2001 TOYOTA HIGHLANDER differential

C50336C83648
SST
C50337C83649
SST
C50338
C50339
31-20
- TRANSFERTRANSFER ASSY (4WD)
3098 Author
: Date
:
46. INSTALL RING GEAR MOUNTING CASE PLATE WASHER
(a) Install the ring gear mounting case plate washer to the transfer case.
HINT:
Reuse the washer.
47. INSTALL CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) Using SST and a press, install the center differential case
tapered roller bearing LH outer race to the transfer case.
SST 09950- 70010 (09951- 07200), 09316- 60011
(09316-00021)
48. INSTALL TRANSFER DRIVEN PINION FRONT
BEARING
(a) Using SST and a press, install the transfer driven pinion
front bearing inner race to the driven pinion.
SST 09316-6001 1 (09316-00041)
49. INSTALL DRIVEN PINION
(a) Install the driven pinion to the transfer case.
(b) Install a new transfer pinion bearing spacer and a new
transfer driven pinion rear bearing inner race to the driven
pinion.

C50361C83652
Matchmarks
C50342C83653
SST
C67688
SST
C67673
31-22
- TRANSFERTRANSFER ASSY (4WD)
3100 Author
: Date
:
(d) Align the matchmarks on the ring gear and transfer ring
gear mounting case and quickly assemble them.
(e) Tighten the12 bolts.
Torque: 78 NVm (790 kgfVcm, 57 ftVlbf)
NOTICE:

Tighten the bolts in diagonal order in splitting several
times.

After the ring gear has well cooled down, fully tighten
the bolts.

Make the bolt heads in order to check if they are re-
tightened or not.
52. INSTALL CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) RH side:
Using SST and a press, install the inner race of the center
differential case tapered roller bearing to the transfer ring
gear mounting case.
SST 09506-35010, 09950-60010 (09951-00430)
NOTICE:
When replacing the inner race, replace it together with the
outer race.
(b) LH side:
Using SST and a press, install the inner race of the center
differential case tapered roller bearing to the transfer ring
gear mounting case.
SST 09223-00010
NOTICE:
When replacing the inner race, replace it together with the
outer race.
53. INSTALL TRANSFER RING GEAR MOUNTING CASE
(a) Install the transfer ring gear mounting case to the transfer
case.
NOTICE:
Damage to the spline, the bearing's rotating surface and
gear face may cause a decrease in their strength. Care
should be taken when installing them.
54. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2
(a) Install the transfer ring gear mounting case washer No.2 to the transfer RH bearing retainer sub-assy.
HINT:
Reuse the washer.

C50344C83654
SST
C57486
C57487
SST
C57488
C57489
- TRANSFERTRANSFER ASSY (4WD)
31-23
3101 Author
: Date
:
55. INSTALL CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) Using SST and a press, install the center differential case
tapered roller bearing RH outer race to the transfer RH
bearing retainer sub-assy.
SST 09950- 60010 (09951- 00620), 09950- 70010
(09951-07150)
56. INSTALL TRANSFER RH BEARING RETAINER
SUB-ASSY
(a) Place the transfer with the face where the transfer RH
bearing retainer sub-assy is to be installed facing up.
(b) Center-align the transfer ring gear mounting case and
the transfer case.
(c) Insert the SST into the transfer RH bearing retainer sub-
assy.
SST 09387-00090
NOTICE:
Insert SST straight in order not to damage the oil seal lip.
(d) Insert the transfer RH bearing retainer sub-assy together
with the SST into the transfer case.
NOTICE:
Interference between the case and retainer, and between
the transfer ring gear mounting case and SST should be
carefully avoided.
HINT:
If the retainer cannot be inserted, tap it in with a plastic hammer.
(e) After inserting the transfer RH bearing retainer sub-assy
into the transfer case, remove the SST.

C83509
C50309
C50345C83655
Ring Gear Mounting
Case Plate Washer 31-24
- TRANSFERTRANSFER ASSY (4WD)
3102 Author
: Date
:
(f) Tighten the 7 bolts.
Torque: 28 NVm (286 kgfVcm, 21 ftVlbf)
57. INSPECT BACKLASH
(a) Set the dial indicator perpendicular to the ring gear face,
fix the driven pinion, and check backlash by moving the
ring gear.
Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 in.)
NOTICE:
Measure it at 3 points or more on the ring gear periphery.
(b) If the measured value is out of standard, select a proper
washer for the center differential case tapered roller bear-
ing on the LH side from the table below and install it to ob-
tain the standard value.
MarkWasher Thickness mm (in.)MarkWasher Thickness mm (in.)MarkWasher Thickness mm (in.)
AA2.07 (0.0814)AB2.10 (0.0826)AC2.13 (0.0838)
BA2.16 (0.0850)BB2.19 (0.0862)BC2.22 (0.0874)
CA2.25 (0.0885)CB2.28 (0.0897)CC2.31 (0.0909)
DA2.34 (0.0921)DB2.37 (0.0933)DC2.40 (0.0944)
EA2.43 (0.0956)EB2.46 (0.0968)EC2.49 (0.0980)
FA2.52 (0.0992)FB2.55 (0.1003)FC2.58 (0.1015)
GA2.61 (0.1027)GB2.64 (0.1039)GC2.67 (0.1051)
HA2.70 (0.1062)HB2.73 (0.1074)HC2.76 (0.1086)
JA2.79 (0.1098)JB2.82 (0.1110)JC2.85 (0.1122)
KA2.88 (0.1133)KB2.91 (0.1145)KC2.94 (0.1157)
LA2.97 (0.1169)LB3.00 (0.1181)
HINT:
When the backlash is larger or smaller than the standard, select
a thinner or thicker washer respectively.
(c) Ring gear mounting case plate washer location is shown
in the illustration.

C50363C83656
Transfer Output Washer
C82792C83635
SST 31-26
- TRANSFERTRANSFER ASSY (4WD)
3104 Author
: Date
:
(d) The location of the transfer output washer for tooth con-
tact adjustment is shown in the illustration.
59. ADJUST TOTAL PRELOAD
(a) Using SST and a torque wrench, measure the initial
torque with the driven pinion being 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)
NOTICE:
Before measurement, rotate the bearing in both directions
several times to make it fit.
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).
(b) If the value is out of standard range, select the washer for
the center differential case tapered roller bearing RH side
from the following table and replace it.
MarkWasher Thickness mm (in.)MarkWasher Thickness mm (in.)MarkWasher Thickness mm (in.)
AA1.47 (0.0578)AB1.50 (0.0590)AC1.53 (0.0602)
BA1.56 (0.0614)BB1.59 (0.0625)BC1.62 (0.0637)
CA1.65 (0.0649)CB1.68 (0.0661)CC1.71 (0.0673)
DA1.74 (0.0685)DB1.77 (0.0696)DC1.80 (0.0708)
EA1.83 (0.0720)EB1.86 (0.0732)EC1.89 (0.0744)
FA1.92 (0.0755)FB1.95 (0.0767)FC1.98 (0.0779)
GA2.01 (0.0790)GB2.04 (0.0803)GC2.07 (0.0814)
HA2.10 (0.0826)HB2.13 (0.0838)HC2.16 (0.0850)
JA2.19 (0.0862)JB2.22 (0.0874)JC2.25 (0.0885)
KA2.28 (0.0897)KB2.31 (0.0909)KC2.34 (0.0921)
LA2.37 (0.0933)LB2.40 (0.0944)LC2.43 (0.0956)
MA2.46 (0.0968)MB2.49 (0.0980)MC2.52 (0.0992)
NA2.55 (0.1003)NB2.58 (0.1015)

C50341C83688
SST
C50364C83699
C50350C83689
SST1.5 to 2.5 mm
(0.059 to 0.098 in.)
C51147C83690
SST
31-28
- TRANSFERTRANSFER ASSY (4WD)
3106 Author
: Date
:
61. REMOVE CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) Fix the transfer RH bearing retainer sub-assy in a vise.
(b) Using SST, remove the center differential case tapered
roller bearing RH outer race and transfer ring gear mount-
ing case washer No.2 from the transfer RH bearing retain-
er sub-assy.
SST 09308-00010
62. INSTALL SIDE GEAR SHAFT HOLDER BEARING
(a) Install the side gear shaft holder bearing to the transfer
RH bearing retainer sub-assy.
(b) Using snap ring pliers, install the side gear shaft holder
hole snap ring.
HINT:
Check that the side gear shaft holder hole snap ring fits in the
groove of the transfer RH bearing retainer sub-assy.
63. INSTALL TRANSFER RH BEARING RETAINER OIL
SEAL
(a) Using SST and a press, install the transfer RH bearing re-
tainer oil seal No.2 to the transfer RH bearing retainer
sub-assy .
SST 09950- 60010 (09951- 00350, 09951- 00560,
09952-06010), 09950-70010 (09951-07150)
NOTICE:
Carefully press-fit so that the oil seal will not be tilted.
(b) Apply small amount of MP grease No.2 to the oil seal lip.
64. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2
(a) Install the selected transfer ring gear mounting washer No.2 to the transfer RH bearing retainer sub-
assy.
65. INSTALL CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) Using SST and a press, install the center differential case
tapered roller bearing RH outer race to the transfer RH
bearing retainer sub-assy.
SST 09950- 60010 (09951- 00620), 09950- 70010
(09951-07150)

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.

3100U-07
C50328C83630SST
C50353C83631
8.7 to 9.3 mm
(0.3425 to 0.3661 in.)SST
- TRANSFERTRANSFER CASE OIL SEAL (4WD)
31-7
3085 Author
: Date
:
TRANSFER CASE OIL SEAL (4WD)
REPLACEMENT
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE)
(SEE PAGE 14-149)
2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE)
(SEE PAGE 14-24)
3. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (2AZ-FE ENGINE TYPE)
(SEE PAGE 31-9)
4. REMOVE TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE) (SEE PAGE 31-9)
5. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE)
(SEE PAGE 40-20)
6. REMOVE TRANSFER ASSY (SEE PAGE 31-9)
7. REMOVE CTR DIFFERENTIAL LOCK SLEEVE (SEE PAGE 31-9)
SST 09308-00010
8. REMOVE TRANSFER CASE OIL SEAL
(a) Using SST, remove the oil seal from the case.
SST 09308-00010
NOTICE:
Do not damage the oil-seal-fitted surface of the case.
9. INSTALL TRANSFER CASE OIL SEAL
(a) Using SST, drive a new oil seal into the case to the posi-
tion shown in the illustration.
SST 09387-00010, 09950-70010 (09951-07150)
NOTICE:
Do not install it obliquely.
(b) Apply small amount of MP grease to the oil seal lip.
10. INSTALL CTR DIFFERENTIAL LOCK SLEEVE (SEE PAGE 31-9)
SST 09950-60010 (09951-00610), 09950-70010 (09951-07150)
11. INSTALL TRANSFER ASSY (SEE PAGE 31-9)
12. INSTALL TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE) (SEE PAGE 31-9)
13. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (2AZ-FE ENGINE TYPE)
(SEE PAGE 31-9)
14. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE)
(SEE PAGE 40-20)
15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149)
16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24)