D0N_TI_LSC Expir

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TECHNICAL INSTRUCTIONS
FOR
LIMITED SERVICE CAMPAIGN D0N
REAR DRIVESHAFT ASSEMBLY REPLACEMENT
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CERTAIN 2011-2012 MODEL YEAR HIGHLANDER HV
I.
OPERATION FLOW CHART
Verify Vehicle Eligibility
1. Check the VIN range.
2. Check the TIS Vehicle Inquiry
System.
Not Covered
No further action required.
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Covered
Inspect the left and right rear
driveshaft assemblies for
disengagement.
NG
Replace left and right rear driveshaft
assemblies and rear differential motor
assembly.
OK
Replace left and right rear driveshaft
assemblies.
Campaign complete, return the vehicle
to the customer.
II. BACKGROUND
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Due to an assembly error during manufacturing, the Rear Driveshaft in certain 2011-2012 Model Year
Highlander Hybrid vehicles can disengage from its inboard joint assembly. If this occurs, the driveshaft
could vibrate and rattle inside the inboard joint, causing a loud noise from the rear of the vehicle while
driving. Continuing to drive the vehicle can damage the housing of the Rear Differential Motor. If the
housing is damaged, the entire differential motor would also require replacement.
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III. IDENTIFICATION OF AFFECTED VEHICLES
A. COVERED VIN RANGE
WMI
Year
VDS
BC3EH
DC3EH
BC3EH
DC3EH
2011
JTE
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2012
VIN Range
Range
2003742 - 2003975
2003733 - 2003980
2003982 - 2008657
2003983 - 2008658
NOTE:
 Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Limited Service
Campaign, and that the campaign has not already been completed prior to dealer shipment or
by another dealer.
 TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not affected
or were completed by another dealer.
IV. PREPARATION
A. PARTS
All covered vehicles will require the replacement of the rear driveshaft assemblies.
Part Number
04003-34148
Part Description
Shaft Kit Rr Drive
Quantity
2
The kit above includes the following parts.
42340-48081
90177-22001
Shaft Assembly, Rear Drive
Nut
1
1
Only a very small number of vehicles will require the replacement of this part, follow the
inspection procedure in these instructions to determine if replacement is required. Parts
will be on Manual Allocation Control (MAC), refer to the dealer letter for details.
Part Number
16492-21050
G1050-48010
04003-36148
Part Description
Packing (For Radiator Drain Cock)
Motor Assembly, Rr Traction W/ Transaxle
Bolt & Gasket Kit:
17451-28040
90109-12082
90119-14099
91552-81265
Gasket Exhaust Pipe
Bolt
Bolt, W/ Washer
Bolt, Flange
2
2
2
2
Quantity
1
1
1
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B. MATERIALS
ONLY use Toyota Super Long Life Coolant and Hybrid transaxle fluid if replacement of the
rear differential motor assembly is required. Refer to the inspection in these instructions for
details.
 Hybrid Transaxle Fluid (ATF WS)=1.8 liters (1.9 US qts, 1.6 Imp. qts)*
 Toyota Genuine 50/50 Pre-Diluted SLLC = Approximately 1quart*
 Shop Cloth
 Brake Cleaner
NOTE:
 The coolant drained from the radiator must be reused.
 Because some coolant will be lost when disconnecting the hoses by the exhaust pipe, a
small amount of coolant will be needed.
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C. TOOLS & EQUIPMENT
 Standard Hand Tools
 Techstream
 Wooden Block


Protective Eye Wear
4 Wheel Alignment machine
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SST – These are essential special service tools that the dealership should have.
Part Number
Part Name
Quantity
00002-03100-S
Electrical Insulating Gloves (Small)
00002-03200-M
Electrical Insulating Gloves (Medium)
1
00002-03300-L
Electrical Insulating Gloves (Large)
09930-00010
DriveShaft Nut Chisel
1
09961-00950
Torque Wrench Adaptor
1
4
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V. COMPONENTS
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VI. INSPECT THE REAR DRIVESHAFT ASSEMBLY
1. INSPECT THE REAR DRIVESHAFT ASSEMBLY FOR
DISENGAGEMENT
a) Approximately one inch from the inner rubber boot,
firmly grab the metal portion of the driveshaft.
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b) Move the driveshaft assembly from side to side and upand-down. If the driveshaft moves excessively, the
inner bearing has disengaged from the shaft.
Note: The driveshaft has some slight backlash by
design.
c) Check both driveshafts in the same manner.
NOTE: Disengagement of the driveshaft may cause damage to the inside of the rear differential
motor. If either driveshaft is found to be disengaged, replacement of the rear differential motor is
required.
Results
BOTH Driveshafts
Engaged
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OK
One or both shafts
disengaged
NG
ACTION REQUIRED
REPLACE THE REAR DRIVESHAFT ASSEMBLY
Both drive shafts must be replaced. Proceed to section VII
REPLACE THE REAR DIFFERENTIAL MOTOR ASSEMBLY AND REAR
DRIVESHAFT ASSEMBLY.
The rear differential motor assembly AND both driveshafts must be
replaced. Proceed to Section VIII
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VII. REPLACE THE REAR DRIVESHAFT ASSEMBLY
The work procedures are performed on both the right and left sides. These
instructions use the left side in explaining the procedures. Always be sure to perform
the same procedures on both the left and right sides.
1. LOOSEN THE 4 DRIVE SHAFT NUTS
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a) Loosen the 4 nuts. DO NOT remove them at this time.
NOTE: If the nuts cannot be loosened due to the
driveshaft spinning, apply the parking brake to hold
the rear tire.
2. REMOVE THE AXLE NUT
a) Remove the rear wheels.
b) Using the SST and a hammer, release the staked part
of the rear axle shaft nut.
SST 09930-00010
c) While applying the brakes, remove the rear axle shaft
nut.
d) Put a mark on the removed nut to identify it cannot be
reused.
3. REMOVE PARKING BRAKE CABLE AND SUSPENTION
COMPONENTS
a) Remove the nut and separate the No.3 parking brake
cable assembly.
b) Remove the 2 bolts, the 2 nuts, and the rear strut rod
assembly.
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NOTE:
 Since lock nuts are used, loosen the bolts.
 If difficult to remove the bolts, use a wooden
block and a jack to slightly lift up the axle
carrier and remove the bolts.
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c) Remove the 2 bolts, the 2 nuts, and the rear No.1
suspension arm assembly.
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NOTE:
 Since lock nuts are used, loosen the bolts.
 Before removing the driveshaft, be sure to
remove the rear No.1 suspension arm assembly,
otherwise it may be damaged by interference
with the boot of the axle carrier.
d) Remove the bolt and the nut, and separate the rear
No.2 suspension arm assembly.
NOTE: Since lock nuts are used, loosen the bolts.
DO NOT allow the rear No.2 suspension
arm assembly to strike the boot of the
wheel hub assembly as it will damage it.
4. REMOVE THE REAR DRIVESHAFT
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a) Remove the 4 nuts and washers.
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b) Using the plastic hammer, disengage the
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driveshaft.
c) Move the wheel hub assembly towards the outside of
the vehicle and hold it in place.
 Move the wheel hub assembly only far
enough to allow the inboard side of
the axle shaft to be cleanly removed
from the motor side flange.
 DO NOT excessively move the wheel
hub assembly, as it may stress the
upper support of the suspension strut.
d
c
d) Separate the inboard side of the driveshaft, and remove
the driveshaft from the wheel hub assembly.
NOTE: Two people may be needed.
e) Put a mark on the removed driveshaft to identify it
cannot be reused.
NOTE: The parts return instructions must be
followed as 100% of axle shaft will be recovered for
this activity.
e
d
5.
INSTALL THE NEW REAR DRIVESHAFT
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DO NOT apply excessive force to the rear
driveshaft to prevent the end cover from
being removed.
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a) Using brake cleaner, remove the corrosion inhibitor on
the tip of the NEW driveshaft.
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 The corrosion inhibitor is colorless
and transparent.
 If the rear driveshaft is installed
without removal of the corrosion
inhibitor, it may cause an overtorqued rear axle shaft nut and
damage the driveshaft.
 DO NOT apply oils or fats after
cleaning of the tip.
b) Move the axle carrier towards the outside of the vehicle
and hold it in place.
c) Insert the NEW driveshaft into the wheel hub assembly.
Move the rear wheel hub assembly until
the inner driveshaft flange does not
interfere with the motor side mounting
flange.
c
b
b
d) Install the inboard side of the driveshaft.
NOTE: Two people may be needed.
d
b
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e) Loosely install the 4 nuts and the 4 washers.
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6. INSTALL THE SUSPENTION COMPONENTS AND THE
PARKING BRAKE CABLE
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a) Temporarily install the rear No.2 suspension arm
assembly with the bolt and nut.
DO NOT allow the rear No.2 suspension
arm assembly to strike the boot of the
wheel hub assembly as it will damage it.
b) Loosely install the rear No.1 suspension arm assembly
with the 2 bolts and the 2 nuts.
c) Check that the identification mark of the rear strut rod
assembly is positioned on the inner side of the vehicle.
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d) Loosely install the rear strut rod assembly with the 2
bolts and the 2 nuts.
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7. LOOSELY INSTALL A NEW REAR AXLE SHAFT NUT.
8. JACK UP THE REAR AXLE SUB-ASSEMBLY
a) Jack up the rear axle sub-assembly, placing a wooden
block underneath to avoid damage. Apply load to the
suspension so that the rear driveshaft assembly is
positioned horizontally.
 DO NOT jack up the rear axle subassembly too high as the vehicle may
fall off of the lift.
 DO NOT bend the brake dust cover.
NOTE:
 If the rear driveshaft assembly cannot be
positioned horizontally as shown in the
illustration even when the rear wheel hub
assembly is jacked up, apply additional load to
the vehicle such as by having a person sit in the
rear seat.
 Use the same procedure for the RH and LH side.
9. TORQUE THE REAR NO. 2 SUSPENSION ARM
ASSEMBLY BOLT AND NUT.
Torque: 82 ft. lbf (112 N m)
10. TORQUE THE NO. 1 SUSPENSION ARM ASSEMBLY
a) Using a torque rench that is 14.96 in (380mm) long with
SST 09961-00950, torque the bolt and nut on the inside
of the No.1 suspension arm assembly.
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Torque:
with SST: 42 ft lbf (57 N m)
 If you are not using the exact tools described in step b) you must refer to the repair
manual for torque specifications. (Link)
 Since a lock nut is used, torque the bolt.
 The final torque must be applied under standard vehicle height conditions.
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11. Torque the bolt and nut on the outside of the No.1
suspension arm assembly.
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Torque: 82 ft lbf(112 N m)
12. Torque the bolt and the rear strut rod assembly.
Torque: 59 ft lbf (80 N m)
13. TORQUE THE BOLT AND THE REAR STRUT ROD
ASSEMBLY.
Torque: 59 ft lbf (80 Nm)
NOTE: For steps “k” through “o”
 Since a lock nut is used, tighten the
bolt.
 The final torque must be applied
under standard vehicle height
conditions.
a) Remove the jack and the wooden block.
14. REINSTALL THE NO. 3 PARKING BRAKE CABLE
ASSEMBLY WITH THE NUT.
Torque: 53 in lbf (6.0 N m)
DO NOT twist the No. 3 parking brake
cable assembly when installing it.
15. TORQUE THE NEW AXLE SHAFT NUT.
a) Using a chisel and a hammer, stake the rear axle shaft
nut.
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Torque: 216 ft lbf (294 N m)
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16. TORQUE THE NEW REAR DRIVESHAFT ASSEMBLY
WITH THE 4 NUTS AND 4 WASHERS.
Torque: 41 ft lbf (56 N m)
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17. REINSTALL THE REAR WHEEL.
Torque: 76 ft lbf (103 N m)
18. INSPECT AND ADJUST REAR WHEEL ALIGNMENT
a) Inspect and adjust rear wheel alignment.
Refer to TIS for instructions on inspect and adjust rear wheel alignment.
19. CHECK FOR SPEED SENSOR SIGNAL
a) Check for speed sensor signal.
Refer to TIS for instructions on check for speed sensor signal.
VIII.REPLACE THE REAR TRACTION W/ TRANSAXLE MOTOR ASSEMBLY AND
REAR DRIVESHAFT ASSEMBLY
 When working with or around a high voltage circuit (in which wiring and
connectors are orange), wear insulated gloves to prevent electric shock.
 Before working with a high voltage system, disconnect the negative terminal of the
auxiliary battery and then the service plug grip. Then leave the vehicle for ten
minutes and, after testing to verify that the capacitor has discharged, start working.
1.
SAFETY PRECAUTIONS
CRITICAL INFORMATION – READ THOROUGHLY
These cautions should be observed when performing this campaign. Failure to follow these cautions
could result in injury.
1. PLACE CAUTION SIGN ON ROOF OF VEHICLE
a)
Place the “Working High Voltage Sign” provided on
the next page to warn others in the shop area.
2. REMOVE ALL PERSONAL JEWELRY AND
BELONGINGS
To prevent shock and short circuits remove all
jewelry and personal belongings (i.e. watch,
bracelet, pocket screw drivers, etc.)
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a)
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(Safety Precautions Continued . . . . )
3. USE INSULATED TOOLS OR INSULATE TOOLS
To prevent shock and short circuits use insulated
tools. If insulated tools are not available insulate the
tools being used with tape.
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a)
4. WEAR INSULATED GLOVES (INSULATED GLOVES
ARE SSTs)
a)
When working around or with high voltage circuit
use insulated gloves.
b)
DO NOT use damaged or wet insulated gloves.
c)
If gloves are dirty, clean them before use as
directed by the glove instruction manual.
5. PROPERLY HANDLE SERVICE PLUG
a) Disconnect the negative terminal of the auxiliary
battery and remove the service plug.
b) Place service plug in your pocket to ensure that it
cannot be accidentally reinstalled by another
technician.
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c) Wait ten minutes before working on any high voltage
system.
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NOTE:
 See step VII. REPLACE THE REAR DRIVESHAFT ASSEMBLY for the detachment procedure of the
driveshaft.
 DO NOT contaminate or damage the O-ring when the No.3 wire cable and extension wire assembly
are removed.
 DO NOT disconnect the ground cable from a location other than what is shown in the technical
instructions; otherwise it will be difficult to remove the rear differential motor assembly. Perform
the work according to the procedure.
2.
REMOVE THE REAR DIFFERENTIAL MOTOR ASSEMBLY AND REAR DRIVESHAFT
ASSEMBLY
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 Confirm the coolant is not hot before beginning any work.
 The coolant drained from the radiator must be reused, confirm that a clean
container is used when draining the coolant.
 DO NOT reuse any coolant that is drained when disconnecting the coolant hoses
by the exhaust gas control actuator, this coolant may be contaminated when
drained.
 DO NOT mix the coolant drained from the radiator with the coolant drained from the
hoses.
a) Remove the rear differential motor assembly and rear driveshaft assembly.
Refer to TIS for instructions on rear differential motor assembly removal.
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3.
INSTALL NEW REAR DIFFERENTIAL MOTOR ASSEMBLY AND NEW REAR DRIVESHAFT
ASSEMBLY
a) Install the rear differential motor assembly and rear driveshaft assembly.
Refer to TIS for instructions on rear differential motor assembly installation.
◄ VERIFY REPAIR QUALITY ►
Confirm the torque on all lock nuts.
Confirm the rear axle shaft nut.
Ensure all nuts and bolts are torqued to the specifications.
Confirm the 4 nuts and washers are torqued on each inboard side of the driveshaft assemblies.
Confirm the No. 2 suspension arm assembly bolts and nuts are torqued to specifications.
Ensure the rear strut road assembly bolts and nuts are torqued (2 on each side).
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−
−
−
−
−
−
If you have any questions regarding these technical instructions, please contact your regional
representative.
IX. Appendix
A. CAMPAIGN DESIGNATION DECODER
D
0
Year Campaign is Launched Repair Phase
8 = 2008
9 = 2009
A = 2010
B = 2011
C = 2012
D = 2013
E = 2014
F = 2015
Etc...
0 = Remedy
1 = Interim (Remedy
not yet available) “1”
will change to “0” when
the Remedy is
available
B
Current Campaign Letter
for this year
1st Campaign = A
2nd Campaign = B
3rd Campaign = C
4th Campaign = D
5th Campaign = E
6th Campaign = F
7th Campaign = G
8th Campaign = H
9th Campaign = I
Etc...
Examples:
A0D = Launched in 2010, Remedy Phase, 4th Campaign Launched in 2010
C1B = Launched in 2012, Interim Phase, 2nd Campaign Launched in 2012
D0B = Launched in 2013, Remedy Phase, 1st Campaign Launched in 2013
B. CAMPAIGN PARTS RETURN
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a) All parts replaced under this campaign will be on 100% parts recovery. Failure to return the
replaced parts will result in an immediate debit.
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