Parts for your 2005 Toyota Highlander-Universal joints

2005 Toyota Highlander/Kluger universal joints: what’s fitted and how to look after them

Based on Toyota’s 2001–2007 Highlander/Kluger repair manual (Drivetrain/Propeller Shaft section), the Toyota Electronic Parts Catalogue, and common aftermarket manuals (e.g., Haynes for 2001–2007 Highlander/RX), universal joints are fitted to 2005 Highlander/Kluger models with All-Wheel Drive (AWD). These AWD variants run a two‑piece propeller shaft to the rear differential with a universal joint at each end and a centre support bearing. Front‑Wheel Drive (FWD) models don’t use driveline universal joints because they don’t have a rear prop shaft, instead they use constant‑velocity (CV) joints on the front half‑shafts.

For AWD owners, those universal joints (often called U‑joints) let the prop shaft transfer torque to the rear diff while dealing with angles and suspension movement. They’re compact, tough, and crucial for smooth take‑offs and quiet cruising. On many Toyota shafts of this era, the U‑joints are sealed and staked into the shaft from factory. That means they’re not designed for routine greasing, and Toyota typically supplies the complete propeller shaft assembly rather than the joints on their own. A quality driveline shop can still replace the crosses and rebalance the shaft if you prefer a rebuild.

As part of regular servicing of your 2005 Toyota Highlander/Kluger AWD universal joints, a quick check goes a long way. Look for perished seals, rust bleed around the caps, or play when the shaft is unloaded. On the road, early warnings include a light chirp that speeds up with vehicle speed, a faint shudder under acceleration, or a clunk when shifting from reverse to drive. Left to worsen, you’ll feel more vibration and may risk collateral damage to the centre bearing or diff flanges.

If the joints are the sealed type, replacement is the fix once wear is present. When refitting or rebuilding, marking the yokes to maintain phasing is essential, and torque the flange bolts to spec with new hardware where required. If you’ve got an aftermarket prop shaft with grease nipples, a quick pump of quality lithium‑based grease every 10,000–15,000 kilometres (or at each service) helps them last. After any U‑joint or shaft work, a test drive checking for vibration across the speed range is smart, and a shaft balance may be needed if there’s any noticeable buzz.

• Service tip: Inspect during every oil change, it’s fast and can prevent bigger bills.
• Use: AWD models have two U‑joints, FWD models don’t have driveline U‑joints.
• Repair path: Replace the complete shaft or have a driveline shop rebuild and balance.

Q: How can someone tell if their 2005 Highlander/Kluger has U‑joints fitted?

Check the badge or build plate for “AWD” or “4WD”.

Look underneath: an AWD has a propeller shaft running to the rear differential.

FWD models have no rear diff and no long shaft down the centre tunnel.

The prop shaft on AWD has a universal joint at each end.

A workshop can confirm by VIN against the Toyota EPC.

AWD ride height may be slightly different at the rear.

Owners’ manuals outline AWD features and maintenance notes.

Service invoices may list “prop shaft” or “rear diff oil”.

Haynes/repair manuals show AWD driveline diagrams with U‑joints.

Test on gravel: AWD often launches with less front wheel slip.

Scan tools may display AWD system data on some trims.

When unsure, a quick hoist inspection answers it in minutes.

Q: Can the U‑joints be replaced separately, or does the whole prop shaft need replacing?

From factory, many Toyota shafts use staked, non‑serviceable U‑joints.

Toyota often sells the complete propeller shaft assembly as the service part.

Skilled driveline shops can press out the staked joints and fit new crosses.

After a rebuild, proper phasing and balancing are critical for smooth running.

Costs vary, a rebuild can be cheaper than a brand‑new shaft.

Aftermarket shafts may include greaseable U‑joints and are fully serviceable.

If a centre support bearing is noisy, replace it during U‑joint work.

Always use quality joints matched to the original dimensions.

Replace flange bolts and apply correct torque values on reassembly.

A road test at multiple speeds checks for residual vibration.

If vibration persists, return for re‑balance or angle inspection.

For heavy towing, consider periodic inspections even if joints feel fine.