Toyota Highlander Hybrid 6 2005-06

Transfer Case Removal & Installation

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  1. Remove the engine/transaxle assembly.
  2.  
  3. Drain the transaxle.
  4.  
  5. With the 2.4L engine, remove the stiffener plate (5 bolts).

    Click image to see an enlarged view

    Fig. Stiffener plate-Highlander

  6.  
  7. With the 2.4L engine, remove the right rear engine mount bracket (3 bolts).
  8.  
  9. Separate the engine and transaxle.
  10.  
  11. Remove the 2 bolts and 6 nuts and separate the transfer case from the transaxle. It will be necessary to break it loose with a plastic mallet.
    NOTE
    Keep the transfer case level during removal. Don-t grasp the oil seals.



    Click image to see an enlarged view

    Fig. Transfer case fastener locations-Highlander

  12.  

To install:

  1. Clean all grease from the mating surfaces.
  2.  
  3. Apply a continuous 1.2mm diameter bead of silicone gasket material to the transaxle and transfer case as shown.

    Click image to see an enlarged view

    Fig. Gasket material application-Highlander

  4.  
  5. Join the transfer case to the transaxle within 10 minutes of gasket material application. If not, remove the material and start again.
  6.  
  7. Torque the nuts and bolts to 51 ft. lbs. (69 Nm).
  8.  
  9. The remainder of installation is the reverse of removal. Observe the following torques:

    Engine mount bracket: 47 ft. lbs. (64 Nm)
     
    Stiffener plate: 25 ft. lbs. (34 Nm)
     
    Drain plug: 36 ft. lbs. (49 Nm)
     

  10.  

 
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