🔧 Highlander - Front Strut Assembly Replacement

Replacing the front struts on your Highlander restores ride control, braking stability, and steering feel. For a beginner DIYer, the safest method is installing complete loaded strut assemblies, which include the spring, mount, and strut already assembled.

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

---

⚠️ Safety & Precautions

• ⚠️ Replace front struts in pairs. Do both left and right sides so the suspension stays balanced.
• ⚠️ Do not loosen the center nut on the strut shaft if using a complete loaded strut. The spring is under heavy pressure and can cause serious injury.
• ⚠️ Support your Highlander with jack stands before working underneath or inside the wheel well.
• ⚠️ Never rely on a floor jack alone to hold the vehicle.
• ⚠️ Keep the brake hose and ABS wheel speed sensor wire from stretching while the strut is removed.
• ⚠️ A wheel alignment is required after strut replacement because camber and toe can change.

---

🔧 Required Tools

You'll need the following tools for this repair:

• Floor jack rated 3-ton minimum
• Jack stands rated 3-ton minimum
• Wheel chocks
• 21mm lug nut socket
• 19mm socket
• 22mm socket
• 12mm socket
• 14mm socket
• 3/8-inch ratchet
• 1/2-inch breaker bar
• 1/2-inch ratchet
• Torque wrench 20-250 Nm
• Torque wrench 5-60 Nm
• 19mm box-end wrench
• 22mm box-end wrench
• Flat pry bar 18-inch
• Rubber mallet
• Paint marker
• Bungee cord 24-inch
• Penetrating oil spray
• Mechanic gloves
• Safety glasses

A breaker bar is a long handle used to loosen very tight bolts safely with steady force.

---

🔩 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 if damaged or corroded
• Front sway bar link nuts - Qty: 2 if removed or damaged

---

📋 Before You Begin

• 🚗 Park your Highlander on a flat, solid surface.
• 🅿️ Shift to Park and set the parking brake.
• 🧱 Place wheel chocks behind both rear wheels.
• 🔩 Loosen the front lug nuts slightly before lifting the vehicle.
• 📏 Plan for a professional wheel alignment after the repair.
• 🛠️ Spray penetrating oil on the lower strut bolts and sway bar link nuts 10-15 minutes before removal.

---

🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Loosen the Front Wheel Lug Nuts

• Use a 21mm lug nut socket and 1/2-inch breaker bar to loosen each front wheel lug nut about one turn.
• Do not remove the lug nuts yet.
• Loosen while tires touch ground.

Step 2: Raise and Support the Front of the Vehicle

• Use a floor jack rated 3-ton minimum to lift the front of your Highlander at the front center jacking point.
• Place jack stands rated 3-ton minimum under the front side pinch welds or approved support points.
• Lower the vehicle slowly onto the jack stands.
• Gently shake the vehicle by hand to confirm it is stable.

Step 3: Remove the Front Wheels

• Use a 21mm lug nut socket and 1/2-inch ratchet to remove the loosened lug nuts.
• Remove both front wheels by hand.
• Slide the wheels under 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 lower strut bracket and steering knuckle.
• The steering knuckle is the large metal part that holds the wheel hub and connects to the suspension.
• This mark helps keep the alignment close enough to drive to the alignment shop.

Step 5: Free the Brake Hose and ABS Wire Brackets

• Use a 12mm socket and 3/8-inch ratchet to remove the brake hose bracket bolt from the strut.
• Use a 10mm socket and 3/8-inch ratchet if the ABS wire bracket uses a smaller bolt.
• Move the hose and wire gently aside by hand.
• Secure them with a 24-inch bungee cord if needed so they do not hang or stretch.
• ABS means anti-lock braking system; the wire reads wheel speed for braking control.

Step 6: Disconnect the Sway Bar Link from the Strut

• Use a 19mm socket and 1/2-inch ratchet to remove the sway bar link nut from the strut bracket.
• If the stud spins, hold the back side with a 19mm box-end wrench while removing the nut with the 19mm socket.
• Push the sway bar link out of the strut bracket by hand.
• The sway bar link is a short rod that helps reduce body roll in turns.

Step 7: Support the Steering Knuckle

• Place the floor jack lightly under the lower control arm near the ball joint.
• Raise the jack just enough to support the suspension, not lift the vehicle off the jack stand.
• This keeps the steering knuckle from dropping when the strut bolts are removed.

Step 8: Remove the Lower Strut Bolts

• Use a 22mm socket and 1/2-inch breaker bar on the lower strut nuts.
• Hold the bolt heads with a 22mm box-end wrench if they turn.
• Remove the two lower nuts with the 22mm socket and 1/2-inch ratchet.
• Tap the bolts out with a rubber mallet if they are stuck.
• Use a flat pry bar 18-inch only if needed to gently separate the strut bracket from the knuckle.

Step 9: Remove the Upper Strut Mount Nuts

• Open the hood by hand.
• Locate the three upper strut mount nuts on the strut tower.
• Use a 14mm socket and 3/8-inch ratchet to remove two upper nuts completely.
• Loosen the third upper nut but leave it threaded on a few turns while supporting the strut by hand.
• Do not loosen the large center shaft nut.

Step 10: Remove the Old Strut Assembly

• Support the strut assembly with one hand.
• Use a 14mm socket and 3/8-inch ratchet to remove the final upper mount nut.
• Lower the strut out through the wheel well by hand.
• Keep fingers clear of pinch points between the strut and fender.

Step 11: Compare the New Strut Assembly

• Place the old and new loaded strut assemblies side by side on the ground.
• Confirm the brake hose bracket, sway bar link bracket, and top mount stud positions match.
• Make sure the left and right struts are not swapped.
• Match brackets before installing.

Step 12: Install the New Strut Assembly

• Guide the new strut assembly up into the strut tower by hand.
• Start the three upper mount nuts by hand to avoid cross-threading.
• Use a 14mm socket and 3/8-inch ratchet to snug the upper nuts lightly.
• Do not fully torque them yet.

Step 13: Attach the Strut to the Steering Knuckle

• Use the floor jack to raise or lower the steering knuckle until the lower strut holes line up.
• Insert the two lower strut bolts by hand.
• Install the lower nuts by hand.
• Use a 22mm socket, 22mm box-end wrench, and torque wrench 20-250 Nm to tighten the lower strut nuts.
• Torque to 240 Nm (177 ft-lbs)

Step 14: Torque the Upper Strut Mount Nuts

• Use a 14mm socket and torque wrench 5-60 Nm to tighten the three upper strut mount nuts.
• Torque to 80 Nm (59 ft-lbs)
• Do not tighten or loosen the center strut shaft nut.

Step 15: Reconnect the Sway Bar Link

• Insert the sway bar link stud into the strut bracket by hand.
• Install the nut by hand.
• Use a 19mm socket and torque wrench 20-250 Nm to tighten the sway bar link nut.
• If the stud spins, hold it with a 19mm box-end wrench while tightening.
• Torque to 74 Nm (55 ft-lbs)

Step 16: Reattach Brake Hose and ABS Wire Brackets

• Position the brake hose bracket on the new strut by hand.
• Use a 12mm socket and torque wrench 5-60 Nm to tighten the brake hose bracket bolt.
• Torque to 29 Nm (21 ft-lbs)
• Position the ABS wire bracket by hand.
• Use a 10mm socket and torque wrench 5-60 Nm if your bracket uses a 10mm bolt head.
• Torque to 8 Nm (71 in-lbs)
• Confirm the hose and wire do not rub the tire or strut.

Step 17: Repeat on the Other Front Side

• Repeat Steps 4 through 16 on the opposite front strut.
• Use the same tools and torque specs.
• Keep parts separated left and right during installation.

Step 18: Reinstall the Front Wheels

• Lift each wheel onto the hub by hand.
• Install lug nuts by hand first to avoid cross-threading.
• Use a 21mm lug nut socket and 1/2-inch ratchet to snug the lug nuts in a star pattern.
• A star pattern means tightening across the wheel, not around in a circle.

Step 19: Lower the Vehicle

• Use the floor jack rated 3-ton minimum to lift the vehicle slightly off the jack stands.
• Remove the jack stands by hand.
• Lower your Highlander slowly to the ground.

Step 20: Torque the Lug Nuts

• Use a 21mm lug nut socket and torque wrench 20-250 Nm to tighten the lug nuts in a star pattern.
• Torque to 103 Nm (76 ft-lbs)
• Recheck each lug nut once more after the first full pass.

---

✅ After Repair

• ✅ Bounce the front of your Highlander gently by hand. It should settle quickly without repeated bouncing.
• ✅ Turn the steering wheel lock-to-lock while parked and listen for rubbing, clunks, or stretched hoses.
• ✅ Test drive slowly at first over a smooth road.
• ✅ Listen for knocking noises from the strut mount, sway bar link, or lower bolts.
• ✅ Get a professional wheel alignment as soon as possible.
• ✅ Recheck lug nut torque after 25-50 miles.

---

💰 DIY vs Shop Cost

Shop Cost: $850-$1,400 (parts + labor)

DIY Cost: $300-$650 (parts only)

You Save: $550-$750 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2.5-4 hours.

---

🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.