[Hig03]

So interesting. I'm on an almost identical journey with the rusted through engine cradle. two years ago I replaced the rusted through rear cross-member on my 150K '03 base V6 (and other stuff like the gas tank and exhaust) taking identical one off a 1999 RX300 in the U-pull-it yard with almost no rust on it (pic below-before treatment). Haven't had much luck with POR15 on the engine cradle previously, it peeled off after a year, so I had the "new" rear cross member sandblasted and professionally coated with the heavy duty and UV resistant stuff they use on Caterpillar construction vehicles. So far so good, still like new.

Anyway. I now have the replacement engine cradle all ready and coated looking like new with new control arms to go with it. I'll try to get a pic of that too. My intention is to pull the motor and replace all the worn out stuff like crank/rear main/cam/valve stem seals, manifold and valve cover gaskets, knock sensors, timing belt, water pump, steering rack, blah blah blah. Actually not too bad $ for parts, maybe $3K to get this great girl though the next 150K miles. What's holding me up is tackling pulling the motor to begin with. I've pulled a few other motors, but always out the top, never by dropping the cradle with motor and trans on it. I have an engine hoist but don't have a lift, so putting the car 3-4 feet in the air is not something I can see doing in the driveway. I can imagine pulling the motor out the top, just a little hesitant to start it and find out I'm wrong. Curious about Kingoyota2 remarks about dropping the old cradle. Seems if you can just drop the cradle, you could maybe do the opposite and lift out the engine (after separating from trans). Does that seem right, or am I missing something?

So good luck with your project, would love to see photos if you have time during the job. I'll no doubt be doing something very similar next summer.

 

[Hig03]

How was dropping the rear subframe? I’m probably going to have do it on my 2002 in order to swap my rear differential to an LSD as the gas tank spans both sides of the car.

Might just grab myself a 2013 Highlander rear subframe in good condition as my old one is kinda rough and the bushings are cracked.

I didn't start out to do it, but when replacing gas tank it became obvious the frame was so rusted through it could have been dangerous. The diff has a separate carrier so can be removed without removing subframe. Carrier is in the picture above on the bench behind the subframe, and by itself below.

Overall it was generally pretty straightforward, not hard at all though would have been a lot easier with two people especially when putting it all back together. Took me a day to figure out dropping it, and about 4 hours to put back in (with arms, struts, wheels/brakes, etc) once I understood it better. I hope a 2013 fits, I never even checked since the Lexus one was there on a car right next to the one I went to see at the u-pull-it. kinda fell in my lap.

 

[Hig03]

Nice work! You’re lucky those bolts came out! I had to cut each and every one off for the rear control arms when I replaced them. You’d be surprised how many 2nd gen (2008-2013) parts are compatible. I already have the 2nd gen front & rear brakes, front sway bar, rear knuckles and soon the fronts! They’re all a little beefed up, easier to find and hardly cost any more than 1st gen parts.

I saw the carrier and I was wondering how you got those rear bolts out with the tank in the way? Seems awfully tight. My friend was able to remove one and swing it out on one side of his 2006 AWD, but the 04-07 models have no gas tank on the pass side.

So remember my project started off as gas tank replacement so it was already out of the way, as were drive shaft, exhaust, etc. Eventually just about everything aft of the rear cat that could be removed came off including fuel filler neck since that was severely rusted too and needs the subframe to be at least loosened an inch or two to remove. None of it was particularly difficult, I'm no professional mech, but I was definitely motivated to try to save my baby from the rust so I went a little crazy getting everything cleaned up and protected. That's my plan for the front end next summer.

 

[Hig03]

Mr-Dave pulled his from the top. See post 11.

v6 excessive oil usage

My wife recently bought an 04 with the 3.3 vvt with 79,000 miles. I noticed blue smoke at startup, and soon found it used oil quickly. I have repaired or restored a lot of cars over the years, but this is my first Toyota experience. I first suspected valve seal leak, and checked for oil...

www.toyotanation.com

Nice. I've only ever found one post saying it can be done, now this is the second. Woo! Maybe it's not so bad after all. Thanks for the tip!