T-SB-0037-14

@TOYOTA
Technical Service Bulletin
June 4, 2014
T-SB-0037-14
Horn Radiator Support Bracket
Service
Category
Vehicle Exterior
Section
Horn
Market
Toyota Supports ~
ASE Certification -
USA
Applicability
YEAR(S)
MODEL(S)
2005 - 2014
Tacoma
ADDITIONAL INFORMATION
Introduction
Some 2005 - 2014 model year Tacoma vehicles used in severe off-road service conditions may
exhibit a cracked Horn Mounting Bracket. Use the procedure in this bulletin to address this condition .
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
BD1407
Support S/A Radiator Upper (One Side)
0.7
Combo A
0.3
53205-04010
53205-04011
62
16
Opposite Side
APPLICABLE WARRANTY
• This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months
or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
• Warranty application is limited to occurrence of the specified condition described in this
bulletin.
Parts Information
PART NUMBER
PART NAME
QTY*
53236-04010
Bracket, Horn Mounting , No. 2
1
53237-04010
Bracket, Horn Mounting , No. 3
1
90269-05025
Rivet
5
* Quantity shown for all parts is for one side only. If both horn brackets need replacing , double the quantity when ordering.
© 2014 Toyota Motor Sales, USA
Page 1 of 11
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@ TOYOTA
T-58-0037-14
June 4, 2014
Page 2 of 11
Horn Radiator Support Bracket
New Parts Identification
Figure 1. Replacement Horn Mounting Brackets
1
I
2
Horn Mounting Bracket No. 2
I
Horn Mounting Bracket No. 3
Required Tools & Equipment
REQUIRED TOOLS & MATERIAL
QUANTITY
Vise Grip
1
Drill
1
5 mm (13/64 in .) Drill Bit
1
5/16 in. Spot Weld Cutter or Drill Bit
1
Hammer
1
Center Punch
1
Rivet Gun
1
Silver Permanent Marker
1
Masking Tape
As Needed
Epoxy Panel Adhesive
(3M ™ Scotch-Weld™ Epoxy Adhesive DP125, or
3M™ Panel Bonding Adhesive 08115 , or
LORD Fusor® 380NS/383NS Adhesive , or Equivalent)
As Needed
Automotive Grade Paint Primer (Brush-on Type)
As Needed
© 2014 Toyota Motor Sales, USA
@TOYOTA
June 4, 2014
T-58-0037-14
Page 3 of 11
Horn Radiator Support Bracket
Repair Procedure
Removal of Original Horn Mounting Brackets
1. Remove radiator grille assembly per Repair Manual instructions.
Refer to the Technical Information System (TIS) , applicable model and model year
Repair Manual:
• 2005 Tacoma :
Vehicle Exterior- Exterior Panels!Trim - "Front Bumper Cover: Replacemen t"
• 2006 I 2007 I 2008 I 2009 I 2010 I 2011 I 2012 I 2013 I 2014 Tacoma :
Vehicle Exterior- Exterior Panels!Trim - "Exterior: Front Bumper: Removal"
• 2005 Tacoma :
Vehicle Exterior- Door/Hatch - "Hood: Adjustment"
• 2006 I 2007 I 2008 I 2009 I 2010 I 2011 I 2012 I 2013 I 2014 Tacoma :
Vehicle Exterior- Door/Hatch - "Engine Hood/Door: Hood: Disassembly"
2. Remove upper radiator support plastic cover (if applicable) .
3. Remove hood lock lever, horn , and horn cable
for clearance.
Figure 2.
© 2014 Toyota Motor Sales, USA
@ TOYOTA
T-SB-0037-14
June 4, 2014
Page 4 of 11
Horn Radiator Support Bracket
Repair Procedure
Removal of Original Horn Mounting Brackets (Continued)
4. Identify 4 spot welds (2 per bracket) retaining
the horn mount weld nut brackets to the upper
radiator support (Figure 3) . If horn mount weld
nut brackets are missing , proceed to Preparation
for Horn Mounting Bracket Installation .
Figure 3.
r-.:- ----.,,=;--
-
- - -- --
-----.
5. Center punch spot welds (Figure 4) , then drill using 5/16 inch spot weld cutter or equivalent
drill bit (Figure 5) .
Figure 4.
Figure 5.
© 2014 Toyota Motor Sales, USA
@TOYOTA
T-58-0037-14
June 4, 2014
Page 5 of 11
Horn Radiator Support Bracket
Repair Procedure
Removal of Original Horn Mounting Brackets (Continued)
6. Remove original horn mount weld nut bracket from Figure 6.
underside of upper radiator support and discard . . - - - - - - - - - - - - - - - - - - - - - ,
© 2014 Toyota Motor Sales, USA
@TOYOTA
T-SB-0037-14
June 4, 2014
Page 6 of 11
Horn Radiator Support Bracket
Repair Procedure (Continued)
Preparation for Horn Mounting Bracket Installation
1. Remove any burrs or rough edges on the upper radiator support.
2. Apply masking tape to the upper radiator
support as shown. Temporarily install and center
Horn Mounting Bracket No. 2 onto the upper
radiator support.
3. Using the supplied rivets, align the bracket with
the removed spot welds . Using the bracket as
a template , mark the 3 hole locations onto the
upper radiator support with a pen as shown .
Figure 1.
~---------------~
Figures.
.-------------
© 2014 Toyota Motor Sales, USA
@TOYOTA
June 4, 2014
T-SB-0037-14
Horn Radiator Support Bracket
Repair Procedure
Preparation for Horn Mounting Bracket Installation (Continued)
4. Using a vise grip, clamp Horn Mounting Brackets
No. 2 and No. 3 together.
Figure 9.
© 2014 Toyota Motor Sales, USA
Page 7 of 11
@TOYOTA
T-SB-0037-14
June 4, 2014
Page 8 of 11
Horn Radiator Support Bracket
Repair Procedure
Preparation for Horn Mounting Bracket Installation (Continued)
5. Using a 5 mm drill bit, drill 5 hole locations through
Horn Mounting Bracket No. 3.
Figure 10.
6. To prevent corrosion , use an automotive grade paint primer to coat the edges of the holes that
were drilled . A brush-on type is recommended for a more accurate application .
7. Test fit all 5 rivets through Horn Mounting Bracket
No. 2, upper radiator support, and Horn Mounting
Bracket No. 3.
Figure 11 .
~---------------~
© 2014 Toyota Motor Sales , USA
@TOYOTA
June 4, 2014
T-SB-0037-14
Page 9 of 11
Horn Radiator Support Bracket
Repai r Procedure (Continued)
Installation of Horn Mounting Brackets
1. Apply adhesive to Horn Mounting Bracket No. 2 and Horn Mounting Bracket No. 3.
A. Dispense three 2-inch beads of epoxy panel
Figure 12.
adhesive and mix thoroughly.
Epoxy Panel Adhesive:
3M ™ Scotch-Weld ™ Epoxy Adhesive DP125
or
3M ™ Panel Bonding Adhesive 08115
or
LORD Fuso r® 380NS/383NS Adhesive ,
or Equivalent
B. Apply epoxy panel adhesive to the bottom side of Horn Mounting Bracket No. 2 (Figure 13)
and top side of Horn Mounting Bracket No. 3 (Figure 14), and set onto the upper radiator
support aligning the bracket holes to the upper radiato r support holes.
Figure 13. Adhesive Applied to Bottom of Horn
Mounting Bracket No. 2
Figure 14. Adhesive Applied to Top of Horn Mounting
Bracket No. 3
2. Install Horn Mounting Bracket No. 2 and Horn Mounting Bracket No. 3.
A. Align Horn Mounting Brackets No. 2 and No. 3 with the holes in the upper
radiator support.
B. Install 5 rivets into the bracket holes.
C. Install the horn mounting bolt.
D. Clamp Horn Mounting Bracket No. 2 and No. 3.
© 2014 Toyota Motor Sales, USA
@TOYOTA
June 4, 2014
T-SB-0037-14
Page 10 of 11
Horn Radiator Support Bracket
Repair Procedure
Installation of Horn Mounting Brackets (Continued)
E. Permanently install the 5 rivets making sure
both Horn Mounting Brackets No. 2 and
No. 3 have been secured to the upper
radiator support.
Figure 16. Top View of Completed Repair
Figure 15.
l"""""- - - - .iii!'.".----::;;-:;----;:--- -....,;r - --:-1
Figure 17. Underside View of Completed Repair
© 2014 Toyota Motor Sales , USA
@TOYOTA
June 4, 2014
T-SB-0037-14
Page 11 of 11
Horn Radiator Support Bracket
Repair Procedure
Installation of Horn Mounting Brackets (Continued)
3. If both horn brackets need replacement, repeat the process for the second Horn
Mounting Bracket.
4. Reassemble in reverse order of disassembly.
Refer to TIS, applicable model and model year Repair Manual:
• 2005 Tacoma:
Vehicle Exterior- Door/Hatch - "Hood: Adjustment"
• 2006 I 2007 I 2008 I 2009 I 2010 I 2011 I 2012 I 2013 I 2014 Tacoma :
Vehicle Exterior - Door/Hatch - "Engine Hood/Door: Hood: Reassembly"
• 2005 Tacoma:
Vehicle Exterior- Exterior Panels/Trim - "Front Bumper Cover: Replacemen t"
• 2006 I 2007 I 2008 I 2009 I 2010 I 2011 I 2012 I 2013 I 2014 Tacoma :
Vehicle Exterior- Exterior Panels/Trim - "Exterior: Front Bumper: Installation "
5. Verify proper operation of the horn.
© 2014 Toyota Motor Sales, USA