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

WARNING: This page is about a different car, the 2016 Toyota Highlander, 2015 Toyota Highlander, and 2014 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT FRONT DIFFERENTIAL CASE

Using SST, rotate the front differential side gear as shown in the illustration.

SST: 09528-52010
1. 09528-05030

Standard

The front differential side gear does not lock when rotated in either direction.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the front differential side gear locks, perform all inspections.
If the front differential side gear still locks even after replacing the malfunctioning parts, replace the front differential case.

INSPECT FRONT DIFFERENTIAL SIDE GEAR THRUST AMOUNT

Using SST and a dial indicator, measure the front differential side gear thrust amount.

SST: 09528-52010
1. 09528-05030

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Front Differential Side Gear Thrust Amount

Front Differential Side Gear Thrust Amount

0.08 mm (0.00315 in.) or less

HINT:

Measure the front differential side gear thrust amount while slowly rotating the front differential side gear.
Make sure to measure the front differential side gear thrust amount for both of the front differential side gears.

If the result is not as specified, replace the 2 front differential side gears, 2 front differential pinions and 2 conical springs.

INSPECT FRONT DIFFERENTIAL PINION BACKLASH

Install SST as shown in the illustration and tighten it.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Turn

Hold

SST: 09528-52010
1. 09528-05010
2. 09953-05010

Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

Secure the front differential case with front differential ring gear in a vise between aluminum plates.
NOTE:
Do not overtighten the vise.

Install the front No. 1 differential pinion shaft to the front differential pinion as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Front No. 1 Differential Pinion Shaft

Using a dial indicator, measure the front differential pinion backlash.

Standard Backlash

0.15 mm (0.00591 in.) or less

If the backlash is not as specified, replace the front No. 1 differential side gear thrust washers with washers of a different thickness. Use the table below to select a front No. 1 differential side gear thrust washer which will ensure that the backlash is within the specification.

FRONT NO. 1 DIFFERENTIAL SIDE GEAR THRUST WASHER THICKNESS:

Part No.	Thickness (mm (in.))
41361-06010	1.50 (0.0591)
41361-06020	1.55 (0.0610)
41361-06030	1.60 (0.0630)
41361-06040	1.65 (0.0650)
41361-06050	1.70 (0.0669)
41361-06060	1.75 (0.0689)
41361-06070	1.80 (0.0709)
41361-06080	1.85 (0.0728)
41361-06090	1.90 (0.0748)

HINT:

Select front No. 1 differential side gear thrust washers of the same thickness for both the right and left side.

INSPECT FRONT DIFFERENTIAL PINION THRUST WASHER

Using a micrometer, measure the thickness of the front differential pinion thrust washer.

Minimum Thickness

0.54 mm (0.0213 in.)

HINT:

Measure the most worn portion of the front differential pinion thrust washer.

If the thickness is less than the minimum, replace the front differential pinion thrust washer.

INSPECT FRONT NO. 1 DIFFERENTIAL PINION SHAFT

Using a micrometer, measure the outer diameter of the front No. 1 differential pinion shaft.

Minimum Outer Diameter

20.499 mm (0.807 in.)

HINT:

Measure the most worn portion of the front No. 1 differential pinion shaft.

If the outer diameter is less than the minimum, replace the front No. 1 differential pinion shaft.