🔧 Highlander - Front Strut Assembly Replacement

Replacing the front struts on your Highlander restores ride control, reduces clunking or bouncing, and helps keep the tires planted on the road. For a beginner, the safest method is replacing complete loaded strut assemblies, which come preassembled with the spring, mount, and strut.

Difficulty Level: Intermediate | Estimated Time: 3-5 hours

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⚠️ Safety & Precautions

• ⚠️ Replace struts in pairs. If one front strut is replaced, replace the other front strut too.
• ⚠️ Use complete loaded strut assemblies. Do not compress the coil spring unless you have proper training and professional spring tools.
• ⚠️ Support your Highlander with jack stands before working underneath or around the wheels. Never rely on a floor jack alone.
• ⚠️ Do not pull, stretch, or kink the brake hose or ABS wheel speed sensor wire.
• ⚠️ After strut replacement, a wheel alignment is required to prevent tire wear and steering pull.
• ⚠️ Your Highlander is a hybrid, but this repair does not require high-voltage system service. Do not touch orange high-voltage cables.

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🔧 Required Tools

You'll need the following tools for this repair:

• 21mm lug nut socket
• 22mm socket
• 19mm socket
• 17mm socket
• 14mm socket
• 12mm socket
• 6mm hex key socket
• Ratchet handle 1/2-inch drive
• Ratchet handle 3/8-inch drive
• Breaker bar 1/2-inch drive
• Torque wrench 1/2-inch drive 250 ft-lb
• Torque wrench 3/8-inch drive 80 ft-lb
• Box-end wrench 17mm
• Box-end wrench 19mm
• Socket extension 6-inch 3/8-inch drive
• Trim removal tool set
• Flat-blade screwdriver 1/4-inch tip
• Paint marker
• Penetrating oil spray
• Rubber mallet 24-ounce
• Pry bar 18-inch
• Floor jack rated 3-ton minimum
• Jack stands rated 3-ton minimum
• Wheel chocks
• Safety glasses
• Mechanic gloves

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Front loaded strut assembly - Left: 1, Right: 1 - Replace in pairs
• Front strut-to-knuckle bolts and nuts - Qty: 4
• Front stabilizer bar link nuts - Qty: 2
• Front strut upper mounting nuts - Qty: 6

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📋 Before You Begin

• Park your Highlander on level ground.
• Shift to Park and set the parking brake.
• Place wheel chocks behind the rear wheels.
• Open the hood before lifting the vehicle.
• Spray the lower strut bolts and stabilizer link nuts with penetrating oil spray and let it soak for 10 minutes.
• A loaded strut assembly is a complete bolt-in unit with the spring already installed.
• A knuckle is the heavy steering part that the wheel hub and strut attach to.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Loosen the Front Lug Nuts

• Use a 21mm lug nut socket and breaker bar 1/2-inch drive to loosen each front lug nut about half a turn.
• Do this while the tires are still touching the ground.
• Do not remove the lug nuts yet.

Step 2: Lift and Support the Front of the Vehicle

• Use a floor jack rated 3-ton minimum at the front center jacking point.
• Place jack stands rated 3-ton minimum under the front side support points.
• Lower your Highlander gently onto the jack stands.
• Shake the vehicle lightly by hand to confirm it is stable.
• Never work under a jack-only vehicle.

Step 3: Remove the Front Wheels

• Use a 21mm lug nut socket and ratchet handle 1/2-inch drive to remove the loosened lug nuts.
• Remove both front wheels by hand.
• Place the wheels flat under the side of the vehicle as an extra safety backup.

Step 4: Mark the Strut-to-Knuckle Position

• Use a paint marker to draw alignment marks across the strut bracket and steering knuckle.
• This helps keep the alignment close enough to drive safely to an alignment shop.
• It does not replace a professional alignment.

Step 5: Disconnect the Brake Hose and ABS Wire Brackets

• Use a 12mm socket and ratchet handle 3/8-inch drive to remove the brake hose bracket bolt from the strut.
• Use a 10mm socket if the ABS wire bracket uses a smaller bolt on your strut.
• Use a trim removal tool set or flat-blade screwdriver 1/4-inch tip to release any plastic wire clips from the strut body.
• Move the hose and wire aside gently. Do not let them hang tight.

Step 6: Disconnect the Stabilizer Bar Link from the Strut

• Use a 17mm socket and ratchet handle 3/8-inch drive to remove the stabilizer bar link nut from the strut bracket.
• If the stud spins, hold the stud with a 6mm hex key socket while turning the nut with a box-end wrench 17mm.
• A stabilizer bar link connects the strut to the sway bar to reduce body roll in turns.
• Push the link out of the strut bracket by hand.

Step 7: Support the Steering Knuckle

• Place the floor jack rated 3-ton minimum lightly under the lower control arm or knuckle area.
• Lift just enough to support the weight of the suspension.
• Do not raise the vehicle off the jack stand.
• This prevents the brake hose and axle from being pulled downward when the strut is removed.

Step 8: Remove the Lower Strut Bolts

• Use a 22mm socket, breaker bar 1/2-inch drive, and box-end wrench 22mm to loosen the two lower strut-to-knuckle nuts and bolts.
• If a 22mm wrench is not available, use a box-end wrench 19mm only if your replacement hardware uses 19mm nuts.
• Remove the nuts, then tap the bolts out using a rubber mallet 24-ounce.
• If the bolts are stuck, use a pry bar 18-inch gently to relieve tension at the knuckle.
• Keep one hand on the knuckle so it does not tip outward suddenly.

Step 9: Remove the Upper Strut Mount Nuts

• From under the hood, locate the three upper strut mount nuts on the strut tower.
• Use a 14mm socket, socket extension 6-inch 3/8-inch drive, and ratchet handle 3/8-inch drive to remove the three upper mount nuts.
• Do not remove the large center nut on the strut assembly.
• The center nut holds spring tension inside the strut assembly.
• Hold the strut with one hand while removing the last upper nut.

Step 10: Remove the Old Strut Assembly

• Lower the old strut assembly out through the wheel well by hand.
• Guide it around the brake hose and ABS wire carefully.
• Do not let the steering knuckle fall outward.
• Slow movements prevent hose damage.

Step 11: Install the New Loaded Strut Assembly

• Place the new front loaded strut assembly into the wheel well by hand.
• Align the upper studs with the holes in the strut tower.
• Start the three new front strut upper mounting nuts by hand.
• Use a 14mm socket and torque wrench 3/8-inch drive 80 ft-lb to tighten the upper mount nuts to Torque to 80 Nm (59 ft-lbs).

Step 12: Reconnect the Strut to the Steering Knuckle

• Use the floor jack rated 3-ton minimum to raise or lower the knuckle until the bolt holes line up.
• Install the new front strut-to-knuckle bolts and nuts by hand.
• Match your paint marker marks as closely as possible.
• Use a 22mm socket, box-end wrench 22mm, and torque wrench 1/2-inch drive 250 ft-lb to tighten the lower strut bolts to Torque to 240 Nm (177 ft-lbs).

Step 13: Reconnect the Stabilizer Bar Link

• Insert the stabilizer bar link stud into the strut bracket by hand.
• Install the new front stabilizer bar link nut by hand.
• Use a 17mm socket and torque wrench 3/8-inch drive 80 ft-lb to tighten the nut to Torque to 74 Nm (55 ft-lbs).
• If the stud spins, hold it with a 6mm hex key socket and tighten with a box-end wrench 17mm.

Step 14: Reattach Brake Hose and ABS Wire Brackets

• Use a 12mm socket and ratchet handle 3/8-inch drive to reinstall the brake hose bracket bolt.
• Tighten the brake hose bracket bolt to Torque to 29 Nm (21 ft-lbs).
• Use a 10mm socket if needed to reinstall the ABS wire bracket bolt.
• Tighten the ABS wire bracket bolt to Torque to 8 Nm (71 in-lbs).
• Clip all plastic wire retainers back into the strut by hand.

Step 15: Repeat on the Other Side

• Repeat Steps 4 through 14 on the opposite front strut.
• Use the same tools and torque specifications.
• Keep left and right struts on their correct sides.

Step 16: Reinstall the Front Wheels

• Install the front wheels by hand.
• Thread the lug nuts by hand to avoid cross-threading.
• Use a 21mm lug nut socket and ratchet handle 1/2-inch drive to snug the lug nuts in a star pattern.

Step 17: Lower the Vehicle and Torque the Lug Nuts

• Use the floor jack rated 3-ton minimum to lift your Highlander slightly off the jack stands.
• Remove the jack stands rated 3-ton minimum.
• Lower the vehicle until the tires touch the ground.
• Use a 21mm lug nut socket and torque wrench 1/2-inch drive 250 ft-lb to tighten the lug nuts in a star pattern to Torque to 103 Nm (76 ft-lbs).

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✅ After Repair

• Turn the steering wheel left and right while parked. Listen for rubbing, popping, or pulling wires.
• Check that the brake hoses and ABS wires are clipped in place on both struts.
• Take a slow test drive around the block. Listen for clunks.
• Schedule a four-wheel alignment as soon as possible.
• Recheck lug nut torque after 25-50 miles using a 21mm lug nut socket and torque wrench 1/2-inch drive 250 ft-lb.

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💰 DIY vs Shop Cost

Shop Cost: $900-$1,500 (parts + labor)

DIY Cost: $350-$750 (parts only)

You Save: $400-$850 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 3-4 hours.

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🎯 Ready to get started?

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