Suspension System - Front: Removal & Installation — Suspension System - Front — Suspension Front

Removal

Remove front wheel. Check wheel bearing backlash and deviation (rotational free play). See «WHEEL BEARING INSPECTION»(ref-164671-S21148067582004081200000) under ADJUSTMENTS & INSPECTION.
Unstake the locknut. Hold drive shaft from turning by applying brakes and remove drive shaft lock nut. Remove brake caliper and disc and support caliper out of way.
On Highlander with ABS, remove ABS speed sensor and wire harness clamp. Loosen 2 nuts on lower end of shock absorber (DO NOT remove).
Remove cotter pin and nut from tie rod end. Use separator tool to disconnect tie rod end from steering knuckle.
Remove 2 nuts and 1 bolt and disconnect lower ball joint from lower control arm. Remove 2 nuts and bolts from lower end of shock absorber. Remove steering knuckle and axle hub from vehicle. see scheme 5
Mount assembly in vise. Carefully pry dust deflector from hub. Remove cotter pin and nut, and use separator tool to remove lower ball joint from hub assembly.
Use slide hammer and attaching plate to remove axle hub. Place axle hub on press and use appropriate support plates to press inner bearing race from axle hub. Remove 4 bolts and remove dust cover.
Remove wheel bearing snap ring. Place inner race against outside of bearing and press wheel bearing from axle hub. see scheme 5

Installation

To install, reverse removal procedure. Use NEW snap ring after pressing in NEW wheel bearing. Use NEW cotter pins. Tighten bolts to specifications. See TORQUE SPECIFICATIONS .

Raise and support vehicle. Remove front wheel.
Remove the nut and disconnect the stabilizer bar link from the shock absorber. (Scheme 6)
Loosen the center nut. (Scheme 7)
Remove the bolt, disconnect the flexible hose and ABS speed sensor wire harness bracket. (Scheme 8)
Remove the 2 nuts and bolts on the lower side of shock absorber. (Scheme 9)
Remove the 3 nuts on the upper side of the shock absorber. (Scheme 10) Remove the shock absorber with the coil spring.

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Install the shock absorber with the 2 bolts. Install the 3 nuts to the upper side of the shock absorber, and torque the nuts. See «TORQUE SPECIFICATIONS»(ref-164671-S03347412402004081200000) .
Install the 2 nuts to the lower side of shock absorber, and torque the nuts. See «TORQUE SPECIFICATIONS»(ref-164671-S03347412402004081200000) .
Fully tighten the center nut. See «TORQUE SPECIFICATIONS»(ref-164671-S03347412402004081200000) .
Install the flexible hose and ABS speed sensor wire harness bracket with the bolt. See «TORQUE SPECIFICATIONS»(ref-164671-S03347412402004081200000) .
Install the stabilizer bar link with the nut See «TORQUE SPECIFICATIONS»(ref-164671-S03347412402004081200000) .
Install the front wheel. See «TORQUE SPECIFICATIONS»(ref-164671-S03347412402004081200000) .
Inspect and adjust front wheel alignment, see «WHEEL ALIGNMENT»(ref-164671-S07482049442004081200000) .

For an exploded view (Scheme 11)

Remove engine assembly with transaxle. See REMOVAL & INSTALLATION in appropriate ENGINE MECHANICAL article in ENGINES.
Remove the 3 nuts and engine mounting insulator. (Scheme 12)
Remove the 2 bolts on the front side of the lower suspension arm. (Scheme 13)
Remove the bolt and nut on the rear side of the lower suspension arm. Remove the lower suspension arm. Remove the lower suspension arm bushing stopper from the lower suspension arm shaft. (Scheme 14)

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Install the lower suspension arm bushing stopper to the lower suspension arm shaft. Install the lower suspension arm with the 2 bolts to the front side, and torque the nuts. See «TORQUE SPECIFICATIONS»(ref-164671-S03347412402004081200000) .
Install the lower suspension arm with the bolt and nut to the rear side. See «TORQUE SPECIFICATIONS»(ref-164671-S03347412402004081200000) .
Install the engine mounting insulator with 3 nuts. See «TORQUE SPECIFICATIONS»(ref-164671-S03347412402004081200000) .
Install engine. See REMOVAL & INSTALLATION in appropriate ENGINE MECHANICAL article in ENGINES.

Note. For removal and installation reference (Scheme 15)and (Scheme 16).

Scheme 15

Scheme 15: Removal

Scheme 16

Raise and support vehicle. Remove front wheel.
Remove the 2 nuts and the stabilizer bar link. (Scheme 6)
Remove the 2 bolts No. 2 bracket and the No. 1 bracket. Repeat procedure for other side. (Scheme 17)
Separate the tie rod assembly using the Ball Joint Puller (09628-62011). See «LOWER BALL JOINT»(ref-164671-S32164801992004081200000) removal.
For V6 engine type, separate steering gear outlet return tube. Separate steering intermediate shaft sub-assembly. Separate pressure feed tube assembly. Remove rack and pinion power steering gear assembly. See appropriate POWER RACK & PINION article in STEERING.
Remove front stabilizer bar and No. 1 bushing.

Scheme 17

Install front stabilizer bar bushing No. 1 to the inner side of the bushing stopper on the stabilizer bar. (Scheme 18)
Install front stabilizer bar.
If removed, Install rack and pinion power steering gear assembly. Install steering intermediate shaft assembly. Install pressure feed tube assembly. Install steering gear outlet return tube. See appropriate POWER RACK & PINION article in STEERING.
Install the tie rod end to steering knuckle with the nut. See «TORQUE SPECIFICATIONS»(ref-164671-S03347412402004081200000). Install a new cotter pin.
Install 2 front stabilizer No. 1 brackets with 2 bolts. See «TORQUE SPECIFICATIONS»(ref-164671-S03347412402004081200000).
Install the stabilizer bar link assembly with 2 nuts. See «TORQUE SPECIFICATIONS»(ref-164671-S03347412402004081200000).
Install front wheel. See «TORQUE SPECIFICATIONS»(ref-164671-S03347412402004081200000).
Inspect and adjust front wheel alignment, see «WHEEL ALIGNMENT»(ref-164671-S07482049442004081200000).

Scheme 18

Removal & Installation

Remove front wheel.
Using the Drive Shaft Nut Chisel (09930-00010) and a hammer, unstake the part of the lock nut. While applying the brakes, remove the front axle hub lock nut. (Scheme 19)
Separate the speed sensor from the steering knuckle by removing the bolt.
Remove the bolt and separate the speed sensor from the steering knuckle. (Scheme 21)
Separate the brake caliper from the drive shaft by remove the 2 bolts. (Scheme 22)
Remove the front disc.
Remove the cotter pin and nut from tie rod assembly. Using the Ball Joint Puller (09628-62011), separate the tie rod end from the steering knuckle. (Scheme 23)
Remove the bolt and 2 nuts, and separate the lower suspension arm from the lower ball joint. (Scheme 24)
Using a plastic hammer, separate the drive shaft from the axle hub.
Remove the 2 bolts, nuts and steering knuckle with axle hub. (Scheme 25)
Remove the cotter pin and nut from the lower ball joint assembly. (Scheme 25)
Using the Ball Joint Puller (09628-62011), remove the ball joint. (Scheme 26)
To install, reverse removal procedures. See «TORQUE SPECIFICATIONS»(ref-164671-S03347412402004081200000). Inspect and adjust front wheel alignment, see «WHEEL ALIGNMENT»(ref-164671-S07482049442004081200000). Ensure ABS works correctly.