TOYOTA HIGHLANDER 2001 Service Repair Manual

C82983
SST
C82792C83635
SST
SA1143
Boiling Water
- TRANSFERTRANSFER ASSY (4WD)
31-21
3099 Author
: Date
:
(c) Using SST, tighten a new transfer gear nut (at a standard
torque.)
SST 09326-2001 1, 09556-16030
Torque:
277 to 378 NVm (2,820 to 3,855 kgfVcm, 204 to 279 ftVlbf)
NOTICE:
Do not stake the transfer gear nut.
HINT:
Use a torque wrench with a fulcrum length of 750 mm (29.53 in.)
50. INSPECT AND ADJUST DRIVEN PINION PRELOAD
(a) Using SST and a torque wrench, measure the initial
torque of the driven pinion.
Preload (at starting):
New bearing:
1.1 to 1.6 NVm (11 to 16 kgfVcm, 9.7 to 14.2 in.Vlbf)
Used bearing:
0.9 to 1.4 NVm (9 to 14 kgfVcm, 8.0 to 12.4 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)
NOTICE:
Measure preload after rotating the bearing both clockwise
and counterclockwise to make it fit.
(b) If the preload is too large, replace the transfer pinion
bearing spacer with a new one.
(c) If the preload is too small, repeatedly adjust the preload
by tightening the transfer gear nut 5 to 10 degrees at a
time until the standard value is obtained.
(d) If the preload is insufficient, even though the tightening
torque of the transfer gear nut exceeds the maximum of
the standard value, loosen the transfer gear nut and apply
gear oil SAE 90 (GL-5) to the transfer gear nut and the
screw thread and the base of the driven pinion. And then
repeat the preceding operation. If the tightening torque is
smaller than the standard, replace the transfer pinion
bearing spacer with a new one and adjust it.
SST 09326-2001 1, 09556-16030
Torque: 378 NVm (3,855 kgfVcm, 279 ftVlbf)
51. INSTALL RING GEAR
(a) Completely remove grease and moisture on the contact
surfaces of the ring gear and the transfer ring gear mount-
ing case.
(b) Heat the ring gear in boiling water from 90 to 100C (194
to 212F).
(c) Carefully take the ring gear out of the boiling water.

C50361C83652
Matchmarks
C50342C83653
SST
C67688
SST
C67673
31-22
- TRANSFERTRANSFER ASSY (4WD)
3100 Author
: Date
:
(d) Align the matchmarks on the ring gear and transfer ring
gear mounting case and quickly assemble them.
(e) Tighten the12 bolts.
Torque: 78 NVm (790 kgfVcm, 57 ftVlbf)
NOTICE:

Tighten the bolts in diagonal order in splitting several
times.

After the ring gear has well cooled down, fully tighten
the bolts.

Make the bolt heads in order to check if they are re-
tightened or not.
52. INSTALL CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) RH side:
Using SST and a press, install the inner race of the center
differential case tapered roller bearing to the transfer ring
gear mounting case.
SST 09506-35010, 09950-60010 (09951-00430)
NOTICE:
When replacing the inner race, replace it together with the
outer race.
(b) LH side:
Using SST and a press, install the inner race of the center
differential case tapered roller bearing to the transfer ring
gear mounting case.
SST 09223-00010
NOTICE:
When replacing the inner race, replace it together with the
outer race.
53. INSTALL TRANSFER RING GEAR MOUNTING CASE
(a) Install the transfer ring gear mounting case to the transfer
case.
NOTICE:
Damage to the spline, the bearing's rotating surface and
gear face may cause a decrease in their strength. Care
should be taken when installing them.
54. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2
(a) Install the transfer ring gear mounting case washer No.2 to the transfer RH bearing retainer sub-assy.
HINT:
Reuse the washer.

C50344C83654
SST
C57486
C57487
SST
C57488
C57489
- TRANSFERTRANSFER ASSY (4WD)
31-23
3101 Author
: Date
:
55. INSTALL CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) Using SST and a press, install the center differential case
tapered roller bearing RH outer race to the transfer RH
bearing retainer sub-assy.
SST 09950- 60010 (09951- 00620), 09950- 70010
(09951-07150)
56. INSTALL TRANSFER RH BEARING RETAINER
SUB-ASSY
(a) Place the transfer with the face where the transfer RH
bearing retainer sub-assy is to be installed facing up.
(b) Center-align the transfer ring gear mounting case and
the transfer case.
(c) Insert the SST into the transfer RH bearing retainer sub-
assy.
SST 09387-00090
NOTICE:
Insert SST straight in order not to damage the oil seal lip.
(d) Insert the transfer RH bearing retainer sub-assy together
with the SST into the transfer case.
NOTICE:
Interference between the case and retainer, and between
the transfer ring gear mounting case and SST should be
carefully avoided.
HINT:
If the retainer cannot be inserted, tap it in with a plastic hammer.
(e) After inserting the transfer RH bearing retainer sub-assy
into the transfer case, remove the SST.

C83509
C50309
C50345C83655
Ring Gear Mounting
Case Plate Washer 31-24
- TRANSFERTRANSFER ASSY (4WD)
3102 Author
: Date
:
(f) Tighten the 7 bolts.
Torque: 28 NVm (286 kgfVcm, 21 ftVlbf)
57. INSPECT BACKLASH
(a) Set the dial indicator perpendicular to the ring gear face,
fix the driven pinion, and check backlash by moving the
ring gear.
Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 in.)
NOTICE:
Measure it at 3 points or more on the ring gear periphery.
(b) If the measured value is out of standard, select a proper
washer for the center differential case tapered roller bear-
ing on the LH side from the table below and install it to ob-
tain the standard value.
MarkWasher Thickness mm (in.)MarkWasher Thickness mm (in.)MarkWasher Thickness mm (in.)
AA2.07 (0.0814)AB2.10 (0.0826)AC2.13 (0.0838)
BA2.16 (0.0850)BB2.19 (0.0862)BC2.22 (0.0874)
CA2.25 (0.0885)CB2.28 (0.0897)CC2.31 (0.0909)
DA2.34 (0.0921)DB2.37 (0.0933)DC2.40 (0.0944)
EA2.43 (0.0956)EB2.46 (0.0968)EC2.49 (0.0980)
FA2.52 (0.0992)FB2.55 (0.1003)FC2.58 (0.1015)
GA2.61 (0.1027)GB2.64 (0.1039)GC2.67 (0.1051)
HA2.70 (0.1062)HB2.73 (0.1074)HC2.76 (0.1086)
JA2.79 (0.1098)JB2.82 (0.1110)JC2.85 (0.1122)
KA2.88 (0.1133)KB2.91 (0.1145)KC2.94 (0.1157)
LA2.97 (0.1169)LB3.00 (0.1181)
HINT:
When the backlash is larger or smaller than the standard, select
a thinner or thicker washer respectively.
(c) Ring gear mounting case plate washer location is shown
in the illustration.

C50346
K3673 C30886C83636
Proper ContactHeel ContactFace Contact
Toe ContactFlank Contact Select an adjusting washer that will bring
the driven pinion closer to the ring gear.
Select an adjusting washer that will shift
the drive pinion away from the ring gear.
- TRANSFERTRANSFER ASSY (4WD)
31-25
3103 Author
: Date
:
58. INSPECT TOOTH CONTACT BETWEEN RING GEAR
AND DRIVEN PINION
(a) Apply red lead primer thinly and uniformly to both faces
of the ring gear and rotate it several times.
NOTICE:
Check the tooth contact on the ring gear at 4 places or
more.
(b) Observe the pattern shown by red lead primer.
(c) In case of poor tooth contact, select a washer for the driv-
en pinion bearing front side from the following table and
replace it.
NOTICE:
If the washer thickness is changed, the backlash will be
also changed.
MarkWasher Thickness mm (in.)MarkWasher Thickness mm (in.)MarkWasher Thickness mm (in.)
AA1.20 (0.0472)AC1.22 (0.0480)BB1.24 (0.0488)
CA1.26 (0.0496)CC1.28 (0.0503)DB1.30 (0.0511)
EA1.32 (0.0519)EC1.34 (0.0527)FB1.36 (0.0535)
GA1.38 (0.0543)GC1.40 (0.0551)HB1.42 (0.0559)
JA1.44 (0.0566)JC1.46 (0.0574)KB1.48 (0.0582)
LA1.50 (0.0590)LC1.52 (0.0598)MB1.54 (0.0606)
NA1.56 (0.0614)NC1.58 (0.0622)PB1.60 (0.0629)
QA1.62 (0.0637)QC1.64 (0.0645)

C50363C83656
Transfer Output Washer
C82792C83635
SST 31-26
- TRANSFERTRANSFER ASSY (4WD)
3104 Author
: Date
:
(d) The location of the transfer output washer for tooth con-
tact adjustment is shown in the illustration.
59. ADJUST TOTAL PRELOAD
(a) Using SST and a torque wrench, measure the initial
torque with the driven pinion being contact with the ring
gear face.
SST 09326-2001 1
Torque:
New bearing:
Driven pinion preload +0.2 to 0.4 NVm
(+2.3 to 3.9 kgfVcm, 1.8 to 3.5 in.Vlbf)
Used bearing:
Driven pinion preload +0.15 to 0.30 NVm
(+1.6 to 3.1 kgfVcm, 1.3 to 2.7 in.Vlbf)
NOTICE:
Before measurement, rotate the bearing in both directions
several times to make it fit.
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).
(b) If the value is out of standard range, select the washer for
the center differential case tapered roller bearing RH side
from the following table and replace it.
MarkWasher Thickness mm (in.)MarkWasher Thickness mm (in.)MarkWasher Thickness mm (in.)
AA1.47 (0.0578)AB1.50 (0.0590)AC1.53 (0.0602)
BA1.56 (0.0614)BB1.59 (0.0625)BC1.62 (0.0637)
CA1.65 (0.0649)CB1.68 (0.0661)CC1.71 (0.0673)
DA1.74 (0.0685)DB1.77 (0.0696)DC1.80 (0.0708)
EA1.83 (0.0720)EB1.86 (0.0732)EC1.89 (0.0744)
FA1.92 (0.0755)FB1.95 (0.0767)FC1.98 (0.0779)
GA2.01 (0.0790)GB2.04 (0.0803)GC2.07 (0.0814)
HA2.10 (0.0826)HB2.13 (0.0838)HC2.16 (0.0850)
JA2.19 (0.0862)JB2.22 (0.0874)JC2.25 (0.0885)
KA2.28 (0.0897)KB2.31 (0.0909)KC2.34 (0.0921)
LA2.37 (0.0933)LB2.40 (0.0944)LC2.43 (0.0956)
MA2.46 (0.0968)MB2.49 (0.0980)MC2.52 (0.0992)
NA2.55 (0.1003)NB2.58 (0.1015)

C50349C83657
Transfer Ring
Gear Mounting
Case Washer
No.2
C70532
C83509
C82797
C82981
SST
- TRANSFERTRANSFER ASSY (4WD)
31-27
3105 Author
: Date
:
(c) The location of the transfer ring gear mounting case
washer No.2 for preload adjustment is shown in the il-
lustration.
(d) Using a chisel, stake the transfer gear nut.
60. REMOVE TRANSFER RH BEARING RETAINER
SUB-ASSY
(a) Remove the 7 bolts from the transfer RH bearing retainer
sub-assy .
(b) Using a screwdriver and a hammer, make a opening be-
tween the transfer RH bearing retainer sub-assy and the
transfer case.
NOTICE:
Be careful not to damage the transfer RH bearing retainer
sub-assy and the transfer case.
(c) Using SST, remove the transfer RH bearing retainer sub-
assy from the transfer case.
SST 09520-10021

C50341C83688
SST
C50364C83699
C50350C83689
SST1.5 to 2.5 mm
(0.059 to 0.098 in.)
C51147C83690
SST
31-28
- TRANSFERTRANSFER ASSY (4WD)
3106 Author
: Date
:
61. REMOVE CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) Fix the transfer RH bearing retainer sub-assy in a vise.
(b) Using SST, remove the center differential case tapered
roller bearing RH outer race and transfer ring gear mount-
ing case washer No.2 from the transfer RH bearing retain-
er sub-assy.
SST 09308-00010
62. INSTALL SIDE GEAR SHAFT HOLDER BEARING
(a) Install the side gear shaft holder bearing to the transfer
RH bearing retainer sub-assy.
(b) Using snap ring pliers, install the side gear shaft holder
hole snap ring.
HINT:
Check that the side gear shaft holder hole snap ring fits in the
groove of the transfer RH bearing retainer sub-assy.
63. INSTALL TRANSFER RH BEARING RETAINER OIL
SEAL
(a) Using SST and a press, install the transfer RH bearing re-
tainer oil seal No.2 to the transfer RH bearing retainer
sub-assy .
SST 09950- 60010 (09951- 00350, 09951- 00560,
09952-06010), 09950-70010 (09951-07150)
NOTICE:
Carefully press-fit so that the oil seal will not be tilted.
(b) Apply small amount of MP grease No.2 to the oil seal lip.
64. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2
(a) Install the selected transfer ring gear mounting washer No.2 to the transfer RH bearing retainer sub-
assy.
65. INSTALL CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) Using SST and a press, install the center differential case
tapered roller bearing RH outer race to the transfer RH
bearing retainer sub-assy.
SST 09950- 60010 (09951- 00620), 09950- 70010
(09951-07150)

C50352
C57486
C57487
SST
C57488
- TRANSFERTRANSFER ASSY (4WD)
31-29
3107 Author
: Date
:
66. INSTALL O-RING
(a) Coat 2 new O-rings with hypoid gear oil.
(b) Install the 2 O-rings to the transfer RH bearing retainer
sub-assy .
NOTICE:
Be careful not to twist the O-ring but to fit it properly in the
retainer 's groove.
67. INSTALL TRANSFER RH BEARING RETAINER
SUB-ASSY
(a) Place the transfer with the surface where the transfer RH
bearing retainer sub-assy is facing up.
(b) Align the centers of the transfer ring gear mounting case
and the transfer case.
(c) Insert SST into the transfer RH bearing retainer sub-
assy.
SST 09387-00090
NOTICE:
Insert SST straight in order not to damage the oil seal.
(d) Insert the transfer RH bearing retainer sub-assy together
with SST into the transfer case.
NOTICE:

Avoid interference between the case and the retainer,
and between the SST and the transfer ring gear
mounting case.

Carefully check the retainer's O-ring for damage and
incorrect fitting.
HINT:
If the retainer cannot be inserted into the case, tap it in with a
plastic hammer.

C57489
C83509
C82792C83650
SST
C50351C83691SST
0.7 to 1.3 mm
(0.028 to 0.051 in.)
31-30
- TRANSFERTRANSFER ASSY (4WD)
3108 Author
: Date
:
(e) After inserting the transfer RH bearing retainer sub-assy
into the transfer case, remove the SST.
(f) Tighten the 7 bolts.
Torque: 28 NVm (286 kgfVcm, 21 ftVlbf)
68. INSPECT TOTAL PRELOAD
(a) Using SST and a torque wrench, measure the initial
torque with the driven pinion being in contact with the ring
gear face.
SST 09326-2001 1
Torque:
New bearing:
Driven pinion preload +0.2 to 0.4 NVm
(+2.3 to 3.9 kgfVcm, 1.8 to 3.5 in.Vlbf)
Used bearing:
Driven pinion preload +0.15 to 0.30 NVm
(+1.6 to 3.1 kgfVcm, +1.3 to 2.7 in.Vlbf)
HINT:

Use a torque wrench with a fulcrum length of 160 mm
(6.30 in.).

If the preload is too large, inspect the transfer RH bearing
retainer sub-assy.
69. INSTALL TRANSFER RH BEARING RETAINER OIL
SEAL
(a) Using SST, install the transfer RH bearing retainer oil seal
to the transfer RH bearing retainer sub-assy to the posi-
tion as shown in the illustration.
SST 09223-4601 1
NOTICE:
Install the oil seal carefully so that it will not be tilted.
(b) Apply MP grease to the oil seal lip.