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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Suspension >> Rear Suspension >> Suspension System (Rear) - Service Information >> REAR SUSPENSION MEMBER (for HV Model) >> Installation [12/2019 - ] >> Procedure

Installation [12/2019 - ]: Procedure

  1. INSTALL HOLE PLUG 
    1. Install the 12 hole plugs to the rear suspension member sub-assembly as shown in the illustration.

      HINT: 

      The upper and lower hole plug shapes are different.

      GTY620503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL BOLT (for 2WD) 
    1. Install the 2 bolts to the rear suspension member sub-assembly.
      GTY620504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 86 N.m (877 kgf/cm, 63 ft.lbf) 

  3. INSTALL REAR SUSPENSION MEMBER FRONT BODY MOUNTING CUSHION (for LH Side) 
    1. Confirm the installation direction and temporarily install a new rear suspension member front body mounting cushion.
      NOTE:
      • Position the rear suspension member front body mounting cushion in the correct direction.
      • Do not apply lubricant to the outer sleeve of the rear suspension member front body mounting cushion.
      GTY915348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View from Underneath
      Front of the Vehicle
      Outside of the Vehicle
    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 molybdenum grease to the threads and tip of the SST center bolt before use.

      HINT: 

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

      GTY874414Courtesy 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.

      GTY878222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
    4. Remove SST from the rear suspension member sub-assembly.
  4. INSTALL REAR SUSPENSION MEMBER FRONT BODY MOUNTING CUSHION (for RH Side) 
    1. Confirm the installation direction and temporarily install a new rear suspension member front body mounting cushion.
      NOTE:
      • Position the rear suspension member front body mounting cushion in the correct direction.
      • Do not apply lubricant to the outer sleeve of the rear suspension member front body mounting cushion.
      GTY919163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View from Underneath
      Front of the Vehicle
      Outside of the Vehicle
    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 molybdenum grease to the threads and tip of the SST center bolt before use.

      HINT: 

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

      GTY842771Courtesy 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.

      GTY906210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
    4. Remove SST from the rear suspension member sub-assembly.
  5. INSTALL REAR SUSPENSION MEMBER REAR BODY MOUNT CUSHION LH 
    1. Confirm the installation direction and temporarily install a new rear suspension member rear body mount cushion LH.
      NOTE:
      • Position the rear suspension member rear body mount cushion LH in the correct direction.
      • Do not apply lubricant to the outer sleeve of the rear suspension member rear body mount cushion LH.
      GTY880794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View from Underneath
      *b 15°
      Front of the Vehicle
      Outside 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 molybdenum grease to the threads and tip of the SST center bolt before use.

      HINT: 

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

      GTY909066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, install the rear suspension member rear body mount cushion LH until there is no clearance between the rear suspension member sub-assembly and rear suspension member rear body mount cushion LH.
      • 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.

      GTY923395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
    4. Remove SST from the rear suspension member sub-assembly.
  6. INSTALL REAR SUSPENSION MEMBER REAR BODY MOUNT CUSHION RH 
    1. Confirm the installation direction and temporarily install a new rear suspension member rear body mount cushion RH.
      NOTE:
      • Position the rear suspension member rear body mount cushion RH in the correct direction.
      • Do not apply lubricant to the outer sleeve of the rear suspension member rear body mount cushion RH.
      GTY904124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View from Underneath
      Front of the Vehicle
      Outside 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 molybdenum grease to the threads and tip of the SST center bolt before use.

      HINT: 

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

      GTY904320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, install the rear suspension member rear body mount cushion RH until there is no clearance between the rear suspension member sub-assembly and rear suspension member rear body mount cushion RH.
      • 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.

      GTY918314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
    4. Remove SST from the rear suspension member sub-assembly.
  7. INSTALL DIFFERENTIAL MOUNT CUSHION (for AWD) 
    1. Temporarily install a new differential mount cushion to the rear suspension member sub-assembly from the rear of the vehicle as shown in the illustration.
      GTY873696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a -3° to 3°
      *b Protrusion
      Front of the Vehicle
      NOTE:
      • Make sure that the differential mount cushion is aligned within 3° from the center.
      • Install the differential mount cushion so that the protrusion is positioned as shown in the illustration.
      • 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)
      • SST: 09570-24011 
      GTY919132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold *b Turn
      Front of Vehicle SST Bolt Position
      NOTE:
      • Apply molybdenum grease to the threads of the SST center bolt before use.
      • Be sure to install the SST bolt straight.
    3. Using a vernier caliper, measure the length indicated by (A) in the illustration. (Step *2)
      GTY928221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Measure at several points to ensure that the differential mount cushion is pressed in evenly.
      • Do not measure on a weld bead.
    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)

      13.6 to 14.6 mm (0.535 to 0.575 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)

      7.6 to 8.6 mm (0.299 to 0.339 in.)

  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 SUSPENSION MEMBER UPPER STOPPER 
    1. Install the 2 rear suspension member upper stoppers to the rear suspension member sub-assembly.
  11. INSTALL REAR SUSPENSION MEMBER LOWER STOPPER RETAINER 
    1. Install the 2 rear suspension member lower stopper retainers to the rear suspension member sub-assembly.
  12. INSTALL REAR TRACTION MOTOR WITH TRANSAXLE ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 6

  13. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY 
    1. Using an engine lifter, 2 attachments and 2 wooden blocks or equivalent tools, support the rear suspension member sub-assembly, and raise the rear suspension member sub-assembly until there is no clearance between the rear suspension member sub-assembly and vehicle body.
      GTY931460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Engine Lifter
      *b Attachment
      *c Wooden Block
      Attachment and Wooden Block Placement Location
      WARNING:
      • The rear suspension member sub-assembly is a very heavy component. Make sure that it is supported securely.
      • If the rear suspension member sub-assembly is not securely supported, it may drop, resulting in serious injury.
      GTY917457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Use attachments and wooden blocks to keep the rear suspension member sub-assembly level.
      • Keep supporting the rear suspension member sub-assembly until the installation has been completed.
    2. 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.
      GTY876781Courtesy 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.

  14. CONNECT FLOOR UNDER WIRE (for AWD) 
    WARNING:

    Be sure to wear insulated gloves.

    1. Install the HV floor under wire to the rear traction motor with transaxle assembly with the 2 bolts.

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

      NOTE:
      • Make sure that the connector is fully engaged.
      • Do not damage the terminals, interlock connector or rear traction motor with transaxle assembly during installation.
      • Do not touch the waterproof seal or terminals of the connector.
      • Do not allow any foreign matter or water to enter the rear traction motor with transaxle assembly.
      • Although the connector may feel loose, this is not due to a malfunction.
      GTY938517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Waterproof Seal
    2. Engage the clamp.
      GTY880986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL FRAME WIRE (w/ Wire Harness) 
    1. w/ Height Control Sensor:
      1. Engage the clamp.
      2. Install the frame wire to the rear suspension member sub-assembly with the nut.

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

    2. for AWD:
      1. Install the frame wire to the rear suspension member sub-assembly with the bolt and clamp.

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

      2. Install the frame wire to the rear traction motor with transaxle assembly with the 2 bolts.

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

      3. Connect the 2 connectors.
    3. for 2WD:
      1. Install the frame wire to the rear suspension member sub-assembly with the bolt.

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

  16. INSTALL REAR DRIVE SHAFT LH SNAP RING (for AWD) 

    Refer to PROCEDURE - Step 1

  17. INSTALL REAR DRIVE SHAFT RH SNAP RING (for AWD) 

    HINT: 

    Perform the same procedure as for the LH side.

  18. INSTALL REAR DRIVE SHAFT ASSEMBLY LH (for AWD) 

    Refer to PROCEDURE - Step 2

  19. INSTALL REAR DRIVE SHAFT ASSEMBLY RH (for AWD) 

    HINT: 

    Perform the same procedure as for the LH side.

  20. TEMPORARILY INSTALL REAR UPPER CONTROL ARM ASSEMBLY LH 
    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.

      GTY917480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the rear axle carrier sub-assembly to the rear upper control arm assembly with the bolt 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.
      GTY917469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. TEMPORARILY INSTALL REAR UPPER CONTROL ARM ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  22. TEMPORARILY INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY LH 

    See step  1 [12/2019 - 10/2022], or see step  1 [10/2022 - ]

  23. TEMPORARILY INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

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

    See step  2 [12/2019 - 10/2022], or see step  2 [10/2022 - ]

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

    HINT: 

    Perform the same procedure as for the LH side.

  26. INSTALL REAR LOWER COIL SPRING INSULATOR LH 

    See step  3 [12/2019 - 10/2022], or see step  3 [10/2022 - ]

  27. INSTALL REAR LOWER COIL SPRING INSULATOR RH 

    HINT: 

    Perform the same procedure as for the LH side.

  28. INSTALL REAR COIL SPRING LH 

    See step  4 [12/2019 - 10/2022], or see step  4 [10/2022 - ]

  29. INSTALL REAR COIL SPRING RH 

    HINT: 

    Perform the same procedure as for the LH side.

  30. INSTALL REAR LOWER STABILIZER BRACKET 

    See step  3

  31. INSTALL REAR STABILIZER BAR 

    See step  4

  32. TEMPORARILY INSTALL REAR STABILIZER LINK ASSEMBLY LH 

    See step  5

  33. TEMPORARILY INSTALL REAR STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  34. INSTALL REAR SKID CONTROL SENSOR LH (for AWD) 

    Refer to PROCEDURE - Step 14

  35. INSTALL REAR SKID CONTROL SENSOR RH (for AWD) 

    HINT: 

    Perform the same procedure as for the LH side.

  36. CONNECT NO. 2 PARKING BRAKE WIRE ASSEMBLY (for AWD) 
    1. Connect the No. 2 parking brake wire assembly connector to the rear skid control sensor.
  37. CONNECT NO. 1 PARKING BRAKE WIRE ASSEMBLY (for AWD) 

    HINT: 

    Perform the same procedure as for the LH side.

  38. INSTALL REAR AXLE SHAFT NUT LH (for AWD) 

    Refer to PROCEDURE - Step 11

  39. INSTALL REAR AXLE SHAFT NUT RH (for AWD) 

    HINT: 

    Perform the same procedure as for the LH side.

  40. INSTALL REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY LH (w/ Height Control Sensor) 

    Refer to INSTALLATION [12/2019 - ]

  41. CONNECT REAR FLEXIBLE HOSE LH 
    1. Connect 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) 

      GTY911646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. CONNECT REAR FLEXIBLE HOSE RH 

    HINT: 

    Perform the same procedure as for the LH side.

  43. STABILIZE SUSPENSION 

    See step  3

  44. INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY LH 

    See step  7 [12/2019 - 10/2022], or see step  7 [10/2022 - ]

  45. INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  46. INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY LH 
    1. Install the rear No. 2 suspension arm assembly LH (rear axle carrier sub-assembly side) with the bolt.

      See step  8 [12/2019 - 10/2022], or see step  8 [10/2022 - ]

  47. INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  48. INSTALL REAR STABILIZER LINK ASSEMBLY LH 

    See step  8

  49. INSTALL REAR STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  50. INSTALL REAR UPPER CONTROL ARM ASSEMBLY LH 
    1. Install the rear upper control arm assembly to the rear axle carrier sub-assembly with the bolt.

      Torque: 110 N.m (1122 kgf/cm, 81 ft.lbf) 

      NOTE:

      Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.

  51. INSTALL REAR UPPER CONTROL ARM ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  52. INSTALL REAR SUSPENSION ARM COVER LH 

    See step  9 [12/2019 - 10/2022], or see step  9 [10/2022 - ]

  53. INSTALL REAR SUSPENSION ARM COVER RH 

    HINT: 

    Perform the same procedure as for the LH side.

  54. INSTALL TAIL EXHAUST PIPE ASSEMBLY 

    Refer to INSTALLATION [12/2019 - 10/2022] , or refer to INSTALLATION [10/2022 - ]

  55. INSTALL SERVICE PLUG GRIP (for AWD) 

    Refer to INSTALLATION [12/2019 - 11/2023] , or refer to INSTALLATION [11/2023 - ]

  56. INSTALL REAR WHEEL 

    Refer to PROCEDURE - Step 1 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 1 [10/2022 - ]

  57. INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY LH 
    1. Install the rear No. 2 suspension arm assembly LH (rear suspension member sub-assembly side) with the nut.

      See step  12 [12/2019 - 10/2022], or see step  12 [10/2022 - ]

  58. INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  59. ADD HYBRID TRANSAXLE FLUID (for AWD) 

    Refer to PROCEDURE - Step 2

  60. INSPECT FOR HYBRID TRANSAXLE FLUID LEAK (for AWD) 
  61. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 6 [12/2019 - 10/2022] , or refer to PROCEDURE - Step 6 [10/2022 - ]

  62. INSPECT AND ADJUST REAR WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [12/2019 - 09/2020] , or refer to ADJUSTMENT [09/2020 - 10/2022] , or refer to ADJUSTMENT [10/2022 - 11/2023] , or refer to ADJUSTMENT [11/2023 - 11/2024] , or refer to ADJUSTMENT [11/2024 - ]

  63. CHECK FOR SPEED SENSOR SIGNAL (for AWD) 

    Refer to TEST MODE PROCEDURE [12/2019 - 11/2023] , or refer to TEST MODE PROCEDURE [11/2023 - ]

  64. PERFORM INITIALIZATION 
    Parking Assist Monitor System Refer to CALIBRATION [12/2019 - 10/2022] , or refer to CALIBRATION [10/2022 - ]
    Panoramic View Monitor System Refer to CALIBRATION [12/2019 - 10/2022] , or refer to CALIBRATION [10/2022 - 11/2023] , or refer to CALIBRATION [11/2023 - ]
    Lighting System (EXT) (w/ AFS) Refer to INITIALIZATION [12/2019 - 11/2023] , or refer to INITIALIZATION [11/2023 - ]
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