TI 2001-2004

TECHNICAL INSTRUCTIONS
FOR
LIMITED SERVICE CAMPAIGN CSD
*****************************
CERTAIN 2001-2004 MODEL YEAR SEQUOIA
*****************************
WARM STATE FRAME INSPECTION/REPLACEMENT
I.
OPERATION FLOWCHART
Verify Vehicle Eligibility:
1. Check the VIN range
2. Check the TIS vehicle Inquiry system
f---No---..j
No further action required.
I
Yes
l
Perform the visual and functional test on the spare tire carrier.
Remove the spare tire.
(Note your findings)
•
l
Perform the Pre-Hoist Visual Inspection.
,j.
Inspect the frame in the green area specified below for p'eroration of
1Omm or lamer .
:~:] ~ ~0·~1
•
Yes----,
•
Was 1Omm or larger perforation found in the green area specified
below?
I
No
Proceed with Frame and Spare
Did the spare tire carrier meet Toyota's inspection criteria?
Tire Carrier Replacement
No
Yes
Replace the Spare Tire Carrier.
Campaign Completed.
1
,,
-
.,. ··•·
11.
PREPARATION
A. TOOLS & EQUIPMENT
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Above Ground Lift (Required)
Alignment Rack
NC Service Equipment with Manifold Gauges
Brake Bleeder
Cooling System Tester
Engine Hoist (Qty: 2) or Hydraulic Mini Crane (Qty: 2)
Engine Sling Device
Floor Jack
Protective Gloves
Protective Eyewear
Ratcheting Tie Down Strap (2 in X 27 ft, Minimum Work Load Capacity: 3,000 lbs)
Standard Hand Tools
Special Service Tools (SST)
o 09325-4001 O - Transmission Oil Plug
o 09520-01010 - Drive Shaft Remover Attachment
o 09520-32040 - Slide Hammer
o 09610-20012 - Pitman Arm Puller
o 09617-24011 -Steering Rack Wrench or Equivalent
o 09628-62011 - Ball Joint Puller
o 09922-10010-Variable Open Wrench
Techstream
Torque Wrench
B. SUPPLIES
•
•
•
•
•
•
•
•
•
•
ATF D-11 or DEXRON®lll (DEXRON®ll)-As needed
Hypoid Gear Oil API GL-5 SAE 75W-90 - 1.15 liter (4WD Only, Front Differential)
MP Grease
Marker
ND-OIL 8 Compressor Oil -As needed
R 134a Refrigerant - As needed
Silicon Lubricant
Toyota DOT 3 Brake Fluid - 3 pints
Toyota Long Life Coolant - 2 gallons
Vinyl Tape
2
C. PARTS
To assist dealers in determining the correct part number(s) to order, a website has been set up to look
up part numbers by VIN. Please go to http://toyota-frame-parts-lookup.imagespm.info select the
appropriate campaign/vehicle, enter the VIN, and the correct part numbers to order will be displayed.
The website is for part(s) application reference only and won't order the parts or confirm
campaign completion status.
•
•
•
The parts will need to be ordered through the Dealer Daily Parts System,
ETAs for the parts will be available via the normal system.
Frame ETAs will be made available on the Dealer Daily website, in the MAC reference area.
Note: When first logging in; enter your dealer code and the default password; XXXXX. Upon
logging in the website will ask for you to reset the password and provide an email address.
An illustration of the parts replaced and their location(s) have been provided. Please reference the
"Illustration Name" and "Page" columns in the parts tables below
Individual Parts:
Part Number
04001-751 oc
04001-7520C
04001-7530C
04001-7540C
Part Description (Model Year)
Frame, Sub-Assy (01-02)
Frame, Sub-Assy (03-04)
Frame, Sub-Assy (01-02 w/Towing Hitch)
Frame, Sub-Assy (03-04 w/Towing Hitch
Quantity
1
1
1
1
Illustration Name
Frame & Misc Parts
Frame & Misc Parts
Frame & Misc Parts
Frame & Misc Parts
Page
Illustration Name
Front Differential
Front Suspension & Front
Drives haft
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Spare Tire Carrier
Exhaust System
Front Differential
Exhaust System
Front Suspension & Front
Driveshaft
Page
6
6
6
6
Individual Parts (Continued):
Part Number
12157-10010
Part Description (Model Year)
Gasket, Drain Plug
Quantity
43425-04020
Ring, Drive Shaft Snap
2
47316-0C040
47322-0C030
47323-0C020
47325-0C020
47326-0C020
51900-0C020
90080-43034
Tube, FR Brake, No.6
Tube, RR Brake, No.2
Tube, RR Brake, No.3
Tube, RR Brake, No.5
Tube, RR Brake, No.6
Carrier, Spare Tire
Gasket, Exhaust Pipe (01-02)
90430-24003
90917-06083
Gasket
Gasket, Exhaust Pipe (03-04)
1
1
1
1
1
1
2
1
2
95381-04045
Pin, Cotter
2
1
10
8
9
9
9
9
9
6
12
10
12
8
3
Parts Kits:
Part Number
04001-7010C
Part Description
Parts Kit No.1 - Common Replacement Kit A-1 (01-04MY)
Quantity
1
The kit listed above includes the following parts:
.
16492-21050
18495-38020
23232-41081
47351-34040
47353-35110
47354-35100
48409-34020
48409-34030
48452-35020
48824-34030
48829-34020
77285-34031
77285-34060
77285-34080
77285-34200
90069-08009
90119-08516
90178-08011
90178-10024
90179-08054
90179-08068
90179-10071
90719-14062
90182-10004
90201-09019
90252-03015
90430-12026
90460-22001
90460-46005
90468-08035
90904-12066
90904-12067
90904-12068
90917-06085
90949-01C06
91621-80816
94130-01232
94622-31200
95381-03225
1
2
1
1
1
1
2
2
4
Ring, O Radiator
Retainer, Converter RR Flange
Gasket
Bracket, Flexible Hose, No. 5
Bracket, Flexible Hose, No. 3
Bracket, Flexible Hose, No. 4
Cam Sub-Assy, Toe Adjust
Cam Sub-Assy, Toe Adjust
Plate, Toe Adjust, No. 2
Bracket Stabilizer RH
Bracket Stabilizer LH
Clamp, Fuel Tube, No. 1
Clamp, Fuel Tube, No. 1
Clamp, Fuel Tube, No. 1
Clamp, Fuel Tube, No. 1
Ring,O
Bolt, w/ Washer
Nut, Flange
Nut, Flange
Nut
Nut
Nut
Nut
Nut, w/ Washer
Washer, Plate
Pin, Cotter
Gasket
Clamp, Hose
Clamp, Hose
Clip
Way,2
Way,2
Way, 2
Gasket, Exhaust Pipe
Clamp
Bolt, w/ Washer
Nut, Hexagon
Washer, Plate
Pin, Cotter
.
1
1
5
1
1
1
1
10
4
4
1
6
4
1
2
1
2
1
2
2
4
1
1
1
1
7
6
6
6
2
Radiator
Exhaust System
Fuel System
Brake Tubes
Brake Tubes
Brake Tubes
Front Suspension & Front Driveshaft
Front Suspension & Front Driveshaft
Front Suspension & Front Driveshaft
Front Suspension & Front Driveshaft
Front Suspension & Front Driveshaft
Fuel Tubes
Fuel Tubes
Fuel Tubes
Fuel Tubes
Air Conditioning
Front Floor Panel &Front Floor Member
Rear Bumper
Front Bumper
Auto Trans Shaft Cable
Front Floor Panel &Front Floor Member
Engine Mounting
Rear Spring &Shock Absorber
Front Suspension & Front Oriveshaft
Auto Trans Shaft Cable
Front Suspension & Front Driveshaft
Fuel System
Fuel Tank
Fuel Tank
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Exhaust System
Brake Tubes
Brake Tubes
Rear Bumper
Rear Bumper
Power Steering
13
12
12
9
9
9
8
8
8
8
8
10
10
10
10
13
14
14
13
13
14
11
7
8
13
8
12
13
13
9
9
9
9
12
9
9
14
14
11
4
Parts Kits (Continued):
Part Number
04001-7030C
Part Description
Parts Kit No.3 - Common Replacement Kit B-1 (01-04MY)
The kit listed above includes the followin
,a
~-
- .,
.
47313-0C012
47314-0C011
47317-0C011
82164-0C040
89542-0C010
89543-0C010
89545-0C020
89546-0C020
90069-08007
90080-11180
90080-11180
90080-11180
90080-11275
90080-11373
90080-11373
90080-11387
90080-11410
90080-11482
90080-11482
90080-11491
90080-11492
90080-1155 5
90080-46263
90069-08009
90119-A0026
90119-A0027
90119-A0064
90119-A0077
Tube, FR Brake, No. 7
Wire, Frame
Sensor, Speed, Front RH
Sensor, Speed, Front LH
Sensor, Speed, Rear RH
Sensor, Speed, Rear LH
Ring,O
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, wt Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt. w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Clamp
Ring,0
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt. w/ Washer
arts:
t.
'
Tube, FR Brake, No. 3
Tube, FR Brake, No. 4
1
1
1
1
1
1
1
1
1
4
4
2
2
5
5
4
2
2
4
6
4
2
1
1
4
2
4
2
Quantity
1
Brake Tubes
Brake Tubes
Brake Tubes
Wire Harness Clamos
ABS
ABS
ABS
ABS
Air Conditionirn::i
Rear Sorina & Shock Absorber
Soare Wheel Carrier
Fuel Tubes
Front Suspension & Front Driveshaft
Susoension Crossmember & Under Cover
Fuel Tank
Enoine Mountina
Front Susoension & Front Driveshaft
Front Susoension & Front Driveshaft
Rear Sorina & Shock Absorber
Frame & Misc. Parts
Frame & Misc. Parts
Power SteerinQ
Exhaust Svstem
Air Conditionina
Rear Sumner
Rear Bumoer
Rear Bumoer
Fuel Tank
a
9
-
9
9
10
11
11
11
11
13
7
6
10
8
6
13
11
8
8
7
6
6
11
12
13
14
14
14
13
5
D.
PARTS ILLUSTRATION
Frame & Misc Parts
ir--
Individual parts
04001-•·uu .
*Part Number Vanes
Suspension Crossmember &
Under Cover
. Parts Kit No.3
90080-11492 (4)
S are Tire Carrier
Parts Kit No.3
90080-11373 (5)
6
Rear S rin & Shock Absorber
7
Front Sus ension & Front Driveshaft
;--
''
--- ---- ---
~
--- -- -
~
,------~
Individual Parts
95381-04045 (2)
Parts Kit No.1
90182-10004 (2)
,
Parts Kit No.1
48409-34030 (2)
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Parts Kit No.1
48452-35020 (2)
No.~ ~
Parts Kit
484, 52-35020 (2)
~
~
,.-->
Parts Kit No.3
90080-11275 (2)
~Q:?' ·-----,
I
Parts Kit No.1
48409-34020 (2)
~
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'\' "
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:.----
Parts Kit No.3
,
90080-11410 (2)
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O y " ,__
.1 '""
-
1
..._.
~
~
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Parts Kit No.1
90252-03015 (2)
8
Brake Tubes
Parts Kit No.1
90468-08035
.Parts Kit No.3
47313-0C012
',,_~
Parts Kit No.1
'll:
90904-12066
Parts Kit No.3
..
.ti
~
47314-0C011
\)\l
_,,,.,
Parts Kit No.1
91621-80816
-
~~
.
1
PartsKitNo.1 : ;
90468-08035
-~
' '
.
Parts Kit No.1
91621-80816
'
''
Parts Kit. No.1-a
~g:4~;t2~~i ~
fl,'""
i <
·-J
''
47322-0C030
91621-80~
(::;; ~1'
\
Individual Parts
.
.
Parts KitNo.1
47353-35110
PartsKitNo.3
\_
47317-0C011
J
·,
:
Parts Kit No.1
~0468-08035
\!::
''I Parts
Kit No.1
-g~
:
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~- - -, c
:
<
Parts Kit No.1
90904-12068
'•,J
:...:(;,;; \
I
/I
i
... ~
47354-35100
t :
""
: 91621-80816
~
~------J
-g-.1
;1621-80816
~ ~ ~ I ~fl I ~ >__,,~ r2--i
&_·?~ ~~r.z
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Parts Kit No.1
90949-01 C06 (7)
9
Fuel Tubes
I
~
I
Parts Kit No. 1 Parts Kit No.3 Parts Kit No.1
77285·34060 90080-11180 77285-34200
(TYPE BJ
,.
~
~
fK~J
-~ ~
~
Parts Kit No.3
Parts Kit No.1
90080-11180
5 34080 (TYPE C)
7728 -
Wire Harness Clam s
Front Differential
e
Parts Kit No.3
82164-0C040
Individual Parts
12157-10010
Individual Parts
90430-24003
10
Power Steerin
f
Parts Kit No.1
95381-03225
i
~
fl--,/'~
r;?_
/
90080-11555
/
Parts Kit No.3
',,
'
-----0-@
~----·
ABS
~Parts
'!'
Kit No.1
95381-03225
En ine Mountin
11
Fuel S stem
Exhaust S stem
Parts Kit No.3 & 4
90080-46263
•M_,..,J.J
90917-06085
<:····"111
.. ·..
..
·-.
:(@~L. ~---<1>
;;380~~---~-----~--.,,....,..,
\~7-- .
:
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-··
-··
.-· ... --·
----·
-·· -··
Parts Kit No.1
~"""'
Individual Parts
90080-43034
•
\
/
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e
·.
or
Individual Parts
Individual Parts
900800;3034
'
90917-06083
L-------------------------------1
Individual Parts
90917-06083
J
.
'
''
Parts Kit No.1
184~020
·----------1
12
Fuel Tank
«, ,,,
I;
~-'·
er:.~
"'~ ~t
~~~
Parts Kit No.3
90119-A0077
Auto Trans Shift Cable
Air Conditionin
Parts Kit No.1 & 3
90069-08009 ~
-<"
/
-("/-,®
~~
~
\\__:::
"i
:
i
\
~
~v,9---
®
: _/I
/
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!/ Parts Kit No.3
90069-08007
FrontBum er
Parts Kit No.1
16492-21050
13
Rear Bum er
Parts Kit No.3
90119-1064 (4)
:~~
·~--
Parts Kit No.1
90178-08011 (4) \
~
\-~
W--- Parts Kit No.3
li
90119-A0027 (2)
Parts Kit No.3
90119-A0026 (4) __,.
.
:
:~
"1C<:::::~~--
+----Parts Kit No.1
'
94622-31200 (6)
'\__ Parts Kit No.1
94130-01232 (6)
Front Floor Panel & Front Floor Member
14
Ill.
VEHICLE INSPECTION WORK PROCEDURE
A.
FUNCTIONAL AND VISUAL INSPECTION OF THE SPARE TIRE CARRIER
r-=5~~~;;;::=;;~~~11. FUNCTIONAL TEST OF THE SPARE TIRE CARRIER
a) Lower and raise the spare tire with the tools provided with the
vehicle and ensure it is operating properly.
Note: Do not operate the spare tire carrier with an impact
because damage will occur to. the spare tire carrier.
b) Completely lower the spare tire and remove it from the carrier
040029
2. VISUALLY INSPECT THE SPARE TIRE CARRIER PLATE FOR RUST COROSSION
a) Visually inspect the top and bottom of the spare tire carrier plate for rust corrosion as shown below.
.
..
.
..
Top
. . . .
..
. ..
.
,
Bottom
~:
.
.
•
If rust is not obvious, proceed
to next step.
•
Bottom
..
..
.
~
Top
.
II
<"f2
.
.
.
' t-
.
•
•
..
•,
\
( o)
•
•
•
J
NG
·
b) Inspect the top center portion (40 mm diameter circle) of the spare tire carrier plate for rust corrosion and
confirm it contains less than 80% rust.
Proceed to next step
NG
•
c) Inspect the bottom edge of the spare tire carrier plate for rust corrosion around the perimeter; confirm that
rust corrosion does not cover the entire perimeter.
®
•.
•
NG.
Rust
®
Rust
NG
If the spare tire carrier does not pass anv of the inspection criteria, the spare tire carrier
will need to be replaced.
If the frame does not pass the inspection (below) and requires replacement, the carrier is
included in the arts su lied for the frame re lacement.
15
B. FRAME INSPECTION
1. PERFORM INITIAL PRE-HOIST INSPECTION
2. VISUALLY INSPECT THE FRAME
a) Visually inspect the specific areas (highlighted in green) of the frame assembly as shown for
visible signs of perforation.
Judgment Criteria
- Perforation (hole) of less than 10 mm
-Spare Tire Carrier Passes Visual
Ins ection
- Perforation (hole} of less than 10 mm
- S are Tire Carrier Fails Ins ection
Frame Carrier
OK
OK
OK
NG
NG
NG
Perforation (hole) of 10 mm or more
mti!fil1111. 8
Action
Campaign Complete
Proceed to section IV Spare Tire Carrier
Re lacement
• Replace the frame and spare tire carrier
• Proceed to section V. VEHICLE CONDITION
INSPECTION below to begin the frame
replacement process.
Note: If the frame fails the inspection the spare tire carrier will
be replaced automatically.
NOTE: Use safety glasses & gloves when performing the under vehicle inspection, rust may flake off.
IV.
SPARE TIRE CARRIER REPLACEMENT PROCEDURE (If applicable)
1. REMOVE THE SPARE TIRE CARRIER
a) Loosen the 4 bolts holding the spare tire carrier.
b) Remove the 4 bolts and Spare Tire Carrier from the crossmember.
2. INSTALL THE SPARE WHEEL CARRIER
a) Install the NEW spare tire carrier with the 4 NEW bolts.
b) Torque the 4 bolts evenly in several increments.
Torque Spec: 15 ft·lbf (20 N·m, 204 kgf·cm)
V.
VEHICLE CONDITION INSPECTION
Visually inspect both the vehicle interior and exterior. Note any damage found during the visual
inspection prior to beginning work.
As you disassemble the vehicle you may encounter parts that are in need of replacement. which
are not covered by this repair procedure. If this is the case, please take the time to inform the
customer that these parts can be .replaced with no or minimal labor cost.
16
VI.
FRAME REPLACEMENT WORK PROCEDURE
·
•
.
Due to the size and weight of the frame, only above-ground lifts are to be utilized when performing
the frame replacement on 2001 - 2004 Sequoia Vehicles. If a dealership is not equipped with
above-ground lifts, the frame replacement may need to be sublet to a body shop or other dealership
business.
A. SAFETY CHECKLIST & PRECAUTIONS WHEN DRAINING THE FUEL SYSTEM
Always remember "SAFETY FIRST".
Be extremely careful when handling fuel to prevent fires from occurring.
Before beginning work on the fuel system, perform the following safety check list.
Before removin an fuels stem art, drain all fuel to revent s illin .
1. AIR VENTILATION
D
0
D
D
Perform work in a well ventilated area.
DO NOT work underground or in an area where fuel vapors may fill the room due to poor ventilation.
Quickly clean up any spilled fuel with a dry cloth and dissipate the fuel vapors.
Dry all cloths that have come in contact with fuel in a well ventilated area and dispose of them properly
(according to applicable local regulations).
2. FIRES AND IGNITION SOURCES ARE STRICTLY PROHIBITED
D Fires and ignition sources are prohibited while working on the fuel system.
0 Clearly display the sign found on the next page stating "WORKING WITH GASOLINE, NO FIRES OR
IGNITION SOURCES".
D Smoking is prohibited near the work area.
D DO NOT work in areas where there are welders, grinders, drills, electric motors, heaters, etc.
D DO NOT use work lamps or any other electrical appliance due to the risk of sparks flying from the power
switch or a rise in temperature.
D DO NOT use metal hammers while working, due to the risk of flying sparks.
D DO NOT start any engines or perform any of the above in neighboring work bays.
3. FIRE EXTINGUISHER
D Have a fire extinguisher ready and available before beginning work.
4. PREVENT STATIC ELECTRICITY
D To help prevent static electricity, lightly wet the floor with water, but not to the point where it creates a
D
hazardous working. condition.
Place appropriate warning cones or stand signs around the area as a caution.
5. PRECAUTIONS WHEN USING A LIFT
D For bays equipped with auto lifts, cover all access cover joints with duct tape.
D In the event that fuel has leaked inside the auto lift, remove the access cover and clean up any spilled
fuel. Dissipate fuel vapors until the smell is gone.
6. PREVENT THE FUEL FROM SPRAYING
D When disconnecting any fuel tubes, pipes, hoses or connectors there may still be some pressure
D
remaining, even after discharging the system. To prevent the fuel from spraying, cover the tubes, pipes
or connectors with a shop rag before disconnecting.
Remember to always wear protective goggles especially when disconnecting fuel tubes, pipes, hoses or
connectors.
7. PREVENT THE FUEL FROM CONTACTING OTHER PARTS
0
Do not allow the fuel to come in contact with any parts made of rubber or leather.
8. ASSIGN A SAFETY SUPERVISOR
D Assign a safety supervisor to be in charge of all safety precautions and fire hazards around the work
area.
17
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18
• Copiar y exhibir al trabajar
TICABAJANDO CON
GASOLINA
I'
NINGUN INCENDIOS
NINGUNA FUENTE
DE IGNICION
I'
Supervisor
.....
co
B. DEPRESSURIZE THE FUEL SYSTEM PRESSURE AND EVACUATE A/C REFIGERANT
• The actual vehicle specs, equipment and parts required may differ than what is shown.
Please use the correct specs and parts for the model you are working on.
• For additional repair information, please reference to the appropriate repair manual.
• DO NOT disconnect any part of the. fuel system until you have discharged the fuel
pressure.
• Even after discharging the fuel pr_essure, place a piece of cloth around the lines, pipe,
hoses, and connectors as you separate them to reduce the risk of fuel spraying on
yourself, in the engine compartment, and onto other parts.
• Before commencing the operation, set the vehicle in the center of a lift, stop it in a
position where all the doors can be opened, and center the steering wheel so that the
· front wheels are in a straight-ahead oosition .
.
1. CHECK FOR DTCs TO ENSURE VEHICLE ORIGINAL OPERATING CONDITION
a) Remove the junction block cover.
b) Remove the fuel pump relay.
3. DISCHARGE THE FUEL SYSTEM PRESSURE
c) Start the engine.
d) After the engine has stopped, turn the ignition switch OFF.
e) Crank the engine again to check that it does not start.
NOTE: Make sure to follow the procedure listed above; this prevents a large amount of gasoline from
leaking out of the high pressure fuel line when it is disconnected.
4. EVACUATE THE A/C REFRIGERANT
20
C. PREPERATION FOR REMOVAL OF THE BODY ASSY
1. RECORD THE RADIO STATION PRESETS
2. DISCONNECT THE NEGATIVE(-) BATTERY TERMINAL CABLE
Note: if the vehicle is equipped with power seats, you will need to access the front passenger seat
bolts prior to disconnecting the battery in order to remove the seat to access the chassis wire.
•
Wait at least 90 seconds after disconnecting the negative(-) battery terminal from the
battery to prevent the SRS System from deploying (i.e. airbag, seat belt pretensioner,
etc.).
3. REMOVE THE FOLLOWING INTERIOR PARTS TO ACCESS WIREHARNESS CONNECTORS & CAB
MOUNTING BOLTS
•
•
•
•
•
•
Front Door Scuff Plate LH/RH
Cowl Side Trim Board LH/RH
Passenger Front Seat
Glove Compartment Door
Lower No.2 Instrument Finish Panel
No.4 Heater To Register Duct
•
•
The actual vehicle specs, equipment and parts required may differ than what is
shown. Please use the correct specs and parts for the model you are working on.
For additional repair information, please reference to the appropriate repair manual.
4. DISCONNECT THE FRAME WIRE CONNECTORS
a) Fold back the floor carpet and disconnect the 2
connectors.
b) Disconnect the frame wire harness grommet.
c) Pull out the frame wire harness from the vehicle cab.
5. DISCONNECT THE ENGINE WIRE HARNESS
a) Disconnect the 6 connectors and clamp.
NOTE: The number of connectors will differ depending
on the vehicle specs.
21
'
.•.
6. REMOVE THE FOLLOWl~G PARTS FROM THE CENTER CONSOLE AREA (4WD Only)
•
•
•
•
•
Transfer Shift Lever Knob
Shifting Hole Cover
Upper Console Panel
No.1 Shift and Select Lever Boot
Transfer High and Low Shift Lever
7. SECURE THE STEERING WHEEL
a) Make sure the front wheels are in a straight-ahead
position and the steering wheel is centered.
b) Using the seat belt, hold the steering wheel in position
as shown in the illustration, in order to prevent damage
to the spiral cable.
8. FOLD UP THE 2•• ROW SEATS AND REMOVE REAR PASSENGER DOOR SCUFF PLATES
9. REMOVE THE FOLLOWING INTERIOR COMPONENTS TO ACCESS CAB MOUNTING BOLTS
•
•
•
•
•
2°• Row Seat Outer Belt Floor Anchor
3"' Row Seats (If Equipped)
3"' Row Seats Outer Belt Floor Anchors (If Equipped)
Rear Floor Mat Support Plate
Rear Quarter Trim Panel LH/RH
.
•
•
•
•
•
Place jack stands under the front and rear portions of the frame to support the frame .
DO NOT work directly underneath vehicle when preparing the vehicle for cab body assy
removal, unless noted.
The actual vehicle specs, equipment and parts required may differ than·what is shown .
Please use the correct specs and parts for the model you are working on.
For additional repair information, please reference to the appropriate repair manual for
the vehicle vou are working on.
10. LIFT VEHICLE ON LIFT
11. REMOVE THE FOLLOWING PARTS UNDER VEHICLE COMPONENTS
•
•
No.1 Engine Under Cover
Side Step Assy LH/RH (if applicable)
12. DRAIN THE FOLLOWING FLUIDS
•
•
•
Engine Coolant (including the engine block)
Brake Fluid
Front Differential Oil (4WD ONLY)
Note: DO NOT remove the radiator cap while the radiator and engine are hot, as doing so may cause
the coolant to spray out causing potential injuries.
22
13. DISCONNECT THE AUTOMATIC TRANSMISSION N0.2
OIL COOLER OUTLET TUBE
a) Disconnect the hose.
b) Remove the bolt and disconnect the No.2 oil cooler
outlet tube.
14. DISCONNECT THE TRANSMISSION CONTROL CABLE
a) Remove the 2 nuts and transmission control cable
insulator
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
b) Remove the pin and washer.
c) Remove the 2 bolts and disconnect the transmission
control cable.
NOTE: If the pin is difficult to remove, remove the nut
and then the cable.
15. REMOVE THE NO. 2 STEERING INTERMEDIATE SHAFT
NOTE:
Use precaution when performing this step, as you will
need to work underneath the vehicle.
a) Place match marks on the steering sliding yoke and
No.2 steering intermediate shaft.
b) Remove the bolt (A).
c) Place match marks on the No.2 steering intermediate
shaft and control valve shaft.
d) Remove bolt (B).
e) Slide the No.2 steering intermediate shaft and remove it.
NOTE: If the No. 2 intermediate shaft assy. is stuck, tap
it from below with a brass hammer to disconnect it.
23
16. DISCONNECT THE REAR BRAKE TUBES
a) Using a flare nut wrench, disconnect the 2 rear brake
tubes.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
17. DISCONNECT THE PARKING BRAKE CABLES
a) Disconnect the No.1 parking brake cable from the No.3
parking brake cable.
b) Remove the clip and pin and disconnect the No.2
parking brake cable.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
c) Remove the bolt and cable support bracket from LH side
frame rail.
d) Remove the bolt and disconnect the No.1 parking brake
cable from LH side frame rail.
18. DISCONNECT THE FUEL TANK VENT HOSE
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
24
...
~/
19. DISCONNECT THE FUEL TANK TO FILLER PIPE HOSE
AND FUEL TANK BREATHER HOSE
Front
__/
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
20. DISCONNECT THE FRAME WIRE
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
a) Disconnect the connector for charcoal canister and
clamp(s).
b) Disconnect the connector(s) and clamp(s) for the
receiver hitch.
(Receiver Hitch Equipped Vehicle Only)
NOTE: The number of fastening connectors and clamps
for the frame wire will differ depending on the vehicle
options. Please verify the current vehicle options and
continue.
21. REMOVE THE FOLLOWING FRONT END COMPONENTS
•
•
•
Front Fender Mudguard LH/RH
Front Bumper Assy
Front Bumper Energy Absorber
1----=J~~~~m~~~
22. DISCONNECT THE FRONT FENDER LINERS
a) Remove the 2 screws and disconnect the front fender
liners from the front bumper reinforcement.
25
23. REMOVE THE FRONT FENDER APRON SEALS
a) Remove the 21 clips and 4 front fender apron seals.
RH Side
LH Side
24. DISCONNECT THE FRONT BRAKE TUBES
a) Disconnect the front brake tube.
Note: Seal off the front brake lines to ensure no rust
and debris enters the brake system.
b) Repeat the procedure on the opposite side.
RH Side
26
25. DISCONNECT THE FRONT SPEED SENSOR
CONNECTORS
LH Side
a) Disconnect the clamp and front speed sensor
connector.
b) Repeat the procedure on the opposite side.
\
26. REMOVE THE FOLLOWING PARTS
•
•
Rear Quarter Panel Mudguard LH/RH
Rear Bumper Assy.
27. REMOVE THE REAR BUMPER EXTENSION MOUNTING
BRACKET W/ BACK STEP REINFORCEMENT
a) Loosen the 4 bolts.
b) Remove the 4 nuts and the rear bumper extension
mounting bracket w/ back step reinforcement.
28. REMOVE/DISCONNECT THE FOLLOWING PARTS FROM ENGINE COMPARTMENT AREA
•
•
•
•
•
•
•
•
•
Throttle Body Cover
Air Cleaner
Disconnect accelerator control cable (only on vehicles produced on or before August 2002)
Radiator Inlet Hose (disconnect from engine)
Radiator Outlet Hose ·(disconnect from engine)
Disconnect Heater Coolant Hose
Fan Shroud
External Trans Cooler (If Equipped)
Radiator Assy
NOTE: After disconnecting the automatic transmission oil cooler hoses, plug them and cap the
fittings to prevent the ATF from spilling out.
27
.
·--
29. DISCONNECT THE FOLLOWING ENGINE
COMPARTMENT HOSES
a) Disconnect the brake booster hose.
b) Disconnect the EVAP hose.
c) Disconnect the air hose (for CCV).
1---'--:::=::==::;::::::::--:.:::::;=:::~~c---130. DISCONNECT THE REAR HEATER WATER HOSES
(IF EQUIPPED)
a) Disconnect the 2 rear heater water hoses from the
water pipe.
31. DISCONNECT THE ENGINE WIRE HARNESS
a) Remove the bolt and disconnect the ground wire from
cowl panel.
b) Remove the bolt and the 2 nuts holding the engine wire
harness connector from the cowl panel.
c) Gently pull the engine wire harness out from body
·assembly.
Note: Ensure all connectors have been previously
disconnected from the glove compartment to ensure
you do not damage the wire harness
32. DISCONNECT THE N0.2 ENGINE WIRE HARNESS
a) Disconnect the connector and clamp from inner LH
front fender.
b) Remove the bolt and disconnect the ground wire.
c) Remove the nut and disconnect the positive(+) battery
cable.
d) Remove the nut and 2 clamps and disconnect the No.2
engine wire harness from the junction block.
33. DISCONNECT THE A/C DISCHARGE HOSE AND SUCTION HOSE
28
34. DISCONNECT THE POWER STEERING PUMP OIL
RESERVOIR
a) Remove the 2 nuts and place the power steering
reservoir on the engine assembly.
D. REMOVAL OF THE BODY ASSY
35. REMOVE THE CAB BODY ASSY USING AN ABOVE GROUND LIFT
Note: Before rolling chassis out, mark the location of the tires on the floor, this will help align the
chassis when the cab is reinstalled.
a)
b)
c)
d)
e)
f)
g)
Remove the 8 nuts and 8 washers.
Set the lift arms under the cab body assy. so they DO NOT interfere with the frame or cab mounts.
Check that all wire harnesses, hoses, cables and the steering shaft are disconnected.
Lift the cab assy. up slowly, making sure it does not interfere with anything while being raised.
Raise the cab assy high enough so that the top of the engine clears the lowest point of the cab assy.
Pull the frame assy out from under the cab assembly.
Lower the cab assy all the way down and leave it on the lift.
NOTE:
• Center the cab assy weight on the lift arms so that it does not slant/tilt to one side.
• Raise the cab assy slightly off the frame and verify that it is held securely by the lift arms.
• DO NOTwork directly underneath the vehicle when pulling the frame assy. out from under it.
• DO NOT remove the cab mount bolts, as they will be used as guides during the cab assy.
reinstallation process.
29
.
'
·-
E. DISASSEMBLE THE FRAME
1. PLACE THE FRAME ON A 2"" LIFT
a) Place the frame on the 2"d lift, and secure it with a ratcheting tie down strap. This will prevent the frame
from tilting or falling off as parts are removed.
•
Ratcheting Tie Down: Qty: 1
'
Demensions: 2 in X 27 ft
'
Minimum Work Load Capacity: 3,000 lbs
2. REMOVE THE FOLLOWING PARTS
•
•
•
•
Spare Tire Carrier
Receiver Hitch Bracket Assy (If Equipped)
Front Propeller Shaft (4WD Only)
Rear Propeller Shaft
'
Insert the SST into the transmission after the rear propeller shaft is removed to prevent oil leakage.
(2WD Only)
•
•
•
'
SST: 09325-40010
No.1 Fuel Tank Protector
Fuel Tank Straps
Fuel Tank
NOTE:
Make sure to place matchmarks on the front (if equipped) and rear propeller shafts before removal.
3. REMOVE THE EXHAUST SYSTEM
a) Remove the clamp, 2 rear tail pipe brackets and rear
tail pipe.
b) Remove the 4 bolts, 2 exhaust pipe retainers, 4 exhaust
pipe supports and center exhaust pipe.
c) Remove the 3 exhaust pipe gaskets.
30
•
~~~~~,i~~ri~=14·
1·
DISCONNECT THE FUEL PIPE AND HOSE
a) Remove the pulsation damper and disconnect the No.1
fuel pipe.
b) Remove the 2 gaskets.
c) Disconnect the No.1 fuel hose.
NOTE:
• Put a shop towel under the delivery pipe.
• Slowly loosen the pulsation damper.
5. REMOVE THE DRIVE BELT
6. REMOVE AND SET A SIDE THE POWER STEERING PUMP ASSY
a) Remove the 2 bolts and nut and power steering vane pump assy.
NOTE:
• DO NOT disconnect the power steering pump hoses or lines.
• Make sure to keep the power steering pump reservoir in an upright position to prevent the fluid
from leaking out.
7. DISCONNECT THE A.D.D. ACTUATOR CONNECTOR
(4WD ONLY)
8. REMOVE THE ENGINE AND TRANSMISSION ASSY.
a) Disconnect and remove the necessary items/parts to
prepare the engine and transmission assy for removal.
Ii) Remove the engine and transmission assy.
NOTE:
• When removing the engine and transmission assy,
ALWAYS use 2 engine hoists or mini cranes to lift it
• DO NOT use 1 engine hoist or mini crane to lift the
engine and transmission assy, as the unbalanced
weight may lead to an accident or injury.
• ONLY use engine hoists or mini cranes that can
properly support the weight of the engine and
transmission assy.
• Carefully adjust the 2 engine hoists or mini cranes
used so that the engine and transmission assy is
properly balanced.
9. R.EMOVE THE 4 WHEELS
31
10. DISCONNECT THE REAR SPEED SENSOR
CONNECTOR
a) Remove the 2 clamps and disconnect the rear speed
sensor connector.
b) Repeat the procedure on the opposite side.
11. DISCONNECT THE N0.3 PARKING BRAKE CABLE
a) Remove the bolt and disconnect the No.3 parking brake
cable.
12. REMOVE THE N0.2 PARKING BRAKE CABLE
a) Remove the clip.
b) Remove the 2 bolts.
c) Disconnect the No.2 parking brake cable from the 3
clamps.
13. DISCONNECT THE REAR BRAKE FLEXIBLE HOSES
a) Using a flare nut wrench, disconnect the 2 rear brake
tubes.
b) Remove the bolt and disconnect the No.5 flexible hose
bracket.
14. DISCONNECT THE REAR STABILIZER BAR
a) Remove the 2 nuts and disconnect the 2 rear stabilizer
links from the frame.
b) Remove the 4 bolts, 2 brackets and rear stabilizer bar.
32
-~ -
,
~-
.
15. LOOSEN THE REAR SUSPENSION ARMS
a) Loosen the bolts and nuts of the rear suspension arms,
at the rear axle housing.
b) Loosen the bolts and nuts of the rear suspension arms
at the frame.
16. DISCONNECT THE REAR SHOCK ABSORBERS
a) Using a floor jack raise the rear axle housing.
b) Remove the 2 nuts and 2 retainers and disconnect the
rear shock absorbers.
17. REMOVE THE REAR AXLE HOUSING W/ LINK ASSY
a) Position the floor jack underneath the center section of the rear axle to support during the disassembly
process.
b) Remove the 2 bolts, washer, nut and the rear lateral control rod (Illustration A).
c) Remove the 2 bolts, 2 washers and 2 nuts and disconnect the No.1 rear suspension arms from the
frame (Illustration B).
d) Slowly lower the jack, and remove the rear coil springs and hollow springs (Illustration C).
e) Remove the 2 bolts, 2 washers and 2 nuts and disconnect the lower control arms from the frame
(Illustration C).
f) Roll the rear axle assembly away from frame.
Illustration A
Illustration B
Illustration C
18. DISCONNECT THE N0.1 FRONT BRAKE FLEXIBLE
HOSES
a) Disconnect the front brake tube.
b) Remove the clip and disconnect the No.1 flexible hose.
c) Plug the hose to ensure not rust or debris enter the
brake hose
d) Repeat the procedure on the opposite side.
33
.
.
.
..
19. DISCONNECT THE FRONT SPEED SENSOR
CONNECTORS
a) Remove the 2 bolts and 2 clamps and disconnect the
front speed sensor connector.
b) Repeat the procedure on the opposite side.
20. REMOVE THE FOLLOWING FRONT END COMPONENTS
•
•
•
•
Front Bumper Reinforcement
Front Stabilizer Bar
Front Axle Shaft Nuts (4WD Only)
Tie Rod Ends
0
Remove the cotter pins and nuts.
Using the SST, disconnect the tie rod ends.
0
SST: 09610-20012
Front Lower Ball Joints
0
Remove the cotter pins and nuts.
0
Using the SST, disconnect the lower ball joint.
0
SST: 09628-62011
0
•
21. REMOVE THE FRONT SUSPENSION UPPER ARMS WI
STEERING KNUCKLE AND STRUT ASSY
a) Remove the boll, nut, 2 washers and front suspension
upper arm w/ steering knuckle.
b) Repeat the procedure on the opposite side.
NOTE:
If the drive shaft is difficult to disconnect, tap it loose
with a plastic hammer.
22. REMOVE FRONT STRUT ASSY AND LOWER CONTROL
ARMS
a) Remove Front Strut Assy by removing the three nuts
and bolt.
b) Repeat procedure on opposite side.
c) Remove Front Suspension Lower Control Arm
23. REMOVE THE FOLLOWING POWERTRAIN COMPONENTS
•
•
Power Steering Gear Assy w/ Power Steering Vane Pump
Front Drive Shafts (4WD Only)
Using the SST, remove the drive shafts.
0
SST: 09520-01010, 09520-32040
Front Differential Carrier (4WD Only)
0
•
NOTE:
• When removing the power steering rack with the pump assy attached, have one person support
the power steering rack and the other support the pump assy.
• Keep the power steering pump reservoir in an upright position to prevent fluid from leaking out.
• If the drive shaft is difficult to remove tap it with a plastic hammer.
• Be careful not to damage the dust cover and oil seal.
34
24. REMOVE THE FUEL TUBES
a) Remove the bolts and clamps and the fuel tubes.
NOTE:
• The number of fastening clips and clamps for the
fuel tubes will differ depending on the vehicle
model. Please verify the current vehicle and
continue.
25. REMOVE THE STUD BOLT
,-----;:===::::;-----------,
.::-~~--.::~i?·;.
"'.?
0
)~_:'..<-t"J
..-,.-,
·
/
~
~~
,..,,/,t'llv-·~~~ i:r r
,,"'-~-,\J:l
;:;.:;'~s~{~ \~~:-~
y~-".".o~
A··
-,V'"/
26. REMOVE THE FRONT PARKING BRAKE CABLE
RETAINER BRACKET AND CLAMPS
·,. ·
"/Jy/
·""'."'--~~~J
-~~·
a) Remove the bolt and the front cable retainer bracket
from crossmember.
b) Remove the 2 bolts and the clamps from crossmember
and LH frame rail.
c) Remove the clamp from RH side frame rail.
-··,
~~
27. REMOVE THE REMAINING COMPONENTS
•
•
•
Front Spring Bumpers
Rear Spring Bumpers
Cab Mounting Cushions (Qty: 8)
28. REMOVE THE FRAME FROM THE LIFT
35
F. ASSEMBLE THE NEW FRAME
1. PLACE THE NEW FRAME ON THE LIFT
a) Place the NEW frame on the lift, and secure it with a ratcheting tie down strap. This will prevent the
frame from tilting or falling off as parts are installed.
•
Ratcheting Tie Down: Qty: 1
0
Demension: 2 in X 27 ft
0
Minimum Work Load Capacity: 3,000 lbs
NEW Replacement Parts
2. REINSTALL THE REAR SPRING BUMPER
er
""'~=.
""llilWI""'·""·""
3
a) Reinstall the rear spring bumper with the 2 NEW bolts
and torque to spec.
b) Repeat the procedure on the opposite side.
4
Torque Spec: 29 N·m (296 kgf·cm, 21 ft-lbf)
3. REINSTALL THE FRONT SPRING BUMPER
a) Using the SST, reinstall the No.1 and No.2 front spring
bumpers to the frame and torque to spec.
b) Repeat the procedure on the opposite side.
SST: 09922-10010
Torque Spec: 31 N•m (316 kgf·cm, 23 ft·lbf)
NEW Replacement Parts
Lower Control Arm Cam Assy.
48409-34020
Cam Sub-Assy, Toe
2
48409-34030
Ad"ust
2
48452-35020
Plate, Toe Ad·ust No. 2
1
4
Bolt w/ Washer
3
3
2
90080-11275
90080-11410
2
4. REINSTALL THE FRONT SUSPENSION LOWER CONTROL ARM
a) Reinstall the front suspension lower control arm with 2 NEW bolts, 2 NEW toe adjustment plates, and 2
NEW toe adjustment cams, then torque to spec.
Torque Spec: 130 N·m (1326 kgf·cm, 96 ft·lbf)
b) Repeat the procedure on the opposite side.
36
a) Reinstall the clamp.
b) Reinstall the clamps with the 2 bolts and torque to spec.
c) Reinstall the front parking brake cable retainer bracket
with the bolt and torque to spec.
Torque Spec: 26 N·m (265 kgf·cm, 19 ft·lbf)
a) Reinstall the stud bolt and torque to spec.
Torque Spec: 20 N·m (204 kgf·cm, 15 ft·lbf)
7. REINSTALL THE FRONT BUMPER REINFORCEMENT
NEW Replacement Parts
a) Reinstall the front bumper reinforcement with the 4
NEW nuts and torque to spec.
Torque Spec: 50 N·m (510 kgf·cm, 37 ft·lbf)
8.
NEW Replacement Parts
INSTALL THE REAR.BUMPER REINFORCEMENT SET
(If applicable)
Rear Bumper Reinforcement
a) Install the rear bumper reinforcement set wtth the 6 NEW
bolts, 6 NEW nuts and 6 NEW washers, then torque to
spec.
a
90119-A0026
90119-A0027
94130-01232
94622-31200
Bolt w!Washer
Bolt w/ Washer
3
3
4
2
Nut. Hexa on
Washer, Plate
1•
6
6
Torque Spec: 95 N·m (970 kgf·cm, 70 ft·lbf)
9. REINSTALL THE CAB MOUNTS
a) Reinstall the 8 cab mounts.
Torque Spec: 61 N·m (622 kgf·cm, 45 ft·lbf)
.
@
0
I§
'
~
t
8
~
s
~
'
-
t
37
10. INSTALL THE NEW REAR BRAKE TUBES
a) Install the NEW rear brake tubes with the 7 NEW clamps,
b) Install the NEW 2 way with the NEW bolt and torque to spec.
Torque Spec: 28 N·m (286 kgf·cm, 21 fMbf)
NEW Replacement Parts
47323-0C020
47326-0C020
Tube, RR Brake, No.3
Tube, RR Brake, No.6
NIA*
N/A'
Wa ,2
Clamp
Bolt w/ Washer
•individual Part (s)
90904-12068
90949-01 C06
91621-80816
7
11. REINSTALL THE FUEL TUBES
a) Reinstall the fuel tubes with the NEW bolts and NEW clamps, then torque to spec.
Torque Specs:
Clamp Bolt - 29 N·m (296 kgf·cm, 21 fMbf)
Filter Bolt - 20 N·m (204 kgf·cm, 15 ft·lbf)
NOTE:The number of bolts and clamps will differ depending on the vehicle specs.
~
NEW Replacement Parts
.
77285-34031
77285-34060
77285-34080
77285-34200
90080-11180
Clamp, Fuel Tube, No.1
PEA
Clamp, Fuel Tube, No.1
TYPES
Clamp, Fuel Tube, No.1
TYPEC
Clamp, Fuel Tube, No.1
PEE
Bolt, w/ Washer
5
3
2
12. INSTALL THE NEWFRAME WIRE HARNESS
a) Reconnect the clamps to install the NEW frame wire harness.
b) Reconnect the ground wire with the bolt and torque to spec.
Torque Spec: 29 N·m (296 kgf·cm, 21 ft·lbf)
NOTE: The number of clamps will differ depending on the vehicle specs.
NEW Replacement Parts
~-~~~m~u~IJllk~!filimlmz
l82164-oC04()j
"""""""""""'""""'
Wire, Frame
38
13. REIN STALL THE FRONT DIFFERENTIAL CARRIER
ASSY (4WD ONLY)
a) Reinstall the front differential carrier assy with the 2
bolts, 4 stoppers and 3 nuts, then torque to spec.
b) Reinstall the front differential breather tube with the 2
clamps .
Torque Spec:
Bo/t-137 N·m (1397 kgf·cm, 101 fHbf)
Nut - 87 N·m (887 kgf·cm, 64 ft-lbf)
14. REINSTALL THE POWER STEERING LINK ASSY
WI POWER STEERING VANE PUMP
a) Reinstall the power steering link assy w/ power steering
vane pump with the 6 bolts, washer and 2 nuts , then
torque to spec.
Torque Spec:
Bolt A - 29 N·m (296 kgf·cm, 21 ft-lbf}
Bolt B - 165 N·m (1682 kgf-cm, 122 ft·lbf)
Nut 1 -165 N·m (1682 kgf·cm, 122 ft·lbf}
Nut 2-130 N·m (1326 kgf·cm, 96 ft·lbf)
NOTE:
• When reinstalling the power steering link with the
vane pump attached, have one person support the
power steering link and the other support the vane
pump.
• Make sure to keep the power steering pump
reservoir in an upright position to prevent the fluid
from leaking out.
15. REINSTALL THE FRONT SHOCK ABSORBER ASSY
a) Reinstall the front shock absorber assy with 3 nut (A)
and torque to spec.
b) Reinsta ll the front shock absorber assy to the lower
control arm with the bolt and nut (B), then torque to
spec.
Torque Spec:
Nut A - 64 N·m (653 kgf·cm, 47 fHbf)
Nut B - 135 N·m (1377 kgf·cm, 100 ft-lbf}
c)
16. REINSTALL THE FRONT DRIVE SHAFTS (4WD ONLY)
NEW Replacement Parts
Front Drive Shaft
I
Part Number
I
I
4 3425-04020
I
Part Name
Rina . Drive Shaft Snao
' Individual Part(s)
I
I
Repeat the procedure on the opposite side.
Kit #
I
Qtv
NIA'
I
2
a) Install a NEW snap ring .
b) Reinstall the front drive shaft.
c) Repeat the procedure on the opposite side.
NOTE: Be careful not to damage the dust cover and oil seal.
39
a) Reinstall the front suspension upper arm wl steering
knuckle with the bolt, nut and 2 washers, then torque to
spec.
Torque Spec: 98 N·m (999 kgf·cm, 72 ft·lbf)
b) Repeat the procedure on the opposite side ..
18. REINSTALL THE FOLLOWING PARTS
•
NEW Replacement Parts
Front Lower Ball Joints
Reinstall the front lower ball joint with the nut and
torque to spec.
0
Install the NEW cotter pin.
0
Torque Spec: 140 N·m (1428 kgf·cm, 103 ft-lbf)
0
Repeat the procedure on the opposite side.
Tie Rod Ends
0
Reinstall the tie rod end with the nut and torque to
spec.
0
Install the NEW cotter pin.
0
Torque Spec: 91 N·m (928 kgf·cm, 67 ft·lbf)
0
Repeat the procedure on the opposite side.
Front Axle Shaft Nuts (4WD Only)
Temporarily install the front axle nut. This nut will be
tightened when the vehicle is completed.
0
Repeat the procedure on the opposite side.
Front Stabilizer Bar
0
Reinstall the stabilizer bar and 2 NEW brackets with
the 2 NEW bolts and 2 NEW nuts, then torque to
spec.
0
Torque Spec: 37 N·m (377 kgf·cm, 27 ft·lbf)
0
Reinstall the stabilizer bar link with the 2 nuts and
torque to spec.
Torque Spec: 69 N·m (704 kgf·cm, 51 ft·lbf)
0
Front Lower Ball Joint
fit&iiial!i;,1fili!'llili1.Hii'*rnim@!!ii4j•Rlll
! 90252-03015_
@JJ'J!lauie"'4QQ\1~1-1
Pin, Cotter
.
1
_ 2
_
•
Tie Rod End
•
0
48829-34020
90080-11482
90182-10004
Bracket, Stabilizer, RH
Bracket, Stabilizer. LH
Bolt w/ Washer
Nut. w/ Washer
1
3
2
2
•
0
NEW Replacement Parts
19. CONNECT THE NEW FRONT SPEED SENSORS
a) Install the front speed sensor with the 3 bolts and 2
clamps, then torque to spec.
Torque Spec: 8.0 N·m (82 kgf·cm, 71 in·lbf)
b) Repeat the procedure on the opposite side.
40
20. RECONNECT THE FRONT BRAKE FLEXIBLE HOSES
NEW Replacement Parts
Front Brake Flex Hose
a) Install the NEW bracket with the NEW bolt and torque
to spec.
e
Bracket, Flexible Hose
47353-35110
No. 3
Torque Spec: 28 N·m (286 kgf·cm, 21 ft·lbf)
Bracket, Flexible Hose
47354-35100
90468-08035
No.4
Clip
2
2
b) Reconnect the flexible hose with the NEW clip.
c) Repeat the procedure on the opposite side.
21. INSTALL THE NEW FRONT BRAKE TUBES AND 2
WAYS
NEW Replacement Parts
.a
47317-0C011
90904-12066
90904-12067
Tube, FR Brake, No. 4
3
Tube, FR Brake, No. 7
3
a) Temporarily install the NEW front brake tube and NEW
2way.
b) Reinstall the front brake tube and 2 way with the NEW
bolt and torque to spec.
Way,2
Bolt, wt Washer
2
Torque Spec: 28 N·m (286 kgf·cm, 21 ft·lbf)
c) Reconnect the front brake tube and torque to spec.
Torque Spec: 16 N·m (163 kgf·cm, 12 ft·lbf)
d) Repeat the procedure on the opposite side.
22. REINSTALL THE REAR AXLE HOUSING W/ LINK ASSY
a) Place rear axle on floor jack and position under the
frame.
b) Temporarily reinstall the 2 bolts, 2 nuts and 2 washers
on the frame side of the lower control arms to the frame.
c) Set the rear coil springs and hollow springs on the rear
axle housing.
NOTE:
• After stabilizing the suspension, torque the bolts
and nuts.
• Be sure to raise one side of the rear axle
housing at a time.
• Install the rear lateral control rod after
positioning the body on it.
41
d) Raise the jack, and temporarily install the 2 bolts, 2 nuts
and 2 washers on the frame side of the No.1 rear
suspension arm to the frame.
NOTE:
• After stabilizing the suspension, torque the bolt and
nuts.
• Be sure to raise one side of the rear axle housing at
a time.
• Install the rear lateral control rod after positioning
the body on it.
e) Reconnect the rear shock absorbers with the 2 nuts
and 2 retainers, then torque to spec.
Torque Spec: 58 N·m (591 kgf·cm, 43 ft·lbf)
NEW Replacement Parts
23. RECONNECT THE REAR STABILIZER BAR
a) Reconnect the 2 rear stabilizer links with the 2 nuts and
torque to spec.
Torque Spec: 69 N·m (704 kgf·cm, 51 ft·lbf)
b) Install the 4 NEW bolts and 2 brackets, then torque to
spec.
Torque Spec: 37 N·m (377 kgf·cm, 27 ft·lbf)
NEW Replacement Parts
24. RECONNECT THE REAR BRAKE FLEXIBLE HOSES
a) Install the No.5 flexible hose bracket with the NEW bolt
and torque to spec.
Torque Spec: 28 N·m (286 kgf·cm, 21 ft·lbf)
91621-60816
b) Reconnect the rear brake tubes and torque to spec.
Torque Spec: 16 N·m (163 kgf·cm, 12 ft·lbf)
42
a) Reconnect the No.2 parking brake cable to
the 3 clamps.
b) Reinstall the 2 bolts and torque to spec.
c) Reinstall the clip.
Torque Spec: 26 N·m (265 kgf·cm, 19 ft·lbf)
26. RECONNECT THE N0.3 PARKING BRAKE CABLE
a) Reconnect the No.3 parking brake cable with the bolt
and torque to spec.
Torque Spec: 26 N·m (265 kgf·cm, 19 ft·lbf)
NEW Replacement Parts
Rear Wheel S eed Sensors
P.
89546-0COZO
27. CONNECT THE NEW REAR SPEED SENSOR
CONNECTORS
a) Install the new rear speed sensor
b) Route the rear speed sensor connector and wire with
the 2 clamps.
c) Repeat the procedure on the opposite side.
28. REINSTALL THE 4 WHEELS
29. REINSTALL THE ENGINE AND TRANSMISSION ASSY
a) Reinstall the engine and transmission assy.
NOTE:
• When reinstalling the engine and transmission
assy, ALWAYS use 2 engine hoists or mini cranes.
• DO NOT use 1 engine hoist or mini crane to lower
the engine and transmission assy, as the
unbalanced weight may lead to an accident/injury.
• ONLY use engine hoists or mini cranes that can
properly support the weight of the engine and
transmission assy.
• Carefully adjust the 2 engine hoists or mini cranes
so that the engine and transmission assy is
properly balanced.
43
b) Attach the engine mounts with the 4 bolts and 4 NEW nuts and torque to spec.
Torque Spec: 38 N·m (387 kgf·cm, 28 ft-lbf)
NEW Replacement Parts
NEW Replacement Parts
c) Attach the transmission mount with 4 NEW bolts and
torque to spec.
Transmission Mount
•!ro
Torque Spec: 18 N·m (184 kgf·cm, 13 ft-lbf)
d) Reinstall the items/parts that were removed during the
engine and transmission assy removal.
30. RECONNECT THE A.D.D. ACTUATOR CONNECTOR
(4WD ONLY)
31. REINSTALL THE POWER STEERING VANE PUMP
ONTO ENGINE ASSEMBLY ASSY
a) Reinstall the power steering vane pump assy to the
mounting bracket with the 2 bolts and nut, then torque
to spec.
Torque Spec: 44 N·m (449 kgf·cm, 33 ft-lbf)
44
.•
32. REINSTALL THE DRIVE BELT
33. RECONNECT THE FUEL PIPES AND HOSE
a)
b)
c)
d)
Reconnect the No.1 fuel hose.
Always use 2 NEW gaskets.
Tighten the pulsation damper by hand.
Tighten the pulsation damper to the specified torque
using the SST.
SST: 09617-24011 or equivalent
Torque Spec: 39 N·m (398 kgf·cm, 29 ft·lbf)
34. REINSTALL THE FUEL TANK STRAPS
a) Reinstall the fuel tank straps with the 2 pins and 2
clips.
NEW Replacement Parts
35. REINSTALL THE FUEL TANK
a) Reinstall the fuel tank with the 2 NEW bolts and torque
to spec.
Torque Spec: 62 N·m (632 kgf·cm, 46 ft·lbf)
b) Reinstall the fuel tubes.
c) Connect the clamp and connector(s).
36. REINSTALL THE N0.1 FUEL TANK PROTECTOR
a) Reinstall the No.1 fuel tank protector with the NEW
bolts and NEW nuts, then torque to spec.
Torque Specs: Bolt - 29 N·m (296 kgf·cm, 21 ft·lbf)
NOTE:
• The number of fuel connectors will differ
depending on the vehicle specs.
No.1 Fuel Tank Protector
45
37. REINSTALL THE EXHAUST SYSTEM
a) Install the 3 NEW exhaust pipe gaskets.
b) Reinstall the center exhaust pipe with the 4 exhaust pipe supports, 2 NEW flange retainers and 4 bolts,
then torque to spec.
Torque Spec: 48 N·m (489 kgf·cm, 35 ft·lbf)
c) Reinstall the tail exhaust pipe with the 2 tail pipe brackets.
d) Face the clamp in the direction indicated in the illustration, and torque to spec.
Torque Spec: 32 N·m (326 kgf·cm, 24 ft·lbf)
NEW Replacement Parts
••
18495-38020
90080-43034
a.
Retainer, Converter
2
RR Flange
Gasket, Exhaust
System**
NA'
90080-46263
Clamp
3
90917-06083
Gasket. Exhaust
System**
NA'
90917-06085
2
2
Gasket Exhaust System
*Individual Part(s)
..Only 1 part# is used. The part# varies depending on vehicle model year.
38. REINSTALL THE FRONT PROPELLER SHAFT (4WD ONLY)
a) Aligning the matchmarks, install the front propeller shaft to the transfer case and the front differential with
the 8 bolts, 8 washers and 8 nuts, then torque to spec.
Torque Spec: 74 N·m (755 kgf·cm, 55 ft·lbf)
NEW Replacement Parts
Receiver Hitch
39. REINSTALL THE RECEIVER HITCH BRACKET
SUB·ASSY (IF EQUIPPED)
a) Reinstall the receiver hitch bracket sub-assy with the 1o
NEW bolts and torque. to spec.
Torque Spec: Bolt A - 105 N·m (1071 kgf·cm, 78 ft·lbf)
Torque Spec: Bolt B -105 N·m (1071 kgf·cm, 78 ft·lbf)
46
NEW
~eplacement
40. INSTALL THE SPARE TIRE CARRIER
Parts
a) Install the NEW spare tire carrier with the 4 NEW bolts
and torque to spec.
Torque Spec: 20 N·m (204 kgf·cm, 15 ft·lbf)
Spare Tire Carrier
•individual Part(s)
NOTE:
Install the spare wheel after tightening the rear
suspension arms.
41. REMOVE THE FRAME FROM THE LIFT
a) Remove the ratcheting tie down strap from the frame.
b) Lower the frame to the ground.
G.
REINSTALL THE CAB BODY ASSY
1. INSTALL THE NEW ENGINE COMPARTMENT BRAKE
LINE
NEW Replacement Parts
47313-0C012
47316-0C040
Tube, FR Brake, No 6
3
NA"
47322-0C030
Tube, FR Brake, No 2
NA"
4 7325-0C020
Tube, FR Brake, No 5
*Individual Part(s)
NA"
a) Install the NEW No.3 and NEW No.6 front brake tubes.
b) Install the NEW No.2 and NEW No.5 rear brake tubes.
c) Torque all brake tubes to spec.
Torque Spec: 16 N·m (163 kgf·cm, 12 ft·lbf)
NOTE:
The number of clamps will differ depending on the
vehicle spec.
47
2. REINSTALL THE CAB BODY ASSY
a) Raise the cab assy high enough so that the top of the engine clears the lowest point of the cab.
b) Push the frame under the cab assy.
Note: Line up the wheels with the alignment marks previously made to help align the frame with
the cab.
c) Lower the cab assy slowly, making sure it does not interfere with anything.
d) Adjust the vehicle's frame as needed to align the cab mounts with the cab assy bolts.
e) Once the cab assy is set on the mounts, secure it to the frame with the 8 bolts, 8 nuts and 8 washers
and torque to spec.
Torque Specs: No.1 and No.4 Nut-47 N·m (479 kgf·cm, 35 ft·lbf)
Torque Specs: No.2 Nut - 54 N·m (551 kgf·cm, 40 ft·lbf)
Torque Specs: No.3 Nut - 67 N·m (683 kgf·cm, 50 ft·lbf)
NOTE:
• DO NOT work directly underneath the vehicle when pushing the frame under the cab assy.
• Slowly lower the cab body assy while making sure that the wire harness, steering shaft and
hoses do not interfere with it.
• With 2 to 3 people checking for interference, slowly lower the cab body assy to the frame.
• Center the vehicle's weight on the lift arms so that it does not slant/tilt to one side.
IBQJ]._q=1'-~ ~
~o~
. flo/
llfill~ll---- I ~llfill
~
r;"
· 1' ,~=-:;-irr 11 ~
lllll~~lr:~
lli2dl1.·
1n
rn23J
:1·,I~.,.~
'I !
1
1
I
N
~~-~-~ Ii~ tL, rn23J
•
3. READJUST LIFT ARMS AND LIFT VEHICLE
4. REMOVE THE FRONT WHEELS
5. RECONNECT THE FRONT SPEED SENSOR
CONNECTORS
a) Reconnect the front speed sensor connector.
b) Reinstall the clamp.
·
c) Repeat the procedure on the opposite side.
\
48
•
LHSide
6. RECONNECT THE FRONT BRAKE TUBES
a) Reconnect the front brake tube and torque to spec.
b) Repeat the procedure on the opposite side.
Torque Spec: 16 N·m (163 kgf·cm, 12 ft-lbf)
RH Side
7. REINSTALL THE FRONT FENDER APRON SEALS
a) Reinstall the 4 front fender apron seals with the 21
clips.
RH Side
49
8. RECONNECT THE VANE PUMP OIL RESERVOIR
a) Reinstall the vane pump oil reservoir with the 2 nuts
and torque to spec.
Torque Spec: 8.0 N·m (82 kgf·cm, 71 in·lbf)
9. RECONNECT THE HEATER WATER HOSE
a) Reconnect the 2 rear heater water hoses to the water
pipe.
NEW Replacement Parts
11. RECONNECTTHEA/C DISCHARGE HOSE AND
SUCTION HOSE
a) Install the NEW 0-rings to the discharge hose and
suction hose.
b) Reinstall the discharge hose and suction hose with the
nuts and torque to spec.
Torque Spec: 10 N·m (102 kgf·cm, 7 ft-lbf)
12. RECONNECT THE N0.2 ENGINE WIRE HARNESS
a) Reinstall the No.2 engine wire harness with the nut and
torque to spec.
b) Reconnect the No.2 engine wire harness to the 2
clamps of the junction block.
c) Reinstall the nut and reconnect the positive(+} battery
cable and torque to spec.
d) Reinstall the bolt and reconnect the ground wire to the
LH side inner fender and torque to spec.
e) Reconnect the connector and clamp.
f) Reinstall the fuel pump relay.
g) Reinstall the relay block cover.
Torque Specs: Nut A -10 N·m (102 kgf·cm, 7 ft·lbf)
Torque Specs: Nut B - 13 N·m (133 kgf·cm, 10 ft·lbf)
Torque Specs: Bolt - 8.0 N·m (82 kgf·cm, 71 in·lbf)
50
•
13. RECONNECT THE FOLLOWING ENGINE
COMPARTMENT HOSES
a) Reconnect the EVAP hose
b) Reconnect the air hose (for CCV)
c) Reconnect the brake booster hose.
14. REINSTALL THE RADIATOR
NEW Replacement Parts
a) Install the NEW radiator drain cock plug 0-ring.
b) Tighten the radiator drain cock plug.
c) Reinstall the radiator with the 4 bolts and torque to
spec.
Torque Spec: 12 N·m (122 kgf·cm, 9 ft-lbf)
d) Reconnect the upper and lower radiator hoses,
automatic transmission cooler hoses.
e) Reinstall the fan shroud.
· f) If equipped re-install external transmission cooler
15. RECONNECT THE ACCELERATOR CONTROL CABLE
(ONLY FOR VEHICLES PRODUCED ON OR BEFORE SEPTEMBER 2002)
16. REINSTALL THE FOLLOWING PARTS
•
•
Air Cleaner
Throttle Body Cover
0
Torque Spec: Nut - 8.0 N·m (82 kgf·cm, 71 in·lbf)
17. RECONNECT THE ENGINE WIRE HARNESS
a) Reinstall the engine wire harness connector with the 2
nuts and torque to spec.
b) Reinstall the bolt and torque to spec.
Torque Spec: 8.0 N·m (82 kgf·cm, 71. in·lbf)
c) Reconnect the ground wire to the cowl panel with the
bolt and torque to spec.
Torque Spec: 8.0 N·m (82 kgf·cm, 71 in·lbf)
NEW Replacement Parts
Rear Bum er Extension
18. REINSTALL THE REAR BUMPER EXTENSION
MOUNTING BRACKET W/ BACK STEP
REINFORCEMENT
a) Reinstall the rear bumper extension mounting bracket
wt back step reinforcement with the 4 NEW nuts and
torque to spec.
b) Install the 4 NEW bolts and torque to spec.
Torque Spec: 19 N·m (194 kgf·cm, 14 ft-lbf)
51
··-· .....
19. REINSTALL THE FOLLOWING REAR BODY COMPONENTS
•
Rear Bumper Cover
Torque Spec: 7;0 N·m (71 kgf·cm, 62 in·lbf)
Rear Quarter Panel Mudguard LH/RH
0
•
a) Reconnect the front fender liners with the 2 screws.
21. RECONNECT THE AUTOMATIC TRANSMISSION N0.2
OIL COOLER OUTLET TUBE
a) Reinstall the No.2 oil cooler outlet tube with the bolt and
torque to spec.
b) Reconnect the hose.
Torque Spec: 12 N·m (122 kgf·cm, 9 ft-lbf)
22. REINSTALL THE FOLLOWING FRONT BODY PARTS
NEW Replacement Parts
•
•
LHIRH
•
•
Bolt, w/ Washer
Front Bumper Energy Absorber
Front Bumper Cover
0
Torque Spec: 7.0 N·m (71 kgf·cm, 62 in·lbf)
Front Fender Mudguard LH/RH
Side Step Assy LH/RH with the 10 new bolts and 6 new
nuts.
Torque Spec: 20 N·m (204 kgf·cm, 15 ft·lbf)
0
23. RECONNECT THE FRAME WIRE
a) Reconnect the connector and clamp(s) (For Charcoal
Canistel).
b) Reconnect the connector(s) and clamp(s) (Receiver
Hitch Equipped Vehicles Only).
·
~
Front
NOTE:
The number of fastening connectors and clamps for the
frame wire will differ depending on the vehicle model.
Please verify the current vehicle and continue.
)
52
•
NEW Replacement Parts
Fuel Tank Filler and Breather Hose
Clams
24. RECONNECT THE FUEL TANK TO FILLER PIPE HOSE
AND FUEL TANK BREATHER HOSE
a) Reconnect the fuel tank to filler pipe hose with the 2
NEW clamps.
b) Reconnect the fuel tank breather hose with the 2 NEW
clamps.
NOTE:
• Tighten the clamp of the fuel tank to filler pipe hose
until it comes into contact with the stopper.
25. RECONNECT THE FUEL TANK VENT HOSE
NOTE:
After finishing the connection, check whether the
pipe and the connector are securely connected by
pulling them.
26. RECONNECT THE N0.1 PARKING BRAKE CABLE
a) Reconnect the No.1 parking brake cable with the bolt
and torque to spec.
b) Reinstall the cable support bracket with the bolt and
torque to spec.
Torque Spec: 26 N·m (265 kgf·cm, 19 ft·lbf)
c)
Reconnect the No.2 parking brake cable with the clip
and pin.
d) Reconnect the No.1 parking brake cable to the No.3
parking brake cable and torque to spec.
Torque Spec: 8.0 N·m (82 kgf·cm, 71 in·lbf)
53
•·
.
"---"~~~'\
' Front
27. RECONNECT THE REAR BRAKE TUBES
]
a) Using a flare nut wrench, connect the 2 rear brake
tubes and torque to spec.
Torque Spec: 16 N·m (163 kgf·cm, 12 ft-lbf)
28. RECONNECT THE N0.2 STEERING INTERMEDIATE
SHAFT
a) Make sure the spindles are in a straight-ahead position
and the steering wheel is centered.
b) Aligning the matchmarks, connect the No.2 steering
intermediate shaft to the steering sliding yoke with the
NEW bolt (A).
c) Aligning the matchmarks, connect the No.2 steering
intermediate shaft to the control valve shaft with the
NEW bolt (B).
d) Torque all bolts to spec.
Torque Spec: 35 N·m (357 kgf·cm, 26 ft-lbf)
NEW Replacement Parts
Auto Transmission Control Cable
29. RECONNECT THE TRANSMISSION CONTROL CABLE
a) Reinstall the bolt and connect the transmission control
cable and torque to spec.
Torque Spec: 18 N·m (184 kgf·cm, 13 ft·lbf)
b) Reinstall the pin or NEW nut and NEWwasher, then
torque to spec.
Torque Spec: Nut-13 N·m (133 kgf·cm, 10 ft·lbf) (Only
For Vehicles Produced On Or Before June 2003)
Torque Spec: Nut-15 N·m (153 kgf·cm, 11 ft·lbf) (Only
For Vehicles Produced After June 2003)
NOTE: Vehicles produced after August 2003 is not
equipped with washer.
c)
Reinstall the transmission control cable insulator with the 2
nuts and torque to spec.
Torque Spec: 5.0 N·m (51 kgf·cm, 44 in·lbf)
54
.. -
..
30. REINSTALL FRONT WHEELS
31. LOWER THE VEHICLE
32. RECONNECT THE ENGINE WIRE HARNESS
a) Reconnect the connectors and clamp.
NOTE:
• The number of connectors will differ depending on
the vehicle specs.
• Incorrectly connected connectors may cause the
engine to start improperly. Be certain that the
connectors are correctly connected.
33. RECONNECT THE FRAME WIRE CONNECTOR
a) Reinstall the frame wire harness grommet.
b) Reconnect the 2 connectors.
34. REINSTALL THE FOLLOWING INTERIOR COMPONENTS
a) Glove Compartment
• No.4 Heater To Register Duct
• Lower No.2 Instrument Finish Panel
• Glove Compartment Door
b) Center Console (4WD Only)
• Transfer High and Low Shift Lever
• No.1 Shift and Select Lever Boot
0
Torque Spec: 7.0 N·m (71 kgf·cm, 62 in·lbf)
• Upper Console Panel
• Shifting Hole Cover
• Transfer Shift Lever Knob
c)
Front Seat and Trim
• Front Seat RH
0
Torque Spec: 37 N·m (377 kgf·cm, 27 ft·lbf)
• Cowl Side Trim Board LH/RH
• Front Door Scuff Plate LH/RH
d) Rear Passenger and Cargo Area
• Rear Door Scuff Plate LH/RH
• Rear Quarter Trim Panel LH/RH
• Rear Floor Mat Support Plate
• Rear No.2 Seat Outer Belt Floor Anchor (If Equipped)
0
Torque Spec: 42 N·m (428 kgf·cm, 31 ft·lbf)
• Rear No.1 Seat Outer Belt Floor Anchor
0
Torque Spec: 42 N·m (428 kgf-cm, 31 ft·lbf)
• Rear 3"' Row Seat (/f Equipped)
• Put 2nd Row Seat back into place
35. PUT THE REAR N0.1 SEATS BACK INTO PLACE
55
.
"
H. FINAL ASSEMBLY
1. RECONNECT THE NEGATIVE BATTERY TERMINAL CABLE
2. REFILL THE FOLLOWING
NEW Replacement Parts
Front Differential Gaskets (4WD Only)
a) Brake Fluid
• Fill with Toyota DOT 3 Brake Fluid.
• Remove the brake lines from the master cylinder.
• Bleed the master cylinder.
• Reinstall the brake lines to the master cylinder and
torque to spec.
0
Torque Spec: 16 N·m (163 kgf·cm, 12 ft·lbf)
• Bleed the brake system at each wheel and torque
the bleeder screws to spec.
0
Torque Spec: 11 N·m (112 kgf·cm, 8 ft·lbf)
• Top off brake fluid
b) Coolant
• Refill with Toyota Long Life Coolant.
c) Front Differential (4WD Only)
• Install the NEW drain plug gasket and torque to
spec.
• Torque Spec: 65 N·m (663 kgf·cm, 48 ft·lbf)
• Refill with Hypoid Gear Oil API GL-5 75W-90.
• Install the NEW filler plug gasket and torque to
spec.
Torque Spec: 39 N·m (398 kgf·cm, 29 ft·lbf)
0
d) Recharge NC System
3. START THE VEHICLE AND PERFORM AND INSPECT THE FOLLOWING
•
Fuel System
Start the engine and let it run for 5 seconds, and then stop the engine and inspect for leaks.
0
If there are no leaks, restart the engine and re-inspect.
Bleed Cooling System and Check for Leaks
Brake System Leaks
Front Differential System
Operation of NC System
0
•
•
•
•
4. INSPECT FOR A/C REFRIGERANT LEAKS
5. CHECK THE OPERATION OF THE FOLLOWING ITEMS AND ADJUST AS NEEDED
Make sure to follow the procedure outlined in the appropriate repair manual for the vehicle
you are working on when checking, and if needed, adjusting the operation of the items
listed below. This is an important step, and must be performed thoroughly to ensure
prooer ooeration of these items.
•
•
Parking Brake Lever Travel
Shift Control Lever
56
....
,
-·
-
"
6. CHECK ALL FLUID LEVELS AND ADJUST AS NEEDED
7. REINSTALL AND TORQUE THE REAR LATERAL
CONTROL ROD
NEW Replacement Parts
Rear Lateral Control Rod
jiii[iaiildi!iilliiili!lfm!l'i~!i!ii:fljiilifllm&trihlahkWEl~eiWml
i
_90179-14~
Nut
L1__
1
_
Torque Specs:
Nut: 140 N·m (1428 kgf·cm, 103 ft·lbf)
Bolt: 130 N·m (1326 kgf·cm, 96 ft·lbf)
NOTE:
• After stabilizing the suspension, torque the nut.
• Perform tightening with the vehicle grounded.
8. TORQUE THE BOLTS AND NUTS OF THE REAR SUSPENSION ARMS TO SPEC
Torque Specs: No.1 Rear Suspension Arm (Nut) -140 N·m (1428kgf·cm,103 ft·lbf)
Torque Specs: Bolt Of Lower Control Arm (Bolt) -130 N·m (1326 kgf·cm, 96 ft·lbf)
NOTE:
• After stabilizing the suspension, torque the bolt and nut.
• Perform tightening with the vehicle grounded.
9. REINSTALL THE SPARE WHEEL
NEW Replacement Parts
Front Axle
~~mil§u$D1~!Wi,~Fri
95381-04045
Pin, Cotter
NA'
2
*Individual Part(s)
10. TORQUE THE FRONT AXLE NUTS (4WD ONLY)
a) Remove the front wheels.
b) Torque the front axle nuts to spec.
Torque Spec: 235 N·m (2396 kgf·cm, 173 ft·lb)
c)
d}
e)
f)
Reinstall the lock cap with the NEW cotter pin.
Reinstall the grease cap.
Repeat the procedure on the opposite side.
-Reinstall the front wheels and torque to spec.
Torque Spec: 112 N·m (1142 kgf·cm, 83 ft·lbf)
I
NOTE:
If the holes for the cotter piri are not aligned, tighten the
axle nut further, up to 60°.
11. PERFORM A WHEEL ALIGNMENT
12. CHECK THE HEADLIGHT AIM AND ADJUST AS NEEDED
13. REINSTALL THE N0.1 ENGINE UNDER COVER
NEW Replacement Parts
a) Install the No.1 engine under cover with the NEW bolts
and torque to spec.
Torque Spec: 29 N·m (296 kgf·cm, 21 ft·lbf)
57
.
,
•
<
14. GHECK FOR DTCS AND REPAIR AS NEEDED
15. PERFORM INITIALIZATION
16. FINAL INSPECTION
a) Check the operation of the following systems:
•
•
•
•
•
•
•
•
•
•
4WD System (4WD Only)
Interior Lights
Exterior Lights
HVAC System
Audio System
Power Windows
Power Door Locks
All Gauges, Indicators and Warning Lights
Cooling Fans
Vehicle Height
• Etc.
17. TEST DRIVE THE VEHICLE
..... VERIFY REPAIR
-
QUALITY~
Confirm the all precautions are followed when servicing the vehicle
Confirm the all system work properly and a test drive is conducted to ensure proper vehicle
operation
If ou have an
VII.
APPENDIX
As required by Federal Regulations, please make sure all recalled parts (original parts) removed from
the vehicle are disposed of in a manner in which they will not be reused. Adequate time has been
provided in the repair time to cut up and dispose of the perforated frame.
58