Toyota Highlander 6 2001-06

Stabilizer Bar (Sway Bar) & Links

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Removal & Installation



4-Wheel Drive
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the front wheel and tire assembly.
  4.  
  5. Remove the 2 nuts and the front left side stabilizer link.
    NOTE
    If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.



    Click image to see an enlarged view

    Fig. Removing the left side stabilizer link-right side similar

  6.  
  7. Remove the 2 nuts and the front right side stabilizer link.
    NOTE
    If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.

  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the front wheel and tire assembly.
  12.  
  13. Remove the 2 nuts and the front left side stabilizer link.
    NOTE
    If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.



    Click image to see an enlarged view

    Fig. Removing the left side stabilizer link-right side similar

  14.  
  15. Remove the 2 nuts and the front right side stabilizer link.
    NOTE
    If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.

    1. As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut.
    2.  
    3. Using a torque wrench, turn the nut continuously at a rate of 2-4 seconds per turn and take the torque reading on the 5th turn. Turning torque: 0.4-17.4 inch lbs. (0.05-1.96 Nm).

      Click image to see an enlarged view

      Fig. Inspecting the stabilizer links

    4.  
    5. If the value is not within the specification, replace the front stabilizer link with a new one.
    6.  

  16.  
  17. On 3.3L engines, remove the front exhaust pipe.
  18.  
  19. Remove left and right no. 1 stabilizer brackets bolts and brackets.
  20.  
  21. Remove left and right no. 2 stabilizer bracket, as follows:
    1. Remove the front stabilizer bracket no.2 from the stabilizer bar bushing
    2.  

  22.  
  23. Separate the left and right side tie rod ends with a suitable puller.
  24.  
  25. Separate steering intermediate shaft sub-assembly
  26.  
  27. Disconnect the return tube and pressure feed tube.
  28.  
  29. Remove the power steering link.
  30.  
  31. Remove front stabilizer bar bushing no.1:
    1. Remove the 2 bushings from the stabilizer.
    2.  

  32.  
  33. On 3.3L engines, remove the manifold stay.
    1. On 3.3L engines, remove the exhaust manifold heat insulator no.1.
    2.  

  34.  
  35. On 3.3L engines, remove the exhaust manifold converter.
  36.  
  37. Remove the stabilizer bar from the vehicle.
  38.  

To install:

  1. Install the stabilizer bar.
  2.  
  3. On 3.3L engines, install the following:
    1. Exhaust manifold converter
    2.  
    3. Exhaust manifold heat insulator no.1
    4.  
    5. Manifold stay
    6.  

  4.  
  5. Install the stabilizer bar no. 1 bushing.
    NOTE
    Install the bushing to the outer side of the bush stopper on the stabilizer bar. Place the cutout of the stabilizer bushing facing the rear side as shown in the illustration.



    Click image to see an enlarged view

    Fig. Proper stabilizer bar bushing installation

  6.  
  7. Install the power steering link.
  8.  
  9. Install the pressure feed tube and the return tube.
  10.  
  11. Connect the steering intermediate shaft.
  12.  
  13. Install the right and left tie rod ends
  14.  
  15. Install right and left no. 2 stabilizer brackets to the no. 1 bushings.
  16.  
  17. Install right and left no. 1 stabilizer bracket and secure with the bolts. Tighten the bolts to 12 ft. lbs. (16 Nm).
  18.  
  19. On 3.3L engines, install the front exhaust pipe.
  20.  
  21. Install the right and left stabilizer links and secure with the nuts. Tighten the nuts to 55 ft. lbs. (74 Nm)
    NOTE
    If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.

  22.  
  23. Install the wheel and tire assembly and secure the lug nuts until they are finger-tight.
  24.  
  25. Lower the vehicle, then tighten the lug nuts to 76 ft. lbs. (103 Nm).
  26.  
  27. Bleed the power steering system.
  28.  
  29. Check and adjust the front wheel alignment.
  30.  
  31. Check and adjust the steering wheel center point
  32.  

Except 4wd Models
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the front wheel and tire assembly.
  4.  
  5. Remove the 2 nuts and the front left side stabilizer link.
    NOTE
    If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.



    Click image to see an enlarged view

    Fig. Removing the left side stabilizer link-right side similar

  6.  
  7. Remove the 2 nuts and the front right side stabilizer link.
    NOTE
    If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.

  8.  
  9. Remove front stabilizer left and right side no. 1 bracket bolts, no. 2 brackets and no. 1 brackets.

    Click image to see an enlarged view

    Fig. Removing the stabilizer bracket

  10.  
  11. Separate the left and right side tie rods, using a suitable puller.
  12.  
  13. Separate the steering gear outlet return tube and the pressure feed tube assembly.
  14.  
  15. Separate the steering intermediate shaft sub-assembly.
  16.  
  17. On 4WD vehicles, remove the rack and pinion power steering gear, as outlined in this section.
  18.  
  19. Remove the front stabilizer bar.
  20.  
  21. Remove front stabilizer bar no. 1 bushing
  22.  
  23. Inspect front stabilizer links, as follows:
    1. As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut.
    2.  
    3. Using a torque wrench, turn the nut continuously at a rate of 2-4 seconds per turn and take the torque reading on the 5th turn. Turning torque: 0.4-17.4 inch lbs. (0.05-1.96 Nm).

      Click image to see an enlarged view

      Fig. Inspecting the stabilizer links

    4.  
    5. If the value is not within the specification, replace the front stabilizer link with a new one.
    6.  

  24.  

To install:

  1. Install the front stabilizer bar no. 1 bushing
    NOTE
    Install the bushing to the inner side of the bushing stopper on the stabilizer bar.



    Click image to see an enlarged view

    Fig. Proper installation of the stabilizer bushing

  2.  
  3. Install the front stabilizer bar.
  4.  
  5. Install the rack pinion power steering gear assembly, on 4wd vehicles.
  6.  
  7. Install the steering intermediate shaft sub-assembly.
  8.  
  9. Install pressure feed tube and the steering gear outlet return tube.
  10.  
  11. Install tie rod assemblies
  12.  
  13. Install the right and left front stabilizer brackets with the retaining bolts. Tighten the bolts to 14 ft. lbs. (19 Nm).
  14.  
  15. Install right and left stabilizer links. Tighten the nuts to 55 ft. lbs. (74 Nm).
    NOTE
    If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.

  16.  
  17. Install the wheel and tire assembly and secure the lug nuts until they are finger-tight.
  18.  
  19. Lower the vehicle, then tighten the lug nuts to 76 ft. lbs. (103 Nm).
  20.  
  21. Bleed the power steering system.
  22.  
  23. Check and adjust the front wheel alignment.
  24.  

Hybrid
  1. Make sure the vehicle-s front wheels are in the straight-ahead position.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the remove front wheel and tire assemblies.
  8.  
  9. Remove the engine under cover.
  10.  
  11. Separate the steering intermediate shaft subassembly.
  12.  
  13. Separate the tie rod.
  14.  
  15. Remove the 2 nuts, then remove the front left stabilizer link assembly:
    NOTE
    If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.

  16.  
  17. Remove the 2 nuts, then remove the front right stabilizer link assembly:
    NOTE
    If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.

  18.  
  19. Remove the 2 bolts, then remove the left stabilizer bracket no. 1 from the front frame assembly.
  20.  
  21. Remove the 2 bolts, then remove the right stabilizer bracket no. 1 from the front frame assembly.
  22.  
  23. Remove the left and right no. 2 stabilizer brackets from the bushings.
  24.  
  25. Remove the 2 stabilizer bar bushings no.1 from the stabilizer bar.
  26.  
  27. Remove the front no.3 exhaust pipe subassembly
  28.  
  29. Remove the front exhaust pipe/
  30.  
  31. Remove the bolt, nut and the manifold stay.
  32.  
  33. Remove the power steering link.
  34.  
  35. Remove the front stabilizer bar from the right side of the vehicle.
  36.  
  37. Inspect the turning of the stabilizer link ball joint:
    1. secure the front stabilizer link assembly in a vise using aluminum plates.
    2.  
    3. Install the nut to the front stabilizer link assembly stud.
    4.  
    5. If using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn. The turning torque should be 18 inch lbs. (2.0 Nm) or less.
      NOTE
      If the turning torque is not within the specified range, replace the front stabilizer link assembly with a new one.

    6.  

  38.  
  39. Inspect the dust cover:
    1. Check that the dust cover is not cracked and that there is no grease on it.
    2.  

  40.  

To install:

  1. Install the front stabilizer bar by inserting it from the right side of the vehicle.
  2.  
  3. Install the power steering link.
  4.  
  5. Install the manifold stay with the bolt and nut. Tighten to 25 ft. lbs. (34 Nm).
  6.  
  7. Install the front exhaust pipe.
  8.  
  9. Install the front no.3 exhaust pipe subassembly.
  10.  
  11. Install the 2 front stabilizer bar bushings no.1 to the outer side of the bushing stopper on the front stabilizer bar.
    NOTE
    Place the cutout of the front stabilizer bar bushing no.1 as facing the rear side as shown in the illustration.



    Click image to see an enlarged view

    Fig. Place the cutout of the front stabilizer bar bushing no.1 as facing the rear side as shown

  12.  
  13. Install the right and left no.2 stabilizer brackets to the stabilizer bushings.
  14.  
  15. Install the right and left no.1 stabilizer bracket to the front frame assembly with the bolts. Tighten to 12 ft. lbs. (16 Nm).
  16.  
  17. Install the right and left stabilizer link assemblies with the nuts and tighten to 55 ft. lbs. (75 Nm).
    NOTE
    If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.

  18.  
  19. Connect the tie rod.
  20.  
  21. Connect steering intermediate shaft subassembly.
  22.  
  23. Make sure the front wheels are facing straight-ahead.
  24.  
  25. Install the engine under cover.
  26.  
  27. Install the front wheels.
  28.  
  29. Connect the negative battery cable.
  30.  
  31. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  32.  
  33. Initialize the rotation angle sensor and calibrate torque sensor zero point.
  34.  
  35. Inspect and adjust the front wheel alignment.
  36.  

 
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