 Repair Manual / Drivetrain / Drive Shaft / Propeller Shaft / Front Drive Shaft Assembly / Reassembly

REASSEMBLY

PROCEDURE

1. INSTALL FRONT DRIVE SHAFT BEARING (for RH Side)

(a) Using SST, a steel plate and a press, install a new front drive shaft bearing.

SST: 09527-10011

NOTICE:

The bearing should be completely installed.

*a

Steel Plate

(b) Using a snap ring expander, install a new drive shaft hole snap ring.

NOTICE:

Install the drive shaft hole snap ring securely.

2. INSTALL FRONT DRIVE SHAFT DUST COVER LH

(a) Using a steel plate and a press, install a new front drive shaft dust cover LH.

NOTICE:

  • Make sure to fully install the front drive shaft dust cover LH.
  • Be careful not to damage the front drive shaft dust cover LH.

*a

Steel Plate

3. INSTALL FRONT DRIVE SHAFT DUST COVER RH (for 2WD RH Side)

(a) Using a steel plate and a press, install a new front drive shaft dust cover RH until the dimension (A) from the tip of the front drive inboard joint assembly to the front drive shaft dust cover RH meets the specification.

Dimension (A):

115.5 to 116.5 mm (4.55 to 4.58 in.)

NOTICE:

Be careful not to damage the front drive shaft dust cover RH.

*a

Steel Plate

4. INSTALL FRONT AXLE OUTBOARD JOINT BOOT (for LH Side)

(a) Wrap the splines of the front drive outboard joint shaft assembly with protective tape to prevent the boot from being damaged.

*a

Protective Tape

(b) Install new parts to the front drive outboard joint shaft assembly in the following order:

*1

Front Drive Outboard Joint Shaft Assembly

*2

Front No. 2 Axle Outboard Joint Boot Clamp

*3

Front Axle Outboard Joint Boot

*4

Front Axle Outboard Joint Boot Clamp

Outboard Joint Side

Inboard Joint Side

(1) Front No. 2 axle outboard joint boot clamp

(2) Front axle outboard joint boot

(3) Front axle outboard joint boot clamp

(c) Pack the joint portion of the front drive outboard joint shaft assembly and front axle outboard joint boot with grease.

Standard Grease Capacity:

for TMC Made

81 to 91 g (2.86 to 3.20 oz)

for TMMC Made

137 to 147 g (4.84 to 5.18 oz)

(d) Install the front axle outboard joint boot to the front drive outboard joint shaft assembly groove.

NOTICE:

  • Do not allow grease to adhere to the boot clamp track of the outboard joint boot.
  • Keep the inside of the outboard joint boot free of foreign matter.

5. INSTALL FRONT AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

(a) Secure the drive shaft in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

(b) Install the front axle outboard joint boot clamp to the front axle outboard joint boot.

(c) Place SST onto the front axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

SST: 09521-24010

(d) Tighten SST so that the front axle outboard joint boot clamp is pinched.

NOTICE:

Do not overtighten SST.

(e) Remove SST.

(f) Using SST, measure the clearance of the front axle outboard joint boot clamp.

SST: 09240-00020

Clearance:

for TMC Made

0.5 to 1.5 mm (0.0197 to 0.0590 in.)

for TMMC Made

1.3 mm (0.0511 in.) or less

If the clearance is not as specified, retighten SST.

6. INSTALL FRONT NO. 2 AXLE OUTBOARD JOINT BOOT CLAMP (for LH Side)

(a) Secure the drive shaft in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

(b) Install the front No. 2 axle outboard joint boot clamp to the front axle outboard joint boot.

(c) Place SST onto the front No. 2 axle outboard joint boot clamp, press it against the boot and slightly tighten SST.

SST: 09521-24010

(d) Tighten SST so that the front No. 2 axle outboard joint boot clamp is pinched.

NOTICE:

Do not overtighten SST.

(e) Remove SST.

(f) Using SST, measure the clearance of the front No. 2 axle outboard joint boot clamp.

SST: 09240-00020

Clearance:

for TMC Made

0.5 to 1.5 mm (0.0197 to 0.0590 in.)

for TMMC Made

2.1 mm (0.0826 in.) or less

If the clearance is not as specified, retighten SST.

7. INSTALL FRONT DRIVE SHAFT DAMPER (w/ Drive Shaft Damper)

(a) Temporarily install the front drive shaft damper and 2 new front drive shaft damper clamps to the front drive outboard joint shaft assembly as shown in the illustration.

*A

for TMC Made

*B

for TMMC Made

*1

Front Drive Shaft Damper Clamp

*2

Front Drive Shaft Damper

(b) Set the dimension (A) as specified below.

Dimension (A) for TMC Made:

for LH Side

235.0 to 239.0 mm (9.26 to 9.40 in.)

for RH Side

240.0 to 244.0 mm (9.45 to 9.60 in.)

Dimension (A) for TMMC Made:

for LH Side

288.0 to 292.0 mm (11.34 to 11.49 in.)

for RH Side

276.0 to 280.0 mm (10.87 to 11.02 in.)

(c) Install the 2 front drive shaft damper clamps to the front drive shaft damper.

NOTICE:

Make sure to install the clamps in the correct position.

8. INSTALL FRONT DRIVE SHAFT DAMPER CLAMP (w/ Drive Shaft Damper)

(a) Using needle-nose pliers, install the 2 front drive shaft damper clamps.

9. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY (for TMC Made)

(a) Install new parts to the front drive outboard joint shaft assembly in the following order:

*1

Front Axle Inboard Joint Boot Clamp

*2

Front Axle Inboard Joint Boot

*3

Front No. 2 Axle Inboard Joint Boot Clamp

*a

Protective Tape

Outboard Joint Side

Inboard Joint Side

(1) Front axle inboard joint boot clamp

(2) Front axle inboard joint boot

(3) Front No. 2 axle inboard joint boot clamp

(b) Secure the drive shaft in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

(c) Remove the protective tape.

(d) Align the matchmarks and install the tripod joint to the front drive outboard joint shaft assembly.

NOTICE:

Face the serrated side of the tripod joint outward and install it to the outboard joint end.

*a

Matchmark

(e) Using a brass bar and a hammer, install the tripod joint to the front drive outboard joint shaft assembly.

NOTICE:

  • Do not tap the rollers.
  • Keep the tripod joint free of foreign matter.
  • Make sure to install the tripod joint in the correct direction.

(f) Using a snap ring expander, install a new shaft snap ring to the front drive outboard joint shaft assembly.

(g) Pack the front drive inboard joint assembly and front axle inboard joint boot with grease.

Standard Grease Capacity:

190 to 200 g (6.71 to 7.05 oz)

(h) Install a new front axle inboard joint grommet to the front drive inboard joint assembly.

NOTICE:

  • Securely fit the protrusion on the front axle inboard joint grommet into the front drive inboard joint assembly.
  • Make sure that the lip of the front axle inboard joint grommet is not damaged.

*a

Lip

(i) Align the matchmarks and install the front drive inboard joint assembly to the front drive outboard joint shaft assembly.

*a

Matchmark

10. INSTALL FRONT DRIVE INBOARD JOINT ASSEMBLY (for TMMC Made)

(a) Install new parts to the front drive outboard joint shaft assembly in the following order:

*1

Front Axle Inboard Joint Boot Clamp

*2

Front Axle Inboard Joint Boot

*3

Front No. 2 Axle Inboard Joint Boot Clamp

*a

Protective Tape

Outboard Joint Side

Inboard Joint Side

(1) Front axle inboard joint boot clamp

(2) Front axle inboard joint boot

(3) Front No. 2 axle inboard joint boot clamp

(b) Secure the drive shaft in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

(c) Remove the protective tape.

(d) Align the matchmarks and install the tripod joint to the front drive outboard joint shaft assembly.

NOTICE:

Face the serrated side of the tripod joint outward and install it to the outboard joint end.

*a

Matchmark

(e) Using a brass bar and a hammer, install the tripod joint to the front drive outboard joint shaft assembly.

NOTICE:

  • Do not tap the areas where the rollers contact the tripod joint.
  • Keep the tripod joint free of foreign matter.
  • Make sure to install the tripod joint in the correct direction.

(f) Using a snap ring expander, install a new shaft snap ring to the front drive outboard joint shaft assembly.

(g) Pack the front drive inboard joint assembly and front axle inboard join boot with grease.

Standard Grease Capacity:

189 to 199 g (6.67 to 7.01 oz)

(h) Install the 3 rollers to the tripod joint.

NOTICE:

  • Make sure to install the rollers in the correct direction as shown in the illustration.
  • Do not drop the rollers.

(i) Align the matchmarks and install the front drive inboard joint assembly to the front drive outboard joint shaft assembly.

*a

Matchmark

11. INSTALL FRONT AXLE INBOARD JOINT BOOT

(a) Install the front axle inboard joint boot to the front drive inboard joint assembly.

(b) Check whether the dimension (A) of each drive shaft is within specification.

Dimension (A) for TMC Made:

for LH Side

600.85 mm (1.97 ft.)

for 2WD RH Side

925.55 mm (3.04 ft.)

for AWD RH Side

926.55 mm (3.04 ft.)

Dimension (A) for TMMC Made:

for LH Side

599.6 to 603.6 mm (1.97 to 1.98 ft.)

for 2WD RH Side

925.9 mm (3.04 ft.)

for AWD RH Side

928.1 mm (3.04 ft.)

*A

for LH Side

*B

for RH Side

12. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP

(a) Secure the drive shaft in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

(b) Install the front axle inboard joint boot clamp to the front axle inboard joint boot.

(c) Place SST onto the front axle inboard joint boot clamp, press it against the boot and slightly tighten SST.

SST: 09521-24010

(d) Tighten SST so that the front axle inboard joint boot clamp is pinched.

NOTICE:

Do not overtighten SST.

(e) Remove SST.

(f) Using SST, measure the clearance of the front axle inboard joint boot clamp.

SST: 09240-00020

Clearance:

for TMC Made

0.5 to 1.5 mm (0.0197 to 0.0590 in.)

for TMMC Made

1.3 mm (0.0511 in.) or less

If the clearance is not as specified, retighten SST.

13. INSTALL FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP

(a) Secure the drive shaft in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

(b) Install the front No. 2 axle inboard joint boot clamp to the front axle inboard joint boot.

(c) Place SST onto the front No. 2 axle inboard joint boot clamp, press it against the boot and slightly tighten SST.

SST: 09521-24010

(d) Tighten SST so that the front No. 2 axle inboard joint boot clamp is pinched.

NOTICE:

Do not overtighten SST.

(e) Remove SST.

(f) Using SST, measure the clearance of the front No. 2 axle inboard joint boot clamp.

SST: 09240-00020

Clearance:

for TMC Made

0.5 to 1.5 mm (0.0197 to 0.0590 in.)

for TMMC Made

2.1 mm (0.0826 in.) or less

If the clearance is not as specified, retighten SST.

14. INSPECT FRONT DRIVE SHAFT ASSEMBLY

Click here

    Disassembly
    DISASSEMBLY PROCEDURE 1. SEPARATE FRONT NO. 2 AXLE INBOARD JOINT BOOT CLAMP (a) Secure the drive shaft in a vise between aluminum plates. NOTICE: Do not overtighten the vise. (b) Using pliers, sepa ...

    Installation
    INSTALLATION CAUTION / NOTICE / HINT HINT: Use the same procedure for the RH side and LH side. The following procedure is for the LH side. PROCEDURE 1. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING ...

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