Lexus RX (RX 350L, RX450h) 2016-2022 Repair Manual: Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

NOTICE:

Before installation of each part, thoroughly clean and dry it. Then apply grease or oil as necessary. Do not use alkaline chemicals to clean aluminum parts, rubber parts or precoated bolts. Also, do not use non-residue solvent or other cleaning oils to clean O-rings, oil seals or rubber parts.

PROCEDURE

1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT

(a) Remove the 4 transfer and transaxle setting stud bolts from the transfer case sub-assembly.

2. REMOVE NO. 2 TRANSFER CASE PLUG

(a) Remove the No. 2 transfer case plug from the transfer case sub-assembly.

(b) Remove the gasket from the No. 2 transfer case plug.

3. REMOVE FILLER PLUG (NO. 1 TRANSFER CASE PLUG)

(a) Remove the filler plug (No. 1 transfer case plug) from the transfer case sub-assembly.

(b) Remove the gasket from the filler plug (No. 1 transfer case plug).

4. REMOVE TRANSFER DRAIN PLUG

(a) Remove the transfer drain plug from the transfer case sub-assembly.

(b) Remove the gasket from the transfer drain plug.

5. REMOVE TRANSFER CASE BREATHER PLUG

(a) Using a chisel and hammer, lift the transfer case breather plug slightly.

(b) Using a screwdriver, remove the transfer case breather plug from the transfer case cover sub-assembly.

6. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY

(a) Remove the 8 bolts from the transfer case cover sub-assembly.

(b) Using a brass bar and a hammer, remove the transfer case cover sub-assembly from the transfer case sub-assembly.

NOTICE:

Place the brass bar on the rib protruding from the transfer case cover sub-assembly.

*a

Rib

*b

Brass Bar

7. REMOVE BREATHER OIL DEFLECTOR

(a) Remove the bolt and breather oil deflector from the transfer case cover sub-assembly.

8. REMOVE TRANSFER CASE STRAIGHT PIN

(a) Remove the 4 transfer case straight pins from the transfer case sub-assembly.

9. SECURE TRANSFER ASSEMBLY

(a) Attach the transfer assembly to the overhaul attachment.

10. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR

HINT:

Only perform this procedure when replacement of the transfer extension housing dust deflector or transfer extension housing sub-assembly is necessary.

(a) Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assembly.

11. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL

(a) Using SST, remove the transfer extension housing type T oil seal from the transfer extension housing sub-assembly.

SST: 09308-00010

NOTICE:

Be careful not to damage the transfer extension housing type T oil seal contact surface or the inside surface of the transfer extension housing type T oil seal.

*1

Transfer Extension Housing Type T Oil Seal

12. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY

(a) Remove the 4 bolts.

(b) Using a plastic hammer, remove the transfer extension housing sub-assembly from the transfer case sub-assembly.

13. INSPECT PRELOAD

Click here

14. INSPECT RING GEAR BACKLASH

Click here

15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION

Click here

16. REMOVE TRANSFER CASE OIL SEAL

(a) Using SST, remove the transfer case oil seal from the transfer case sub-assembly.

SST: 09308-00010

NOTICE:

  • Do not damage the transfer case oil seal contact surface to the transfer case sub-assembly.
  • Wear or damage to the front drive shaft oil seal RH (for Inside) on the transmission side will cause transfer oil leakage.

    If it is worn or damaged, replace the front drive shaft oil seal RH (for Inside).

    Click here

*1

Transfer Case Oil Seal

17. REMOVE TRANSFER CASE OIL SEAL RH

(a) Using SST, remove the transfer case oil seal RH from the transfer case sub-assembly.

SST: 09308-00010

NOTICE:

Do not damage the transfer case oil seal RH contact surface to the transfer case sub-assembly.

*1

Transfer Case Oil Seal RH

18. REMOVE BEARING CAP

(a) Remove the 2 bolts and bearing cap from the transfer case sub-assembly.

19. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER

(a) Using SST, a screwdriver and a hammer, remove the No. 1 transfer output shaft spacer from the transfer case sub-assembly.

SST: 09504-22012

NOTICE:

Do not damage the transfer case sub-assembly.

*1

No. 1 Transfer Output Shaft Spacer

*a

Screwdriver

*b

Piece of Cloth

20. REMOVE NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER

(a) Remove the No. 2 transfer ring gear mounting case washer from the transfer case sub-assembly.

21. REMOVE TRANSFER RING GEAR MOUNTING CASE

(a) Remove the transfer ring gear mounting case from the transfer case sub-assembly.

22. REMOVE DRIVEN PINION

(a) Using SST and a hammer, unstake the gear nut.

SST: 09930-00010

HINT:

  • Use SST with the flat side facing outward.
  • Do not machine the tip of SST with a grinder, etc.

(b) Using SST, remove the gear nut.

SST: 09326-20011

SST: 09556-16030

*a

Turn

*b

Hold

(c) Using a press, press out the driven pinion, rear transfer driven pinion bearing (inner race) and transfer pinion bearing spacer.

NOTICE:

  • Place a piece of cloth under the transfer case sub-assembly to prevent the driven pinion from dropping out of the rear transfer driven pinion bearing (inner race).
  • Use wooden blocks or similar objects under the transfer case sub-assembly to keep it level.

*1

Rear Transfer Driven Pinion Bearing (inner race)

*2

Transfer Pinion Bearing Spacer

*3

Driven Pinion

23. REMOVE FRONT TRANSFER DRIVEN PINION BEARING

(a) Using SST and a press, remove the front transfer driven pinion bearing (inner race) from the driven pinion.

SST: 09950-00020

NOTICE:

  • Make sure to keep the outer race of the front transfer driven pinion bearing (inner race) from being applied force as shown the illustration.
  • Do not deform the cage of the front transfer driven pinion bearing (inner race) (when reusing the front transfer driven pinion bearing (inner race)).

(b) Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the front transfer driven pinion bearing (outer race) to remove it from the transfer case sub-assembly.

NOTICE:

Fit the brass bar to the 2 cutouts of the transfer case sub-assembly.

24. REMOVE TRANSFER OUTPUT SHAFT WASHER

(a) Remove the transfer output shaft washer from the transfer case sub-assembly.

NOTICE:

If the transfer output shaft washer is damaged or deformed, replace it with a new one.

25. REMOVE RING GEAR MOUNTING CASE BEARING

(a) for RH side:

(1) Remove the ring gear mounting case bearing (outer race) from the transfer ring gear mounting case.

(2) Using SST, remove the ring gear mounting case bearing (inner race) from the transfer ring gear mounting case.

SST: 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09955-04061

09957-04010

09958-04011

SST: 09950-60010

09951-00440

NOTICE:

  • Use SST (09953-04020) after applying grease to its threads and tip.
  • Do not deform the cage of the ring gear mounting case bearing (inner race) (when reusing the ring gear mounting case bearing (inner race)).
  • Place identification marks on the left and right ring gear mounting case bearings to distinguish them (backside, teeth side). Then store them separately (when reusing the ring gear mounting case bearings).

*a

Turn

*b

Hold

(b) for LH side:

(1) Using SST, remove the ring gear mounting case bearing (inner race) from the transfer ring gear mounting case.

SST: 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09955-04061

09957-04010

09958-04011

SST: 09950-60010

09951-00400

NOTICE:

  • Use SST (09953-04020) after applying grease to its threads and tip.
  • Do not deform the cage of the ring gear mounting case bearing (inner race) (when reusing the ring gear mounting case bearing (inner race)).
  • Place identification marks on the left and right ring gear mounting case bearings to distinguish them (backside, teeth side). Then store them separately (when reusing the ring gear mounting case bearings).

*a

Turn

*b

Hold

(2) Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the ring gear mounting case bearing (outer race) to remove it from the transfer case sub-assembly.

NOTICE:

Fit the brass bar to the 2 cutouts of the transfer case sub-assembly.

(3) Remove the ring gear mounting case plate washer from the transfer case sub-assembly.

NOTICE:

If the ring gear mounting case plate washer is damaged or deformed, replace it with a new one.

26. INSPECT RUNOUT OF RING GEAR

Click here

27. REMOVE RING GEAR

(a) Secure the transfer ring gear mounting case in a vise using aluminum plates.

NOTICE:

Be careful not to damage the transfer ring gear mounting case in the vise.

(b) Put matchmarks on the transfer ring gear mounting case and ring gear.

*a

Matchmark

(c) Remove the 12 bolts.

(d) Using a plastic hammer, remove the ring gear from the transfer ring gear mounting case.

NOTICE:

Do not damage the ring gear teeth.

28. INSPECT TRANSFER RING GEAR MOUNTING CASE

Click here

29. REMOVE REAR TRANSFER DRIVEN PINION BEARING (OUTER RACE)

(a) Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the rear transfer driven pinion bearing (outer race) to remove it from the transfer case sub-assembly.

NOTICE:

Fit the brass bar to the 2 cutouts of the transfer case sub-assembly.

    Installation
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    REASSEMBLY PROCEDURE 1. INSTALL REAR TRANSFER DRIVEN PINION BEARING (OUTER RACE) (a) Using SST and a press, install the rear transfer driven pinion bearing (outer race) to the transfer case sub-ass ...

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