FIXED! Hanging visor
I guess I was lucky that my 2002 Highlander's visor made it 11 years before failing. But thanks to the wisdom of the Internet, it was an easy fix!
I followed the directions found on the TundraSolutions board (referenced earlier in this thread). Here was my exact process, and I've included a couple of photos.
The great thing about this fix vs. other methods is that you don't need to pull the bar out of the visor at all... it's just a bit of microsurgery, adding a screw where there are already pre-drilled holes. It's crazy that Toyota didn't just make them this way to begin with.
1) Remove the visor from the car: do this by using a small flathead screwdriver to pop up the mounting cover, then remove the two Phillips screws, and disconnect the electrical plug.
2) Remove the mirror (there are two more screws under the light cover that you can pop up: see photo), and carefully lift up the vinyl that was covered by the top of the mirror. Be careful not to tear the vinyl. You should already see a hole in the foam core between the channel for the mirror light wires and the mirror recess -- however it may be covered by some brown tape (mine was). Just lift up the tape and you'll see it. (see other photo)
3) Get a sharp razor / Xacto knife and clean just a little of the foam around the hole so it will accommodate a short screw (self tapping). If you look down the hole you will see sheet metal with a hole. This sheet metal strip clamps the visor pivot shaft. Make sure you use a short screw large enough to self-thread into the sheet metal hole but short enough so it will not pierce through the other side of the visor. I screwed the short screw in the hole and tightened just it enough to hold the visor more securely.
3) That's it! Just screw the mirror fixture back in, and reattach the visor in the car.
Now with the screw in place, if it loosens in the future, all you have to do is remove the mirror and lift the vinyl a little, and use a screwdriver to tighten it when needed. With everything reassembled you can’t even tell that any repairs were performed and it only cost the amount of a short screw.
Here are the photos:
They should also be accessible from:
http://www.rav4world.com/forums/members/albums/126170-rlilly/highlander-drooping-visor-fix-4578.html