Toyota Highlander Hybrid 6 2005-06

Transaxle Removal & Installation

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2.4L Engine



  1. Remove the engine/transaxle assembly.
  2.  
  3. Remove the halfshafts.
  4.  
  5. Remove the engine mounting bracket (4wd).
  6.  
  7. Remove the transfer case (4wd).
  8.  
  9. Disconnect the wiring.
  10.  
  11. Remove the starter.
  12.  
  13. Remove the cables and hoses.
  14.  
  15. Remove the filler tube.
  16.  
  17. Remove the front engine mount bracket.
  18.  
  19. Remove the flywheel housing undercover.
  20.  
  21. Turn the crankshaft to gain access to the torque converter bolts. There is one green bolt.
  22.  
  23. Remove the 9 engine-to-transaxle bolts. Separate the transaxle from the engine.
  24.  
  25. Installation is the reverse of removal. Observe the following torques:
    NOTE
    Install the green bolt first.



    Transaxle-to-engine: bolts A 47 ft. lbs (64 Nm); bolts B 34 ft. lbs. (46 Nm); bolts C 27 ft. lbs. (37 Nm)
     
    Torque converter bolts (use a thread locking compound such as Three Bond 1324): 30 ft. lbs. (41 Nm)
     



    Undercover: 69 inch lbs. (8 Nm)
     
    Engine mount bracket: 47 ft. lbs. (64 Nm)
     
    Transfer case-to-transaxle: 51 ft. lbs. (69 Nm)

    Click image to see an enlarged view

    Fig. Engine-to-transaxle bolt identification-2.4L Highlander

     

  26.  

3.3L Engine



  1. Remove the engine/transaxle assembly. See Engine Removal and Installation, earlier in this chapter.
  2.  
  3. Remove the halfshafts.
  4.  
  5. Disconnect the wiring.
  6.  
  7. Remove the starter.
  8.  
  9. Remove the cables and hoses.
  10.  
  11. Remove the filler tube.
  12.  
  13. Remove the front engine mount bracket.
  14.  
  15. Remove the flywheel housing undercover.
  16.  
  17. Turn the crankshaft to gain access to the torque converter bolts. There is one green bolt.
  18.  
  19. Separate the transaxle from the engine.
  20.  
  21. Remove the right stiffener plate.
  22.  
  23. Separate the transfer case from the transaxle.
  24.  
  25. Installation is the reverse of removal. Observe the following torques:
    NOTE
    Install the green bolt first.



    Transaxle-to-engine: bolts A 47 ft. lbs (64 Nm); bolts B 34 ft. lbs. (46 Nm); bolts C 27 ft. lbs. (37 Nm)
     
    Torque converter bolts (use a thread locking compound such as Three Bond 1324): 30 ft. lbs. (41 Nm)
     



    Undercover: 69 inch lbs. (8 Nm)
     
    Stiffener plate: 25 ft. lbs. (34 Nm)
     
    Engine mount bracket: 47 ft. lbs. (64 Nm)
     
    Transfer case-to-transaxle: 51 ft. lbs. (69 Nm)

    Click image to see an enlarged view

    Fig. Transaxle-to-engine bolts-3.3L engine

     

  26.  

Hybrid



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Engine/transaxle assembly. See Engine Removal and Installation, earlier in this chapter.
     
    Manifold stay
     
    Transaxle damper
     
    Front frame assembly
     
    Halfshafts
     
    Flywheel housing undercover
     
    Engine wiring harnesses
     
    Transaxle case cover
     
    Coolant hose
     
    Front engine mounting bracket
     
    Transaxle oil cooler assembly
     
    Transmission control cable bracket
     

  4.  
  5. Remove the 8 mounting bolts and separate the transaxle assembly from the vehicle.
  6.  
  7. Installation is the reverse of removal. Observe the following torques:
    NOTE
    Do not reuse Bolt B.



    Transaxle-to-engine: Bolts A to 47 ft. lbs (64 Nm); Bolt B to 34 ft. lbs. (46 Nm); Bolts C to 47 ft. lbs. (64 Nm); Bolts D to 27 ft. lbs. (37 Nm)
     



    Front engine mounting bracket: 47 ft. lbs. (64 Nm)
     
    Transaxle case cover: 74 inch lbs. (8.4 Nm)
     
    Undercover: 69 inch lbs. (8 Nm)
     

  8.  
  9. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.

    Click image to see an enlarged view

    Fig. Transaxle-to-engine bolts

  10.  

 
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