2012 Lexus LS 460L AWDFACTORY OEM SERVICE PROCEDURE

Transfer Assembly: Disassembly: Disassembly

  1. REMOVE DYNAMIC DAMPER 
    1. Remove the bolt, 2 washers and dynamic damper from the rear transfer case.
      Fig 1: Identifying Bolt, 2 Washers And Dynamic Damper
      GTY262815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE TRANSFER CASE PLUG 
    1. Using a 6 mm hexagon socket wrench, remove the 2 case plugs and 2 O-rings from the front transfer case.
      Fig 2: Identifying Case Plugs And O-Rings
      GTY275962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE FILLER PLUG 
    1. Using a 10 mm hexagon socket wrench, remove the filler plug and gasket from the rear transfer case.
      Fig 3: Identifying Filler Plug And Gasket
      GTY257316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE TRANSFER DRAIN PLUG 
    1. Using a 10 mm hexagon socket wrench, remove the drain plug and O-ring from the front transfer case.
      Fig 4: Identifying Drain Plug And O-Ring From Front Transfer Case
      GTY257315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE TRANSFER CASE BREATHER PLUG 
    1. Remove the breather plug from the front transfer case.
      Fig 5: Identifying Breather Plug
      GTY136389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE NO. 2 TRANSFER CASE PLUG 
    1. Using a 17 mm straight hexagon wrench, remove the case plug and gasket from the rear transfer case.
      Fig 6: Identifying Case Plug And Gasket
      GTY262817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY 
    1. Using SST, hold the companion flange in place.
      • SST: 09213-58014 
      • SST: 09330-00021 

      HINT: 

      Use bolts of size M8 x P1.25 with a length of approximately 55 mm (2.16 in.) or equivalent to secure the companion flange.

      Fig 7: Using SST To Hold Companion Flange
      GTY121806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the companion flange bolt and companion flange from the transfer assembly.
      Fig 8: Identifying Companion Flange Bolt And Companion Flange
      GTY263046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
  8. REMOVE DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY 
    1. Using SST and a hammer, loosen the staked part of the transfer output shaft nut.
      • SST: 09930-00010 
        • Fig 9: Loosening Staked Part Of Transfer Output Shaft Nut
        GTY289476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Completely loosen the staked part of the transfer output shaft nut.
      • Do not damage the threads of the No. 1 differential case.
      • Use SST with the tapered surface facing the No. 1 differential case.
      • Do not grind the end of SST with a grinder or other tool.
    2. Using SST, hold the companion flange in place.
      • SST: 09330-00021 
      • SST: 09950-30012 
        • 09955-03040
        Fig 10: Holding Companion Flange In Place
        GTY273360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
    3. Using a 30 mm socket wrench, remove the transfer output shaft nut.
    4. Using SST, remove the companion flange.
      • SST: 09950-30012 
        • 09951-03010
        • 09953-03010
        • 09954-03010
        • 09955-03040
        Fig 11: Identifying Companion Flange
        GTY268734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
  9. REMOVE TRANSFER EXTENSION HOUSING OIL SEAL 
    1. Using SST, remove the oil seal.
      • SST: 09308-00010 
        • Fig 12: Identifying Oil Seal
        GTY135111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful not to damage the surface of the transfer extension housing that contacts the oil seal.
  10. REMOVE NO. 1 DIFFERENTIAL CASE HOLE SNAP RING 
    1. Using needle-nose pliers, remove the snap ring from the extension housing.
      Fig 13: Identifying Snap Ring
      GTY127859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE TRANSFER EXTENSION HOUSING 
    1. Remove the 11 bolts and bracket.
      Fig 14: Identifying Bolts And Bracket
      GTY262820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an oil pan seal cutter, remove the extension housing.
      NOTE: Be careful not to damage the contact surface of the extension housing or rear transfer case.
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