differential TOYOTA HIGHLANDER 2001 Service Repair Manual

'05 HIGHLANDER_U (L/O 0409)
321
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)

In a rollover crash, an unbelted per-
son is significantly more likely to
die than a person wearing a seat
belt. Therefore, the driver and all
passengers should fasten their seat
belts whenever the vehicle is mo-
ving.

When driving off- road or in rugged
terrain, do not drive at excessive
speeds, jump, make sharp turns,
strike objects, etc. This may cause
loss of control or vehicle rollover
causing death or serious injury. You
are also risking expensive damage
to your vehicle's suspension and
chassis.
NOTICE

If driving through water, such as
when crossing shallow streams,
first check the depth of the water
and the bottom of the river bed for
firmness. Drive slowly and avoid
deep water.

Take all necessary safety measures
to ensure that water damage to the
engine or other components does
not occur.
Water entering the engine air intake
will cause severe engine damage.
Water can wash the grease from
wheel bearings, causing rusting and
premature failure, and may also en-
ter the differentials, transmission
and transfer case, reducing the gear
oil's lubricating qualities.

Sand and mud that has accumulated
in brake drums and around brake
discs may affect braking efficiency
and may damage brake system com-
ponents.

Always perform a maintenance in-
spection after each day of off- road
driving that has taken you through
rough terrain, sand, mud, or water.
For scheduled maintenance informa-
tion, refer to the Scheduled Main-
tenance Guideº or Owner's Manual
Supplementº.
Make sure your coolant is properly pro-
tected against freezing.
Only use Toyota Super Long Life Coolantº
or similar high quality ethylene glycol
based non- silicate, non- amine, non- nitrite,
and non- borate coolant with long- life
hybrid organic acid technology. (Coolant
with long- life hybrid organic acid
technology is a combination of low
phosphates and organic acids.)
See Checking the engine coolant levelº
on page 383 in Section 7- 2 for details of
coolant type selection.
For the U.S.A.ÐToyota Super Long Life
Coolantº is a mixture of 50% coolant and
50% deionized water. This coolant pro-
vides protection down to about -35C
(- 31F).
For CanadaÐToyota Super Long Life
Coolantº is a mixture of 55% coolant and
45% deionized water. This coolant pro-
vides protection down to about -42C
(- 44F).
NOTICE
Do not use plain water alone.
Winter driving tips

'05 HIGHLANDER_U (L/O 0409)
409
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
Generally, it is necessary to change
automatic transmission fluid only if your
vehicle is driven under one of the Special
Operating Conditions listed in your
Scheduled Maintenance Guideº or
Owner 's Manual Supplementº. When
changing the automatic transmission fluid,
use only Toyota Genuine ATF Type T- IVº
(ATF JWS3309 or NWS6500) to aid in
assuring optimum transaxle performance.
Notice: Using automatic transmission
fluid other than Toyota Genuine ATF
Type T- IVº may cause deterioration in
shift quality, locking up of your trans-
mission accompanied by vibration, and
ultimately damage the automatic trans-
mission of your vehicle.
Please contact your Toyota dealer for fur-
ther details.
TRANSFER
(four- wheel drive models)
Oil capacity, L (qt., Imp. qt.):
0.9 (1.0, 0.8)
Oil type:
Hypoid gear oil API GL- 5
Recommended oil viscosity:
Above -18
C (0
F)
SAE 90
Below -18
C (0
F)
SAE 80W or 80W- 90REAR DIFFERENTIAL
(four- wheel drive models)
Oil capacity, L (qt., Imp. qt.):
0.9 (1.0, 0.8)
Oil type:
Hypoid gear oil API GL- 5
Recommended oil viscosity:
Above -18
C (0
F)
SAE 90
Below -18
C (0
F)
SAE 80W or 80W- 90
BRAKES
Minimum pedal clearance when depressed
with the force of 490 N (50 kgf, 110 lbf)
with the engine running, mm (in.):
83 (3.3)
Pedal free play, mm (in.):
2Ð3 (0.08Ð0.12)
Pad wear limit, mm (in.):
1.0 (0.04)
Lining wear limit, mm (in.):
1.0 (0.04)
Parking brake adjustment when depressed
with the force of 294 N (30 kgf, 66 lbf):
5Ð7 clicks
Fluid type:
SAE J1703 or FMVSS No.116 DOT 3STEERING
Wheel free play:
Less than 30 mm (1.2 in.)
Power steering fluid type:
Automatic transmission fluid DEXRONII
or III

1 Reset the oil replacement reminder (“MAINT REQD”) light after replacing engine oil, if vehicle is equipped with this light.2 Perform these service items only if you drive primarily under the conditions indicated.3 See page 37 for details.4 Applies to Corolla Matrix 4WD and Sienna 4WD.
Maintenance Log: Cars
15,000 Miles or 18 Months
qReplace engine oil and oil filter1
qRotate tires (except MR2 Spyder)
qClean cabin air filter (Camry)
qTighten drive shaft bolt (Corolla and Corolla Matrix)
qVisually inspect brake linings/drums and brake pads/discs
qInspect the following:__ Ball joints and dust covers
__ Brake lines and hoses
__ Drive shaft boots
__ Engine coolant
3
__ Exhaust pipes and mountings
Note: Driving in heavy traffic, on dirt roads or in urban, dusty or desert areas may shorten
the life of the cabin air filter. Replacement may be needed if you notice reduced air flow
from the air conditioner and heater or if the windows fog easily when you use the "Fresh"
mode. Consult your dealer if any of these conditions occur.
Additional Maintenance Items for Special Operating Conditions2
Driving in desert or on dirt roads:
qInspect engine air filter
qTi ghten nuts and bolts on chassis
Driving while towing:
qReplace rear differential oil4
qR eplace transfer case oil4
qTi gh ten n uts and bolts on chassis
Dealer Service Verification:
Date:
Mileage:
5
__ Rear differential oil4
__ Steering gear box
__ Steering linkage and boots
__ Transfer case oil
4

1 Reset the oil replacement reminder (“MAINT REQD”) light after replacing engine oil, if vehicle is equipped with this light.2 Perform these service items only if you drive primarily under the conditions indicated.3 Required under the terms of the Emission Control Warranty.4 Inspec tthickness measurement and disc runout.5 Ex cept front differential of Corolla Matrix 4WD with manual transmission.6 See page 37 for details.7 Applies t o Coroll a M atrix 4WD and Sienna 4WD.8 Applies to Corolla Matrix 4WD, MR2 Spyder and Sienna 4WD.
Maintenance Log: Cars
30,000 Miles or 36 Months
qReplace engine oil and oil filter1
qRotate tires (except MR2 Spyder)
qReplace cabin air filter (Camry and Camry Solara)
qReplace engine air filter
qReplace spark plugs (ECHO)3
qTighten drive shaft bolt (Corolla and Corolla Matrix)
qInspect the following:__ Ball joints and dust covers
__ Brake lines and hoses
__ Brake linings/drums and brake pads/discs
4
__ Differential oil5
__ Drive shaft boots
__ Engine coolant6
__ Exhaust pipes and mountings
__ Fuel lines and connections, fuel tank band
and fuel tank vapor vent system hoses
Additional Maintenance Items for Special Operating Conditions2
Driving in desert or on dirt roads:
qTighten nuts and bolts on chassis
Driving while towing:
qR epl ac e f ront diff erential oil (all models with manual transmission
e x ce pt Cor oll a M atrix 4WD)
qReplace manual transmission oil
qRepl ac e r ear differential oil8
qRepl ac e t ran sfer case oil7
qTighten nuts and bolts on chassis
Dealer Service Verification:
Date:
M ileage:
7
__ Fuel tank cap gasket
__ Radiator core and condenser
__ Steering gear box
__ Steering linkage and boots
__ Transfer case oil
7
__ Transmission fluid or oil

1 Reset the oil replacement reminder (“MAINT REQD”) light after replacing engine oil, if vehicle is equipped with this light.2 Per for m t hese service items only if you drive primarily under the conditions indicated.3 See p age 37 for details.4 Applies to Corolla Matrix 4WD and Sienna 4WD.
Maintenance Log: Cars
45,000 Miles or 54 Months
qReplace engine oil and oil filter1
qRotate tires (except MR2 Spyder)
qClean cabin air filter (Camry)
qTighten drive shaft bolt (Corolla and Corolla Matrix)
qVisually inspect brake linings/drums and brake pads/discs
qInspect the following:__ Ball joints and dust covers
__ Brake lines and hoses
__ Drive shaft boots
__ E ngine coolant
3
__ Exhaust pipes and mountings
Note: Driving in heavy traffic, on dirt roads or in urban, dusty or desert areas may shorten
t he life of the cabin air filter. Replacement may be needed if you notice reduced air flow
from the air conditioner and heater or if the windows fog easily when you use the "Fresh"
mode. Consult your dealer if any of these conditions occur.
Additional Maintenance Items for Special Operating Conditions2
Driving in desert or on dirt roads:
qInspect engine air filter
qTighten nuts and bolts on chassis
Driving while towing:
qReplace rear differential oil4
qReplace transfer case oil4
qTighten nuts and bolts on chassis
Dealer Service Verification:
Date:
M ileage:
9
__ R ear differential oil4
__ Steering gear box
__ Steering linkage and boots
__ Transfer case oil
4

1 Reset the oil replacement reminder (“MAINT REQD”) light after replacing engine oil, if vehicle is equipped with this light.2 Perform these service items only if you drive primarily under the conditions indicated.3 R equ ir ed under the terms of the Emission Control Warranty.4 Inspect thickness measurement and disc runout.5 Except front differential of Corolla Matrix 4WD with manual transmission.6 Initial inspection at 60,000 miles/72 months. Inspect every 15,000 miles/18 months thereafter.7 See page 37 for details.8 Applies to Corolla Matrix 4WD and Sienna 4WD.9 Applies t o Corolla Matrix 4WD, MR2 Spyder and Sienna 4WD.
Maintenance Log: Cars
60,000 Miles or 72 Months
qReplace engine oil and oil filter1
qRotate tires (except MR2 Spyder)
qReplace cabin air filter (if equipped)
qReplace engine air filter
qReplace spark plugs (ECHO)3
qTighten drive shaft bolt (Corolla and Corolla Matrix)
qInspect the following:__ Ball joints and dust covers
__ B rake lines and hoses
__ Brake linings/drums and brake pads/discs
4
__ Differential oil5
__ Drive belts6
__ Drive shaft boots
__ Engine coolant7
__ Engine valve clearance
__ Exhaust pipes and mountings
Additional Maintenance Items for Special Operating Conditions2
Dr iv ing in desert or on dirt roads:
qTighten nuts and bolts on chassis
Driving while towing:
qReplace front differential oil
qReplace rear differential oil9
qReplace transfer case oil8
qReplace transmission fluid or oil
qTighten nuts and bolts on chassis
Dealer Service Verification:
Date:
M ileage:
11
__ Fuel lines and connections, fuel tank band
and fuel tank vapor vent system hoses
__ Fuel tank cap gasket
__ Radiator core and condenser
__ Steering gear box
__ Steering linkage and boots
__ Transfer case oil
8
__ Transmission fluid or oil

1 Reset the oil replacement reminder (“MAINT REQD”) light after replacing engine oil, if vehicle is equipped with this light.2 Perform these service items only if you drive primarily under the conditions indicated.3 See page 37 for details.4 Applies to Corolla Matrix 4WD and Sienna 4WD.
Maintenance Log: Cars
75,000 Miles or 90 Months
qReplace engine oil and oil filter1
qRotate tires (except MR2 Spyder)
qClean cabin air filter (Camry)
qTighten drive shaft bolt (Corolla and Corolla Matrix)
qVisually inspect brake linings/drums and brake pads/discs
qInspect the following:__ Ball joints and dust covers
__ Brake lines and hoses
__ Drive belts
__ Drive shaft boots
__ Engine coolant
3
Note: Driving in heavy traffic, on dirt roads or in urban, dusty or desert areas may shorten
the life of the cabin air filter. Replacement may be needed if you notice reduced air flow
from the air conditioner and heater or if the windows fog easily when you use the "Fresh"
mode. Consult your dealer if any of these conditions occur.
Additional Maintenance Items for Special Operating Conditions2
Driving in desert or on dirt roads:
qInspect engine air filter
qTi ghten nuts and bolts on chassis
Driving while towing:
qReplace rear differential oil4
qR eplace transfer case oil4
qTi gh ten n uts and bolts on chassis
Dealer Service Verification:
Date:
Mileage:
13
__ Exhaust pipes and mountings
__ R ear differential oil4
__ Steering gear box
__ Steering linkage and boots
__ Transfer case oil
4

Dealer Service Verification:
Date:
Mileage:
1 Reset the oil replacement reminder (“MAINT REQD”) light after replacing engine oil, if vehicle is equipped with this light.2 Perform these service items only if you drive primarily under the conditions indicated.3 Required under the terms of the Emission Control Warranty.4 Inspec tthic kness measurement and disc runout.5 Ex ce pt front differential of Corolla Matrix 4WD with manual transmission.6 See page 37 for details.7 Applies to Corolla Matrix 4WD and Sienna 4WD.8 Applies to Corolla Matrix 4WD, MR2 Spyder and Sienna 4WD.
Maintenance Log: Cars
90,000 Miles or 108 Months
qReplace engine oil and oil filter1
qRotate tires (except MR2 Spyder)
qReplace cabin air filter (Camry and Camry Solara)
qReplace engine air filter
qReplace spark plugs (ECHO)3
qReplace timing belt (Camry with 1MZFE or 3MZFE, Camry Solara with
3MZFE, Sienna)
qTighten drive shaft bolt (Corolla and Corolla Matrix)
qInspect the following:__ Ball joints and dust covers
__ Brake lines and hoses
__ Brake linings/drums and brake pads/discs
4
__ Differential oil5
__ Drive belts
__ Drive shaft boots
__ Engine coolant
6
__ Exhaust pipes and mountings
Additional Maintenance Items for Special Operating Conditions2
Driving in desert or on dirt roads:
qTighten nuts and bolts on chassis
Driving while towing:
qReplace front differential oil (all models with manual transmission
except Corolla Matrix 4WD)
qReplace manual transmission oil
qReplace rear differential oil8
qReplace transfer case oil7
qTighten nuts and bolts on chassis
Dealer Service Verification:
Date:
M ileage:
__ Fuel lines and connections, fuel tank band
and fuel tank vapor vent system hoses
__ Fuel tank cap gasket
__ Radiator core and condenser
__ Steering gear box
__ Steering linkage and boots
__ Transfer case oil
7
__ Tran smis sion flu id oroil
15

1 Reset the oil replacement reminder (“MAINT REQD”) light after replacing engine oil, if vehicle is equipped with this light.2 Perform these service items only if you drive primarily under the conditions indicated.3Initial replacement at 100,000 miles/120 months. Replace every 50,000 miles/60 months thereafter. See page 37
for additional information.
4 See page 37 for details.5 Applies to Corolla Matrix 4WD and Sienna 4WD.
Maintenance Log: Cars
105,000 Miles or 126 Months
qReplace engine oil and oil filter1
qRotate tires (except MR2 Spyder)
qClean cabin air filter (Camry)
qTighten drive shaft bolt (Corolla and Corolla Matrix)
qVisually inspect brake linings/drums and brake pads/discs
qInspect the following:__ B all joints and dust covers
__ Brake lines and hoses
__ Drive belts
__ Dr ive shaft boots
__ Engine coolant
4
Note: Driving in heavy traffic, on dirt roads or in urban, dusty or desert areas may shorten
the life of the cabin air filter. Replacement may be needed if you notice reduced air flow
from the air conditioner and heater or if the windows fog easily when you use the "Fresh"
mode. Consult your dealer if any of these conditions occur.
Additional Maintenance Items for Special Operating Conditions2
Driving in desert or on dirt roads:
qIn spect engine air filter
qTigh ten n uts and bolts on chassis
Driving while towing:
qReplace rear differential oil5
qR epl ac e transfer case oil5
qTigh ten n uts and bolts on c hassis
Dea ler Service Verification:
Date:
M ilea ge:
17
__ Exhaust pipes and mountings
__ Rear differential oil5
__ Steering gear box
__ Steering linkage and boots
__ Transfer case oil
5

1 Reset the oil replacement reminder (“MAINT REQD”) light after replacing engine oil, if vehicle is equipped with this light.2 Per form these service items only if you drive primarily under the conditions indicated.3 Required under the terms of the Emission Control Warranty. Does not apply to Camry PZEV with 2AZFE in California,
New York, Massachusetts, Maine and Vermont. For this model, replacement interval is 150,000 miles.
4 Inspect thickness measurement and disc runout.5 Except front differential of Corolla Matrix 4WD with manual transmission.6 See page 37 for details.7 Applies to Corolla Matrix 4WD and Sienna 4WD.8 Applies to Corolla Matrix 4WD, MR2 Spyder and Sienna 4WD.
Maintenance Log: Cars
120,000 Miles or 144 Months
qReplace engine oil and oil filter1
qRotate tires (except MR2 Spyder)
qReplace cabin air filter (if equipped)
qReplace engine air filter
qReplace spark plugs3
qTighten drive shaft bolt (Corolla and Corolla Matrix)
qInspect the following:__ B all joints and dust covers
__ Brake lines and hoses
__ Brake linings/drums and brake pads/discs
4
__ Diff erential oil5
__ Drive belts
__ Drive shaft boots
__ Engine coolant
6
__ Engine valve clearance
__ Exhaust pipes and mountings
Additional Maintenance Items for Special Operating Conditions2
Driving in desert or on dirt roads:
qTighten nuts and bolts on chassis
Driving while towing:
qReplace front differential oil
qReplace rear differential oil8
qReplace transfer case oil7
qReplace transmission fluid or oil
qTighten nuts and bolts on chassis
Dealer Service Verification:
Date:
Mileage:
19
__ Fuel lines and connections, fuel tank band
and fuel tank vapor vent system hoses
__ Fuel tank cap gasket
__ Radiator core and condenser
__ Steering gear box
__ St eering linkage and boots
__ Transfer case oil
7
__ Transmission fluid or oil