Brown is one of four starting changes coach Jamie Joseph has made to his side for what he admits will be a physical battle.
Captain Jamie Mackintosh has been named in the reserves, bracketed with Bronson Murray, as the big Southlander struggles with groin and knee injuries, while also carrying a sore elbow.
Hooker Mahonri Schwalger comes into the team for his first start of the season, as does lock Tom Donnelly.
Jarrad Hoeata goes to the blindside flank, with Adam Thomson moving to the other side of the scrum. Alando Soakai moves to the bench. Nick Crosswell makes his first appearance of the season, also on the bench.
In such a big game, the experience of Brown was a factor in the decision to start him ahead of Robbie Robinson, Joseph said.
"It's been a big week for Robbie, with Matt Saunders' father passing away, and Robbie is a very close friend of the family," he said.
"With Brownie being very experienced and it being such a big game of rugby, with Colin [Slade] and Lima [Sopoaga] injured, we are fortunate ..."
Brown (36) last started a match for the Highlanders at Carisbrook in April 2004, when the Highlanders beat the Hurricanes.
Slade was training yesterday but is not yet 100%.
Joseph said the surgeon had cleared him to play, but Slade was still feeling the effects of his broken jaw.
"And what a game to come into after not playing for seven or eight weeks. It would not be fair to him. He's not confident, and still a bit sore.
"The bye comes at a nice time for him and the team, and gives him another fortnight."
Joseph said the moving of Soakai and Rutledge to the bench was not on form and both players had performed well in the first four games.
"We need the experience and a physical presence, and both new players give us that. It's been a hectic schedule for Soaks [Soakai], who has played particularly well for us. It is definitely not a dropping. Just an opportunity for players for different reasons."
The forward pack would have plenty of bulk, which Joseph admitted was part of a plan to impose themselves physically on the Crusaders.
"We have established thus far a physical brand and if we don't come in that area we are going to struggle . . . it is going to be a hell of a match."
The Highlanders were excited to take on the Crusaders, and take part in a derby match.
"All local derbies are going to be special for New Zealand fans. I could tell straight away at the airport after the game, everyone talking about this game, everyone wanting to be part of this game.
"That is because the Crusaders have been so successful and everyone wants to put themselves against the best, and they get a chance on Saturday."
Joseph said the side had a moderate training week after the long trip back from South Africa, but he was happy with the energy levels within the team.
Mackintosh's availability will be decided at a training run this morning.
The Crusaders have 11 past or present All Blacks in their side, and welcome back Owen Franks and Brad Thorn into the starting line-up.
Highlanders v Crusaders
Tomorrow, 5.30pm, Carisbrook
Highlanders: Ben Smith, James Paterson, Kendrick Lynn, Shaun Treeby, Siale Piutau, Tony Brown, Jimmy Cowan (captain), Nasi Manu, Adam Thomson, Jarrad Hoeata, Tom Donnelly, Josh Bekhuis, David Te Moana, Mahonri Schwalger, Chris King.
Reserves: Jason Rutledge, Bronson Murray or Jamie Mackintosh, Nick Crosswell, Alando Soakai, Aaron Smith, Robbie Robinson, Telusa Veainu.
Crusaders: Israel Dagg, Sean Maitland, Robbie Fruean, Sonny Bill Williams, Adam Whitelock, Daniel Carter, Andy Ellis, Kieran Read (captain), Matt Todd, George Whitelock, Sam Whitelock, Brad Thorn, Owen Franks, Corey Flynn, Ben Franks.
Reserves: Quentin MacDonald, Wyatt Crockett, Chris Jack, Jonathan Poff, Kahn Fotuali'i, Mathew Berquist, Zac Guildford.
