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Home >> Toyota >> 2016 >> Highlander Hybrid Limited >> Repair and Diagnosis >> Suspension >> Rear Suspension >> Rear Suspension (Service Information) (Hybrid) >> Rear Suspension Member >> Installation [11/2015 - 11/2016] >> Procedure

Installation [11/2015 - 11/2016]: Procedure

  1. INSTALL HOLE PLUG 
    1. Install the 12 hole plugs to the rear suspension member sub-assembly as shown in the illustration.
      GTY453474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL REAR SUSPENSION MEMBER FRONT BODY MOUNTING CUSHION (for LH Side) 
    1. Temporarily install a new rear suspension member front body mounting cushion while confirming the installation direction.
      GTY455687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A View from Underneath
      *a Front of the Vehicle
      *b Left Side of the Vehicle
      *c 45°
    2. Install SST as shown in the illustration.
      • SST: 09527-17011 
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
      NOTE:

      Apply grease to the threads of the SST center bolt before use.

      HINT: 

      Use SST with the "F" mark facing the rear suspension member front body mounting cushion.

      GTY450132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, install the rear suspension member front body mounting cushion until there is no clearance between the rear suspension member sub-assembly and rear suspension member front body mounting cushion.
      • SST: 09527-17011 
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
      NOTE:

      If the rear suspension member sub-assembly is scratched, apply paint to the scratched areas of the rear suspension member sub-assembly.

      GTY444905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
    4. Remove SST from the rear suspension member sub-assembly.
  3. INSTALL REAR SUSPENSION MEMBER FRONT BODY MOUNTING CUSHION (for RH Side) 
    1. Temporarily install a new rear suspension member front body mounting cushion while confirming the installation direction.
      GTY445168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A View from Underneath
      *a Front of the Vehicle
      *b Left Side of the Vehicle
      *c 45°
    2. Install SST as shown in the illustration.
      • SST: 09527-17011 
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
      NOTE:

      Apply grease to the threads of the SST center bolt before use.

      HINT: 

      Use SST with the "F" mark facing the rear suspension member front body mounting cushion.

      GTY443441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, install the rear suspension member front body mounting cushion until there is no clearance between the rear suspension member sub-assembly and rear suspension member front body mounting cushion.
      • SST: 09527-17011 
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
      NOTE:

      If the rear suspension member sub-assembly is scratched, apply paint to the scratched areas of the rear suspension member sub-assembly.

      GTY433854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
    4. Remove SST from the rear suspension member sub-assembly.
  4. INSTALL REAR SUSPENSION MEMBER REAR BODY MOUNTING CUSHION LH 
    1. Temporarily install a new rear suspension member rear body mounting cushion LH while confirming the installation direction.
      GTY440227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A View from Underneath
      *a Front of the Vehicle
      *b Left Side of the Vehicle
    2. Install SST as shown in the illustration.
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
      NOTE:

      Apply grease to the threads of the SST center bolt before use.

      HINT: 

      Use SST with the "F" mark facing the rear suspension member rear body mounting cushion LH.

      GTY455461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, install the rear suspension member rear body mounting cushion LH until there is no clearance between the rear suspension member sub-assembly and rear suspension member rear body mounting cushion LH.
      GTY441861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
      NOTE:

      If the rear suspension member sub-assembly is scratched, apply paint to the scratched areas of the rear suspension member sub-assembly.

    4. Remove SST from the rear suspension member sub-assembly.
  5. INSTALL REAR SUSPENSION MEMBER REAR BODY MOUNTING CUSHION RH 
    1. Temporarily install a new rear suspension member rear body mounting cushion RH while confirming the installation direction.
      GTY442619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A View from Underneath
      *a Front of the Vehicle
      *b Right Side of the Vehicle
      *c 15°
    2. Install SST as shown in the illustration.
      GTY443739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
      NOTE:

      Apply grease to the threads of the SST center bolt before use.

      HINT: 

      Use SST with the "F" mark facing the rear suspension member rear body mounting cushion RH.

    3. Using SST, install the rear suspension member rear body mounting cushion RH until there is no clearance between the rear suspension member sub-assembly and rear suspension member rear body mounting cushion RH.
      GTY439606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
      NOTE:

      If the rear suspension member sub-assembly is scratched, apply paint to the scratched areas of the rear suspension member sub-assembly.

    4. Remove SST from the rear suspension member sub-assembly.
  6. INSTALL DIFFERENTIAL MOUNT CUSHION 
    GTY445662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Front of the Vehicle
    1. As shown in the illustration, temporarily install a new differential mount cushion to the rear suspension member sub-assembly from the rear of the vehicle.
      NOTE:
      • Make sure that the differential mount cushion aligned within 3° from the center.
      • Be sure to install the differential mount cushion in the correct direction.
    2. Using SST, press the differential mount cushion into the rear suspension member sub-assembly. (Step *1)
      GTY429960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Front of the Vehicle
      • SST: 09570-48010 
      NOTE:
      • Apply grease to the threads of the SST center bolt before use.
      • Install the SST bolts straight and tighten them equally.
    3. Using a vernier caliper, measure the length indicated by (A) in the illustration. (Step *2)
      NOTE:
      • Measure at several points to ensure that the differential mount cushion is pressed in evenly.
      • Do not measure on a weld bead.
      GTY423805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Repeat the steps *1 and *2 to press the differential mount cushion into the rear suspension member sub-assembly until the length indicated by (A) in the illustration is within the specification.

      Reference Length (A)

      6.5 to 7.5 mm (0.256 to 0.295 in.)

      HINT: 

      Reference length (A) = Standard length (B) + Thickness of SST

    5. Remove SST. Using a vernier caliper, measure the differential mount cushion protrusion length indicated by (B) in the illustration and ensure that the measured length is within the specification.

      Standard Length (B)

      0.5 to 1.5 mm (0.0197 to 0.0590 in.)

  7. INSTALL REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 5

  8. INSTALL REAR UPPER CONTROL ARM ASSEMBLY LH 

    See step  1

  9. INSTALL REAR UPPER CONTROL ARM ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  10. INSTALL REAR SPEED SENSOR LH 
    1. Install the rear speed sensor LH to the rear suspension member sub-assembly with the 2 bolts and nut.
      GTY453143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt 

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

      Nut 

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

  11. INSTALL REAR SPEED SENSOR RH 

    HINT: 

    Perform the same procedure as for the LH side.

  12. INSTALL REAR SUSPENSION MEMBER UPPER STOPPER 
    1. Install the 2 rear suspension member upper stoppers to the rear suspension member sub-assembly.
      NOTE:

      Be sure to install the rear suspension member upper stoppers in the correct direction shown in the illustration.

      GTY436302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL REAR SUSPENSION MEMBER REAR UPPER STOPPER 
    1. Install the 2 rear suspension member rear upper stoppers to the rear suspension member sub-assembly.
      GTY436293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY 
    1. Support the rear suspension member sub-assembly with an engine lifter using 2 wooden blocks and 2 attachments or equivalent tools as shown in the illustration.
      WARNING:

      Make sure to secure the rear suspension member sub-assembly to prevent it from dropping.

      NOTE:
      • Use the attachments to keep the rear suspension member sub-assembly level.
      • The rear suspension member sub-assembly is a heavy component. Make sure that it is supported securely.
      • Keep supporting the rear suspension member sub-assembly until the installation has been completed.
      GTY444829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Engine Lifter
      *b Attachment
      *c Wooden Block
      Attachment placement location
    2. Temporarily install the rear No. 1 suspension arm assembly LH.
      1. Support the rear axle assembly LH with a jack using a wooden block as shown in the illustration.
        WARNING:

        Do not jack up the rear axle assembly LH too high as the vehicle may fall.

        NOTE:

        When jacking up the rear axle assembly LH, be sure to jack it up slowly.

        GTY572849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Wooden Block
        *b Jack
        *c Opening
        *d Spacer
        Front of the Vehicle
      2. Temporarily install the rear No. 1 suspension arm assembly LH to the rear axle carrier sub-assembly LH with the spacer and nut (A).
        NOTE:
        • Install the rear No. 1 suspension arm assembly with its opening facing downward.
        • Fully tighten the nut (A) after stabilizing the suspension.
        • Be sure to install the rear No. 1 suspension arm assembly with the spacer facing in the correct direction as shown in the illustration.
      3. Temporarily install the rear No. 1 suspension arm assembly LH to the rear suspension member sub-assembly with the bolt (B) and nut.
        NOTE:
        • Insert the bolt with the threaded end facing the rear of the vehicle.
        • Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.
        • Fully tighten the bolt (B) after stabilizing the suspension.
      4. Slowly lower the rear axle assembly LH.
    3. Temporarily install the rear No. 1 suspension arm assembly RH.

      HINT: 

      Perform the same procedure as for the LH side.

    4. Install the rear suspension member sub-assembly with the 2 rear lower suspension braces, rear lower suspension member stopper LH and rear lower suspension member stopper RH, with the 4 bolts and 2 nuts.
      GTY455386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Lower Suspension Brace - -

      Bolt 

      Torque: 158 N*m (1611 kgf*cm, 117 ft.*lbf) 

      Nut 

      Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) 

      NOTE:

      Be sure to install the rear suspension member sub-assembly with the rear lower suspension braces facing in the correct direction as shown in the illustration.

    5. Lower the engine lifter.
    6. Connect the rear upper control arm assembly LH.
      GTY354813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a brass bar and a hammer, push out the bushing until it is positioned as shown in the illustration.

        HINT: 

        Pushing out the bushing makes it easier to connect the rear upper control arm assembly LH.

      2. Support the rear axle assembly LH with a jack using a wooden block as shown in the illustration.
        GTY434062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Wooden Block
        *b Jack
        WARNING:

        Do not jack up the rear axle assembly LH too high as the vehicle may fall.

        NOTE:

        When jacking up the rear axle assembly LH, be sure to jack it up slowly.

      3. Connect the rear upper control arm assembly LH to the rear axle carrier sub-assembly LH with the bolt and nut.

        Torque: 145 N*m (1479 kgf*cm, 107 ft.*lbf) 

        NOTE:
        • Insert the bolt with the threaded end facing the rear of the vehicle.
        • Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.
      4. Slowly lower the rear axle assembly LH.
    7. Connect the rear upper control arm assembly RH.

      HINT: 

      Perform the same procedure as for the LH side.

  15. CONNECT NO. 6 FLOOR WIRE 

    Refer to PROCEDURE - Step 7

  16. INSTALL FRAME WIRE 
    1. Install the frame wire to the rear suspension member sub-assembly with the bolt, each clamp and each connector as shown in the illustration.
      GTY444707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      NOTE:

      Do not twist the frame wire when installing it.

  17. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY LH 

    See step  2

  18. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  19. INSTALL REAR STABILIZER BAR 

    See step  3

  20. INSTALL REAR STABILIZER LINK SUB-ASSEMBLY LH 

    See step  4

  21. INSTALL REAR STABILIZER LINK SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  22. INSTALL REAR FLEXIBLE HOSE LH 
    1. Install the rear flexible hose LH to the rear upper control arm assembly LH with the bolt.

      Torque: 18.8 N*m (192 kgf*cm, 14 ft.*lbf) 

      GTY451407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not twist the rear flexible hose LH when installing it.
      • Do not damage the rear flexible hose LH when installing it.
      • If the rear flexible hose LH is damaged, replace it with a new one.
    2. Install the rear flexible hose with a new clip.
      GTY448969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear No. 4 Brake Tube
      *2 Rear Flexible Hose LH
      Clip
      NOTE:

      Install the clip as far as it will go.

    3. Using a union nut wrench, connect the rear flexible hose LH to the rear No. 4 brake tube while holding the rear flexible hose LH with a wrench.

      Torque: 15.2 N*m (155 kgf*cm, 11 ft.*lbf) 

      NOTE:
      • Do not kink or damage the brake line.
      • Do not allow any foreign matter such as dirt or dust to enter the brake line from the connecting parts.
      • Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench.

        Refer to PRECAUTION [02/2014 - 11/2016]

  23. INSTALL REAR FLEXIBLE HOSE RH 

    HINT: 

    Perform the same procedure as for the LH side.

  24. INSTALL REAR DRIVE SHAFT ASSEMBLY LH 

    Refer to INSTALLATION [02/2014 - ]

  25. INSTALL REAR DRIVE SHAFT ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  26. INSTALL REAR AXLE SHAFT NUT LH 

    Refer to PROCEDURE - Step 11

  27. INSTALL REAR AXLE SHAFT NUT RH 

    HINT: 

    Perform the same procedure as for the LH side.

  28. INSTALL REAR SPEED SENSOR LH 

    Refer to PROCEDURE - Step 7

  29. INSTALL REAR SPEED SENSOR RH 

    HINT: 

    Perform the same procedure as for the LH side.

  30. CHECK HIGH VOLTAGE CABLE CONNECTION 
    WARNING:

    Wear insulated gloves.

    1. Make sure that the No. 6 floor wire is securely installed with the 2 nuts.
      NOTE:
      • Do not install the No. 6 floor wire at an angle.
      • Be sure to tighten the 2 nuts securely.
      GTY446385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL SERVICE PLUG GRIP 

    Refer to INSTALLATION [02/2014 - ]

  32. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable from the negative (-) auxiliary battery terminal, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [02/2014 - 11/2016]

  33. BLEED BRAKE LINE 

    Refer to BLEEDING [02/2014 - ]

  34. INSTALL CENTER EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 

    Refer to PROCEDURE - Step 5

  35. STABILIZE SUSPENSION 

    See step  2

  36. INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY LH 

    See step  5

  37. INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  38. INSTALL REAR SUSPENSION ARM COVER LH 

    See step  6

  39. INSTALL REAR SUSPENSION ARM COVER RH 

    HINT: 

    Perform the same procedure as for the LH side.

  40. INSTALL REAR WHEEL 

    Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf) 

  41. INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY LH 

    See step  8

  42. INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  43. INSPECT AND ADJUST REAR WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [02/2014 - 11/2016]

  44. CHECK FOR SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [02/2014 - 11/2016]

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