OEM 2002 Toyota Highlander Sway Bar Kit

2002 Toyota Highlander Sway Bar Kit Parts Q&A

• Q: How to replace the front Sway Bar Kit on 2002 Toyota Highlander?

  A: Replace the front sway bar kit starting with front wheel removal then disconnecting both left-hand nuts and link of the sway bar kit assembly while using a hexagon (6 mm) wrench to hold the stud if necessary. Use the identical method to handle the right-hand side after completion on the left. First detach both front sway bar bracket No. 1 from the left side by removing 2 bolts then No. 2 bracket and No. 1 bracket before performing the same steps on the right-hand side. Employ Special Service Tool: 09628-62011 to divide the tie rod assembly on the left side followed by a similar separation process of the right-hand tie rod assembly. Use Special Service Tool: 09023-00100 to disconnect the steering gear outlet return tube before proceeding to remove the pressure feed tube assembly and the steering intermediate shaft sub-assembly. The procedure requires removal of the rack & pinion power steering gear assembly (4WD drive type), the front sway bar kit, followed by removal of front sway bar bush No. 1. Complete the inspection procedure for the left front sway bar link assembly by rotating the ball joint stud backwards and forwards five times before attaching the nut. Then apply torque using a torque wrench while turning the nut continuously within a 2 to 4 second range and acquire the torque reading during the fifth turn aiming for 0.05 - 1.96 Nm (0.5 - 20 kgf-cm, 0.4 - 17.4 inch lbs. also known as 5 to 20 inch lbs. First install the front sway bar bush No. 1 to the inner bushing stopper of the sway bar kit before securing the front sway bar kit and lastly reinstall the rack & pinion power steering gear assembly (4WD drive type) together with the steering intermediate shaft sub-assembly. The installation of the pressure feed tube assembly requires Special Service Tool: 09023-00100 followed by the steering gear outlet return tube then left and right tie rod assembly installation using the same service procedures. Familiarize with the front sway bar bracket No. 1 on the left then install all components including 2 brackets and 2 bolts while torquing them to 19 Nm (194 kgf-cm, 14 ft. lbs.) before repeating the process on the right-hand side. Screw in the front sway bar link assembly to the left using the 2 nuts which need to be torqued to 74 Nm (755 kgf-cm, 55 ft. lbs.). In case the ball joint turns with the nut in place, secure it with a hexagon (6 mm) wrench before proceeding with the right-hand side. The front wheel installation must end with a torque of 103 Nm (1,050 kgf-cm, 76 ft. lbs.) along with front wheel alignment inspection and adjustment.