Page 2529 of 2572

C50352
C57486
C57487
SST
C57488
- TRANSFERTRANSFER ASSY (4WD)
31-29
3107 Author: Date:
66. INSTALL O-RING
(a) Coat 2 new O-rings with hypoid gear oil.
(b) Install the 2 O-rings to the transfer RH bearing retainer
sub-assy .
NOTICE:
Be careful not to twist the O-ring but to fit it properly in the
retainer 's groove.
67. INSTALL TRANSFER RH BEARING RETAINER
SUB-ASSY
(a) Place the transfer with the surface where the transfer RH
bearing retainer sub-assy is facing up.
(b) Align the centers of the transfer ring gear mounting case
and the transfer case.
(c) Insert SST into the transfer RH bearing retainer sub-
assy.
SST 09387-00090
NOTICE:
Insert SST straight in order not to damage the oil seal.
(d) Insert the transfer RH bearing retainer sub-assy together
with SST into the transfer case.
NOTICE:
Avoid interference between the case and the retainer,
and between the SST and the transfer ring gear
mounting case.
Carefully check the retainer's O-ring for damage and
incorrect fitting.
HINT:
If the retainer cannot be inserted into the case, tap it in with a
plastic hammer.
Page 2530 of 2572

C57489
C83509
C82792C83650
SST
C50351C83691SST
0.7 to 1.3 mm
(0.028 to 0.051 in.)
31-30
- TRANSFERTRANSFER ASSY (4WD)
3108 Author: Date:
(e) After inserting the transfer RH bearing retainer sub-assy
into the transfer case, remove the SST.
(f) Tighten the 7 bolts.
Torque: 28 NVm (286 kgfVcm, 21 ftVlbf)
68. INSPECT TOTAL PRELOAD
(a) Using SST and a torque wrench, measure the initial
torque with the driven pinion being in contact with the ring
gear face.
SST 09326-2001 1
Torque:
New bearing:
Driven pinion preload +0.2 to 0.4 NVm
(+2.3 to 3.9 kgfVcm, 1.8 to 3.5 in.Vlbf)
Used bearing:
Driven pinion preload +0.15 to 0.30 NVm
(+1.6 to 3.1 kgfVcm, +1.3 to 2.7 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm
(6.30 in.).
If the preload is too large, inspect the transfer RH bearing
retainer sub-assy.
69. INSTALL TRANSFER RH BEARING RETAINER OIL
SEAL
(a) Using SST, install the transfer RH bearing retainer oil seal
to the transfer RH bearing retainer sub-assy to the posi-
tion as shown in the illustration.
SST 09223-4601 1
NOTICE:
Install the oil seal carefully so that it will not be tilted.
(b) Apply MP grease to the oil seal lip.
Page 2531 of 2572

C50353C83631
SST8.7 to 9.3 mm
(0.343 to 0.366 in.)
C50354
C51160C83692
SST
C50365C83693
C50355C83694
SST
1.1 to 1.9 mm
(0.043 to 0.075 in.)
- TRANSFERTRANSFER ASSY (4WD)
31-31
3109 Author: Date:
70. INSTALL TRANSFER CASE OIL SEAL
(a) Using SST, install the transfer case oil seal to the transfer
case at the position as shown as in the illustration.
SST 09387-00010, 09950-70010 (09951-07150)
NOTICE:
Install the oil seal carefully so that it will not be tilted.
(b) Apply small amount of MP grease to the oil seal lip.
71. INSTALL CTR DIFFERENTIAL LOCK SLEEVE
(a) Coat a new O-ring with hypoid gear oil.
(b) Install the O-ring to the CTR differential lock sleeve.
NOTICE:
Be careful not to twist the O-ring but to fit it properly in the
retainer 's groove.
(c) Using SST, install the CTR differential lock sleeve to the
transfer case.
SST 09950- 60010 (09951- 00610), 09950- 70010
(09951-07150)
(d) Using snap ring pliers, install the shaft snap ring.
NOTICE:
Check that the snap ring is fitted in the groove of the ring
gear mounting case.
72. INSTALL TRANSFER EXTENSION HOUSING TYPE T
OIL SEAL
(a) Using SST, install the transfer extension housing type T
oil seal to the transfer extension housing at the position
as shown in the illustration.
SST 09950- 60010 (09951- 00380, 09951- 00580,
09952-06010), 09950-70010 (09951-07150)
NOTICE:
Install the oil seal carefully so that it will not be tilted.
(b) Apply small amount of MP grease No.2 to the oil seal lip.
Page 2532 of 2572

C50356C83695
SST
C83047C83696
Sealant
C82800
C50332D31105
Sealant-
coated
part
31-32
- TRANSFERTRANSFER ASSY (4WD)
3110 Author: Date:
73. INSTALL TRANSFER EXTENSION HOUSING DUST
DEFLECTOR
(a) Using SST and a press, install a new transfer extension
housing dust deflector to the transfer extension housing
sub-assy .
SST 09950- 60020 (09951- 00710), 09950- 70010
(09951-07150)
74. INSTALL TRANSFER EXTENSION HOUSING
SUB-ASSY
(a) Apply sealant 1281 to the transfer extension housing
sub-assy in continuous beaded form of 1.2 mm diameter
as shown in the illustration.
NOTICE:
Wipe any grease off from the attaching surfaces.
Install the transfer extension housing sub-assy with-
in 10 minutes after applying the sealant.
(b) Install the transfer extension housing sub-assy to the
transfer case with the 4 bolts.
Torque: 26 NVm (260 kgfVcm, 19 ftVlbf)
(c) Remove the transfer assy from the overhaul attachment.
75. INSTALL TRANSFER & TRANSAXLE SETTING STUD
BOLT
(a) Install the 4 transfer & transaxle setting stud bolts to the
parts of the transfer case as shown in the illustration.
Torque: 39 NVm (400 kgfVcm, 30 ftVlbf)
NOTICE:
Install the sealant-coated side of the transfer & transaxle
stud bolt to the transfer case.
Page 2533 of 2572

C69282C83712
6.5 to 7.5 mm
(0.256 to 0.295 in.)
10.8 to 11.8 mm
(0.425 to 0.465 in.)
C51143
C67686
C67689C83713
Sealant
- TRANSFERTRANSFER ASSY (4WD)
31-33
3111 Author: Date:
76. INSTALL TRANSFER CASE STRAIGHT PIN
(a) Using a plastic hammer, install the 4 transfer case straight
pins to the transfer case as shown in the illustration.
77. INSTALL TRANSFER DYNAMIC DAMPER
(a) Install the transfer dynamic damper to the transfer exten-
sion housing sub-assy with the 3 bolts.
Torque: 26 NVm (260 kgfVcm, 19 ftVlbf)
78. INSTALL BREATHER OIL DEFLECTOR
(a) Install the breather oil deflector to the transfer case cover
No.1 with the bolt.
Torque: 6.5 NVm (66 kgfVcm, 57 in.Vlbf)
NOTICE:
Be careful of the direction of the deflector's fold.
79. INSTALL TRANSFER CASE COVER NO.1
(a) Apply sealant 1281 to the transfer case cover No.1 in a
continuous bead of 1.2 mm diameter as shown in the il-
lustration.
NOTICE:
Wipe any grease off from the attaching surfaces.
Install the transfer case cover No.1 within 10 minutes
after application of the sealant.
Page 2534 of 2572
C83507
D30774
SST
C82798
C51159C83714
Driving Plug
Sealant
Gasket
31-34
- TRANSFERTRANSFER ASSY (4WD)
3112 Author: Date:
(b) Install the transfer case cover No.1 to the transfer case
with the 8 bolts.
Torque: 20 NVm (200 kgfVcm, 14 ftVlbf)
80. TRANSFER CASE BREATHER PLUG
(a) Using SST and a hammer, install the transfer case breath-
er plug to the transfer case cover No.1.
SST 09612-10061)
81. INSTALL TRANSFER COVER GASKET
(a) Install a new transfer cover gasket to the transfer case.
82. INSTALL TRANSFER ASSY
(a) Apply sealant 1281 to the transaxle assy and the transfer
assy in continuous beaded form of 1.2 mm diameter as
shown in the illustration.
NOTICE:
Wipe any grease off from the attaching surfaces.
Install it within 10 minutes after applying the sealant.
Sealant stuck on the gasket, case oil seal and driving
plug may cause oil leakage and seizure due to oil
shortage. Care must be taken.
Page 2535 of 2572

C82785
F45388
C82977
No.2 PlugNo.1 Plug
Drain Plug
- TRANSFERTRANSFER ASSY (4WD)
31-35
3113 Author: Date:
(b) Install the transfer assy to the transaxle assy with the 2
bolts and 6 nuts.
Torque: 69 NVm (700 kgfVcm, 51 ftVlbf)
NOTICE:
Check that the gasket is installed to the transfer assy
before instaling them to the transaxle assy.
Install the transfer assy to the transaxle assy without
tilting.
When moving the transfer assy, do not hold the oil
seal on the both sides.
83. INSTALL ENGINE MOUNTING BRACKET RR (2AZ-FE ENGINE TYPE)
(a) Install the engine mounting bracket RR with the 3 bolts.
Torque: 64 NVm (652 kgfVcm, 47 ftVlbf)
84. INSTALL TRANSFER STIFFENER PLATE RH (2AZ-FE
ENGINE TYPE)
(a) Install the stiffener plate RH with the 5 bolts.
Torque: 34 NVm (350 kgfVcm, 25 ftVlbf)
85. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE)
(SEE PAGE 40-20)
86. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149)
87. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24)
88. INSTALL TRANSFER DRAIN PLUG
(a) Install the transfer drain plug with a new drain gasket.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
89. INSTALL TRANSFER CASE NO.2 PLUG
(a) Install the transfer case No.2 plug with a new gasket No.2.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
90. INSTALL TRANSFER CASE NO.1 PLUG
(a) Add oil up to 0 to 5 mm below the lower side of the plug
hole.
Oil quantity: 0.9 L (0.95 US qts, 0.79 lmp. qts)
HINT:
When adding oil, pour it slowly.
(b) Install the transfer case No.1 plug with a new gasket No.1.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
Page 2536 of 2572
141P5-01
SST
A36541
A94204
Timing Marks
Groove
Timing Marks
A53043
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
14-41
2534 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
OVERHAUL
1. REMOVE OIL FILTER SUB-ASSY
(a) Using SST, remove the oil filter.
SST 09228-06501
2. REMOVE OIL FILTER UNION
(a) Using a 12 mm hexagon wrench, remove the union.
3. REMOVE OIL FILLER CAP SUB-ASSY
4. REMOVE VENTILATION VALVE SUB-ASSY
5. REMOVE SPARK PLUG
6. REMOVE CYLINDER HEAD COVER SUB-ASSY
(a) Remove the 8 bolts, 2 nuts, and cylinder head cover.
7. REMOVE CYLINDER HEAD COVER GASKET
8. REMOVE CRANKSHAFT POSITION SENSOR
9. REMOVE CRANKSHAFT PULLEY
(a) Turn the crankshaft pulley and align its groove with timing
mark 0 of the timing chain cover.
(b) Check that the timing marks of the camshaft timing
sprockets are aligned with the timing marks of the No. 1
bearing cap, as shown in the illustration.