Toyota Highlander 6 2001-06

CV-Joints

Print

Overhaul



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the inboard and outboard joint boot clamps.
  4.  
  5. Disassemble the inboard joint tulip, as follows:
    WARNING
    Do not use punch marks.



    Matchmark the tri-pot, inboard joint tulip or center driveshaft to the driveshaft
     



    Inboard joint tulip from the driveshaft
     

  6.  
  7. Remove the inboard and outboard joint clamps.
  8.  
  9. Remove the tri-pot joint, as follows:
    WARNING
    Do not tap the roller.



    Snapring
     
    Matchmark the tri-pot joint to the driveshaft
     
    Tri-pot joint, using a brass bar and hammer
     

  10.  
  11. Remove or disconnect the following:
    NOTE
    Do not disassemble the outboard joint.



    Inboard and outboard joint boots
     



    Dust cover from the center driveshaft, using a press, for 2WD on the right side
     
    Dust cover from the inboard joint tulip, using tool 09950-00020 and a press, for 2WD on the left side and 4WD
     

  12.  
  13. Disassemble the center driveshaft, as follows:

    Snapring
     
    Bearing case, using a press
     
    Straight pin from the bearing case, using a pin punch and hammer
     
    Dust cover, using tool 09950-00020 and a press
     
    Snapring
     
    Bearing, using a press
     

  14.  
  15. Remove the No. 2 dust deflector, using a screwdriver and hammer.

    Click image to see an enlarged view

    Fig. Exploded view of the rear halfshaft-2004-06 Highlander

  16.  

To assemble:

  1. Install a new No. 2 dust deflector, using a press.
  2.  
  3. Assemble the center driveshaft, as follows:

    Straight pin into the bearing case, using a pin punch and hammer
     
    New bearing, using tools 09959-60010, 09950-70010 and a press
     
    New snapring
     
    Bearing with the bearing case assembly to the center driveshaft, using tool 09710-30021 and a press
     
    New snapring
     
    New dust cover, until the clearance between the dust cover and the bearing is 0.039 in. (1.0mm)
     

  4.  
  5. Install or connect the following:

    Right dust cover (2WD), until the distance from the tip of the center drive is 3.39-3.34 in. (86-87mm) to the inner edge of the dust cover
     
    Left side dust cover (2WD and 4WD), using a press
     

  6.  
  7. Temporarily install new outboard/inboard joint boots using new clamps, as follows:
    1. Warp tape around the driveshaft splines.
    2.  
    3. Install the new outboard joint boot onto the driveshaft.
    4.  
    5. Install the new inboard joint boot onto the driveshaft.
    6.  

  8.  
  9. Install the tri-pot joint, as follows:
    WARNING
    Be careful not to tap the roller.



    Tri-pot joint, face the beveled side toward the outboard joint and align the matchmarks
     
    Tri-pot joint onto the driveshaft, using a press
     



    New snapring
     

  10.  
  11. Install the outboard joint boot packed with grease from the boot kit.
  12.  
  13. Install the inboard joint tulip, as follows:

    Pack the inboard joint boot with grease from the boot kit
     
    Inboard joint tulip, by aligning the matchmarks
     
    Temporarily, install the inboard joint boot packed with grease from the kit
     

  14.  
  15. Install the boot clamps to both boots, as follows:

    Both boots to the shaft grooves
     
    Halfshaft length should be 33.055-33.449 in. (839.6-849.6mm) for the right side on 2WD with A/T, 21.397-21.791 in. (543.5-553.5mm) for the left side on 2WD with A/T, 19.929-20.323 in. (506.2-516.2mm) for the right side on 4WD or 19.803-20.197 in. (503-511mm) for the left side on 4WD
     
    Both new boot clamps boot
     
    Bend the band and lock it using a screwdriver
     

  16.  

Hybrid
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the inboard and outboard joint boot clamps.
  4.  
  5. Disassemble the inboard joint tulip, as follows:
    WARNING
    Do not use a punch to make the marks.



    Matchmark the tri-pot, inboard joint tulip or center driveshaft to the driveshaft
     



    Inboard joint tulip from the driveshaft
     

  6.  
  7. Remove the inboard and outboard joint clamps.
  8.  
  9. Remove the tri-pot joint, as follows:
    WARNING
    Do not tap the roller.



    Snapring
     
    Matchmark the tri-pot joint to the driveshaft
     
    Tri-pot joint, using a brass bar and hammer
     

  10.  
  11. Remove or disconnect the following:
    NOTE
    Do not disassemble the outboard joint.



    Inboard and outboard joint boots
     



    Dust cover from the center driveshaft, using a press, for 2WD on the right side
     
    Dust cover from the inboard joint tulip, using tool 09950-00020 and a press, for 2WD on the left side and 4WD
     

  12.  
  13. Disassemble the center driveshaft, as follows:

    Snapring
     
    Bearing case, using a press
     
    Straight pin from the bearing case, using a pin punch and hammer
     
    Dust cover, using tool 09950-00020 and a press
     
    Snapring
     
    Bearing, using a press
     

  14.  
  15. Remove the No. 2 dust deflector, using a screwdriver and hammer.
  16.  

To assemble:

  1. Install a new No. 2 dust deflector, using a press.
  2.  
  3. Assemble the center driveshaft, as follows:

    Straight pin into the bearing case, using a pin punch and hammer
     
    New bearing, using tools 09959-60010, 09950-70010 and a press
     
    New snapring
     
    Bearing with the bearing case assembly to the center driveshaft, using tool 09726-40010 and a press
     
    New snapring
     
    New dust cover, until the clearance between the dust cover and the bearing is 0.039 in. (1.0mm)
     

  4.  
  5. Install or connect the following:

    Right dust cover (2WD), until the distance from the tip of the center drive 4.311 in. (109.5 mm) to the inner edge of the dust cover
     
    Left side dust cover (2WD and 4WD), using a press
     

  6.  
  7. Temporarily install new outboard/inboard joint boots using new clamps, as follows:
    1. Warp tape around the driveshaft splines.
    2.  
    3. Install the new outboard joint boot onto the driveshaft.
    4.  
    5. Install the new inboard joint boot onto the driveshaft.
    6.  

  8.  
  9. Install the tri-pot joint, as follows:
    WARNING
    Be careful not to tap the roller.



    Tri-pot joint, face the beveled side toward the outboard joint and align the matchmarks
     
    Tri-pot joint onto the driveshaft, using a press
     



    New snapring
     

  10.  
  11. Install the outboard joint boot packed with grease from the boot kit.
  12.  
  13. Install the inboard joint tulip, as follows:

    Pack the inboard joint boot with grease from the boot kit
     
    Inboard joint tulip, by aligning the matchmarks
     
    Temporarily, install the inboard joint boot packed with grease from the kit
     

  14.  
  15. Install the boot clamps to both boots, as follows:

    Both boots to the shaft grooves
     
    Halfshaft length should be 33.055-33.449 in. (839.6-849.6mm) for the right side on 2WD with A/T, 21.397-21.791 in. (543.5-553.5mm) for the left side on 2WD with A/T, 19.929-20.323 in. (506.2-516.2mm) for the right side on 4WD or 19.803-20.197 in. (503-511mm) for the left side on 4WD
     
    Both new boot clamps boot
     
    Bend the band and lock it using a screwdriver
     

  16.  

 
label.common.footer.alt.autozoneLogo