RX400h · Service Manual HYBRID SYSTEM

INSTALLATION

Removal / installation


1. INSTALL DUST COVER

  1. C114604E03
    Using SST, steel plate and a press, install a new dust cover.
    SST
    09527-21011  

    NOTICE:
    Do not damage the dust cover.


2. INSTALL DIFFERENTIAL SIDE GEAR SHAFT SUB-ASSEMBLY

  1. Install a new snap ring.

  1. C105716E03
    Using SST, install the side gear shaft.
    SST
    09520-24010   (09520-04010, 09520-32040)

    NOTICE:
    1. Set the snap ring with the opening side facing downward.
    2. Do not tap in the side gear shaft at an angle. If it is installed at an angle, replace the snap ring with a new one and tap in the shaft again.
    3. Do not damage the oil seal.

  1. C114607E01
    Using vernier calipers, measure the distance between the right and left side gear shafts, as shown in the illustration.

    Standard distance:
    272.9 mm (107.44 in.) or less


3. INSTALL REAR DRIVE SHAFT ASSEMBLY

  1. Align the matchmarks.

  1. C108295E01
    Install the rear drive shaft assembly with the 4 nuts and washers.

    Torque:
    56 N*m{ 571 kgf*cm , 41 ft.*lbf }


4. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.2

  1. C105711
    Jack up the rear axle carrier, placing a wooden block to avoid damage.

  1. C105710
    Temporarily tighten the rear suspension arm assembly No.2 with the bolt and nut.

    HINT:
    Insert the bolt from the rear side of the vehicle and lightly tighten the bolt.


5. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.1

  1. C105709
    Temporarily tighten the rear suspension arm assembly No.1 with the bolt and nut.

    HINT:
    Insert the bolt from the front side of the vehicle and lightly tighten the bolt.


6. TEMPORARILY TIGHTEN REAR STRUT ROD ASSEMBLY

  1. C105708
    Temporarily tighten the strut rod assembly rear with the bolt and nut.

    HINT:
    Insert the bolt from the inside of the vehicle and lightly tighten the bolt.


7. STABILIZE SUSPENSION

  1. C107473E01
    Jack up the rear axle carrier, placing a wooden block to avoid damage. Apply load to the suspension so that the rear drive shaft assembly is horizontally positioned.


8. FULLY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.2

  1. C105710
    Fully tighten the bolt.

    Torque:
    112 N*m{ 1,140 kgf*cm , 83 ft.*lbf }

    NOTICE:
    Turn the bolt while holding the nut.


9. FULLY TIGHTEN REAR SUSPENSION ARM ASSEMBLY NO.1

  1. C105709
    Fully tighten the bolt.

    Torque:
    112 N*m{ 1,140 kgf*cm , 83 ft.*lbf }

    NOTICE:
    Turn the bolt while holding the nut.


10. FULLY TIGHTEN REAR STRUT ROD ASSEMBLY

  1. C105708
    Fully tighten the bolt.

    Torque:
    80 N*m{ 816 kgf*cm , 59 ft.*lbf }

    NOTICE:
    Turn the bolt while holding the nut.


11. INSTALL HEIGHT CONTROL SENSOR

  1. I036885
    Install the height control sensor with the 2 bolts.

    Torque:
    7.8 N*m{ 80 kgf*cm , 69 in.*lbf }

  1. E112351
    Install the height control sensor link with the "torx" nut.

    Torque:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

  1. Connect the connector.


12. INSTALL REAR AXLE SHAFT NUT

  1. Using a socket wrench (30mm), install a new rear axle shaft nut.

    Torque:
    294 N*m{ 3,000 kgf*cm , 217 ft.*lbf }

  1. C108171
    Using a chisel and hammer, stake the rear axle shaft nut.


13. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
(Click here)

14. INSTALL EXHAUST PIPE ASSEMBLY (for RH Side)
(Click here)

15. INSTALL REAR WHEEL

16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (for RH Side)

17. ADD AND INSPECT HYBRID TRANSAXLE FLUID

  1. C105706E01
    Check that the oil surface is within 5 mm (0.20 in.) from the lowest position of the inner surface of the transaxle filler plug opening.

    Transaxle fluid quantity:
    1.8 L (1.9 US qts, 1.6 Imp. qts)

    NOTICE:
    1. Stop the vehicle on a flat road.
    2. Recheck the transaxle oil level after driving when exchanging oil.
    3. Insufficient or excessive amounts of transaxle oil may be the cause of some trouble.

  1. Check for leaks if the quantity of oil is low.

  1. Using a socket hexagon wrench 10 mm, install the filler plug and a new gasket.

    Torque:
    39 N*m{ 398 kgf*cm , 29 ft.*lbf }


18. HEADLIGHT AIM ONLY (for RH Side)
(Click here)

19. PERFORM INITIALIZATION (for RH Side)
(Click here)
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