ZH7_Tundra Frame

TECHNICAL INSTRUCTIONS
FOR
WARRANTY ENHANCEMENT PROGRAM ZH7
*****************************
CERTAIN 2007-2008 MODEL YEAR TUNDRA
*****************************
FRAME REPLACEMENT
UPDATED 12.21.17
Update 12.21.17
- Updated Frame Serial Number Tracker Information
The repair quality of covered vehicles is extremely important to Toyota. All dealership
technicians performing this recall are required to successfully complete the most current
version of the E-Learning course “Safety Recall and Service Campaign Essentials”. To ensure
that all vehicles have the repair performed correctly; technicians performing this repair are
required to currently hold at least one of the following certification levels:
• Certified Technician (any specialty)
• Expert Technician (any specialty)
• Master Technician
• Master Diagnostic Technician
Final repair must be signed off and validated by a MDT, Shop Foreman or Service Manager
using the Frame Replacement Inspection Form.
It is the dealership’s responsibility to select technicians with the above certification level or
greater to perform this recall repair. Carefully review your resources, the technician skill level,
and ability before assigning technicians to this repair. It is important to consider technician
days off and vacation schedules to ensure there are properly trained technicians available to
perform this repair at all times.
I.
OPERATION FLOWCHART
Verify Vehicle Eligibility:
1. Check the VIN range
2. Check the TIS vehicle Inquiry system
Yes
Perform pre-hoist inspection.
No
No further action required.
No
Contact your regional
representative for assistance.
Perform Frame Inspection utilizing the Inspection application.
Was perforation 10mm or larger found in the locations identified in
green below (during the rust removal and/or cleaning process)?
Is the vehicle applicable to LSC
H0F?
No
If No, no further action required;
return vehicle to customer.
Yes
Yes
Is your dealership located in a
cold climate state?
Inspection application submits report for FTS approval.
Was approval received from the FTS?
If No, H0F cannot be performed
at your facility; return vehicle to
customer.
Yes
Yes
Order parts and complete frame replacement.
Perform LSC H0F
Yes
WEP Complete
1
II.
PREPARATION
A. TOOLS & EQUIPMENT
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
A/C service equipment
Alignment rack
Brake bleeder
Engine Hanger
° 1GR-FE Engine
- 12281-31060 – Engine hanger no. 1 (Qty: 1)
- 12282-31040 – Engine hanger no. 2 (Qty: 1)
- 90119-08A87 – Bolt (Qty: 4)
° 3UR-FE Engine
- 12281-38150 – Engine hanger no. 1 (Qty: 2)
- 90119-14120 – Bolt (Qty: 2) (Japan sourced parts)
- 90119-A0166 – Bolt (Qty: 2) (Local sourced parts)
Engine hoist (Qty: 2) or Hydraulic mini crane (Qty: 2)
Engine sling (Qty: 2)
Floor jack
Protective eyewear
Protective gloves
Ratcheting tie down strap (2 in X 27 ft, minimum work load capacity: 3,000 lbs)
Special Service Tools (SST)
° 09985-20010 – Air conditioner service tool set or Commercially available air conditioning
manifold gauge set
° 09325-40010 – Transmission oil plug (Transmission A750E)
° 09325-60010 – Transmission oil plug (Transmission AB60E)
° 09610-20012 – Pitman arm puller
° 09520-32040 – A component of SST 09520-24010, Differential side gear shaft puller
° 09520-01010 – Drive shaft remover attachment
° 09951-04010,09952-04010,09953-04020,09954-04010,09955-04031,09958-04011,
– A component of SST 09950-40011, Puller B set
° 09955-04090 – Craw no.9
° 09922-10010-01 – Variable open wrench
Standard hand tools
Techstream
Torque wrench
Torx® T55H tamper resistant socket
Socket wrench 39mm
Hexagon wrench 8, 10
Deep socket wrench 10, 12, 14, 17, 19, 24mm
Union Nut Wrench 10mm
Weights
B. SUPPLIES
•
•
•
•
•
•
•
Toyota Genuine ATF WS or DEXRON® lll (DEXRON® ll) – As needed
Hypoid gear oil API GL-5 SAE 75W-90 – 2.1 liter
R134a refrigerant – As needed
Toyota DOT 3 brake fluid – 3 pints
Toyota long life coolant – 2 gallons
Paint
MP Grease
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 (also linked
through TIS), enter the VIN, and the correct part numbers to order will be displayed. The website is for
part(s) application reference only and will not order the part, nor will it 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.
Individual Parts:
Part Number
04004-1510C
04004-1520C
04004-1530C
04004-1540C
04004-1550C
04004-1560C
04004-1570C
04004-1580C
04004-1590C
04004-1610C
04004-1620C
04004-1630C
04004-1640C
04004-1650C
04004-1660C
04004-1670C
04004-1680C
04004-1690C
04004-1710C
04004-1720C
04004-1730C
04004-1740C
04004-1750C
04004-1760C
04004-1770C
04004-1780C
04004-1790C
04004-1810C
04004-1820C
04004-1830C
04004-1840C
Part Description
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Illustration Name
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
3
Individual Parts (Continued):
Part Number
17176-0P010
47324-0C060
47324-0C080
47324-0C090
47325-0C090
47325-0C100
47325-0C110
48068-09100
48069-09090
48210-0C090
48210-0C100
48210-0C101
48210-0C110
48210-0C120
48210-0C130
48210-0C131
48210-0C140
48210-0C150
48210-0C160
48210-0C170
48210-0C180
48210-0C190
48210-0C210
48210-0C220
48210-0C230
48210-0C240
48210-0C250
48210-0C260
48210-0C280
48210-0C290
48210-0C300
48210-0C310
48210-0C320
48210-0C330
48210-0C340
48210-0C350
48220-0C090
48220-0C100
48220-0C101
48220-0C110
48220-0C120
48220-0C130
48220-0C131
48220-0C140
48220-0C150
48220-0C160
Part Description
Gasket, Airsurge Tank To Intake Manifold
Tube, Rear Brake, No.4
Tube, Rear Brake, No.4
Tube, Rear Brake, No.4
Tube, Rear Brake, No.5
Tube, Rear Brake, No.5
Tube, Rear Brake, No.5
Arm, Sub-Assy, Front Suspension, Lower No.1 RH
Arm, Sub-Assy, Front Suspension, Lower No.1 LH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear RH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Illustration Name
Exhaust System
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Front Suspension
Front Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
4
Individual Parts (Continued):
Part Number
48220-0C170
48220-0C180
48220-0C190
48220-0C210
48220-0C220
48220-0C230
48220-0C240
48220-0C250
48220-0C260
48220-0C280
48220-0C290
48220-0C300
48220-0C310
48220-0C320
48220-0C330
48220-0C340
48220-0C350
51900-34050
77412-34010
77412-34010
77412-34010
82164-0C870
82164-0CA00
82164-0C890
90080-11373
90080-11717
90080-17229
90080-46263
90105-A0179
90105-A0179
90105-A0179
90105-A0179
90117-A0003
90117-A0004
90119-A0169
90119-A0169
90119-A0170
90119-A0219
90119-A0219
90119-A0271
90119-A0271
90126-A0011
90126-A0011
90126-A0011
90189-06236
Part Description
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Spring Assy, Rear LH
Carrier Assy, Spare Wheel
Clamp, Fuel Tube, No.4
Clamp, Fuel Tube, No.4
Clamp, Fuel Tube, No.4
Wire, Frame
Wire, Frame
Wire, Frame
Bolt
Bolt
Nut
Clamp
Bolt
Bolt
Bolt
Bolt
Bolt, U (For Rear Spring)
Bolt, U (For Rear Spring)
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt, Stud (For Exhaust Manifold, RH)
Bolt, Stud (For Exhaust Manifold, LH)
Bolt, Stud (For Manifold To Exhaust Pipe)
Clip
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
1
1
1
2
16
1
1
1
3
4
5
4
4
5
2
1
4
10
4
2
3
3
6
4
Illustration Name
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Spare Tire Carrier
Fuel Tubes
Fuel Tubes
Fuel Tubes
Wire Harness Clamps
Wire Harness Clamps
Wire Harness Clamps
Fuel Tank
Front Bumper
AT Shift Cable
Exhaust System
Engine Mounting
Fuel Tubes
Fuel Tubes
Fuel Tubes
Rear Suspension
Rear Suspension
Under Cover
Under Cover
Engine Mounting
Rear Bumper
Rear Bumper
Rear Bumper
Rear Bumper
Exhaust System
Exhaust System
Exhaust System
Front Fender
5
Individual Parts (Continued):
Part Number
90461-15017
90469-A0004
90469-A0004
90469-A0004
90917-06085
90917-06093
47312-0C080
47313-0C090
47322-0C110
47323-0C090
Part Description
Clamp
Clamp, Brake Tube, No.7
Clamp, Brake Tube, No.7
Clamp, Brake Tube, No.7
Gasket, Exhaust Pipe, Center
Gasket, Exhaust Pipe, Center
TUBE, FR BRAKE, NO.2
TUBE, FR BRAKE, NO.3
TUBE, RR BRAKE, NO.2
TUBE, RR BRAKE, NO.3
Quantity
1
7
8
9
1
1
1
1
1
1
Illustration Name
Exhaust System
Brake Tubes
Brake Tubes
Brake Tubes
Exhaust System
Exhaust System
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Parts Kits:
Part Number
Part Description
Quantity
04004-19134
Parts Kit No.1 – Common Replacement Kit A
1
The kit listed above includes the following parts:
Part Number
48190-34010
48198-34010
48409-34041
48452-34011
77285-34370
77289-26010
77413-34010
90099-14120
90178-18003
90179-06178
90201-19011
90252-04003
90412-10266
90412-10267
90412-10268
94622-51400
Part Description
Cam Assy, Camber Adjust
Cam, Camber Adjust, No.2
Cam Sub-Assy, Front Suspension Toe Adjust
Plate, Front Suspension Toe Adjust, No.2
Clamp, Fuel Tube, No.2
Clamp, Fuel Tube, No.1
Clamp, Fuel Tube, No.5
O-Ring
Nut
Nut
Washer
Cotter Pin
Way, No.1 (For Front Brake Tube)
Way, No.2 (For Front Brake Tube)
Way (For Rear Brake Tube)
Washer
Quantity
2
2
2
2
3
1
1
1
2
6
2
2
1
1
1
10
Illustration Name
Front Suspension
Front Suspension
Front Suspension
Front Suspension
Fuel Tubes
Fuel Tubes
Fuel Tubes
Air Conditioning
Front Suspension
Front Bumper
Front Suspension
Power Steering
Brake Tubes
Brake Tubes
Brake Tubes
Rear Suspension
Page
11
11
11
11
17
17
17
26
11
26
11
19
13-15
13-15
13-15
12
Part Number
Part Description
Quantity
04007-18134
Plug, Hole Kit
1
The kit listed above includes the following parts:
Part Number
90950-01993
90950-01994
90950-01A09
90950-01987
90950-01988
9095001A06
90950-01990
90950-01A11
90950-01A24
Part Number
90950-01A31
Part Description
PLUG HOLE
PLUG HOLE
PLUG HOLE
PLUG HOLE
PLUG HOLE
PLUG HOLE
PLUG HOLE
PLUG HOLE
PLUG HOLE
Part Description
PLUG,HOLE
Quantity
6
6
6
6
2
2
2
2
2
Quantity
2
6
Parts Kits:
Part Number
Part Description
Quantity
04004-1920C
Parts Kit No.2 – Common Replacement Kit B
1
The kit listed above includes the following parts:
Part Number
04483-0C040
04483-0C040
16492-21050
47314-0C020
47315-0C030
or
47315-0C031
48304-0C030
48304-0C030
52238-0C010
77272-0C030
77285-34380
77296-0C010
or
77296-0C020
77414-0C010
90069-08009
90080-10138
or
90105-A0381
90080-11555
90080-17187
90080-46327
90105-A0064
90119-A0380
90119-A0077
90119-A0080
90119-A0169
90119-A0169
90119-A0184
90119-A0192
90119-A0204
90119-A0210
90119-A0222
90119-A0224
90178-A0044
90178-A0049
90178-A0050
90178-A0052
90178-A0067
90178-A0071
90468-A0007
90917-A6002
Part Description
Shackle Kit, Rear Spring RH
Shackle Kit, Rear Spring LH
Packing (For Radiator Drain Cock)
Tube, Front Brake No.4
Quantity
1
1
1
1
Tube, Front Brake No.5
1
Bumper, Front Spring, No.1 RH
Bumper, Front Spring, No.1 LH
Holder, Body Mounting, Rear
Support, Breather Tube, No.1
Clamp, Fuel Tube, No.1
2
2
2
1
3
Clamp, Fuel Tube, No.3
1
Clamp, Fuel Tube, No.6
O-Ring
1
1
Bolt
2
Bolt
Nut
Clip (For Front Fender Apron Seal)
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Nut
Nut
Nut (For Front Suspension)
Nut
Nut
Clip
Gasket, Exhaust Pipe
1
6
22
3
1
2
8
2
4
1
4
2
4
2
4
8
2
10
8
6
2
4
2
7
Part Number
Part Description
Quantity
04004-19334
Parts Kit No.3 – JPN Source Parts Kit 4WD
1
The kit listed above includes the following parts:
Part Number
Part Description
Quantity
12157-10010
43514-34020
43514-34020
90311-47012
or
90311-47027
90311-47013
90430-24003
95381-04050
Gasket, Front Differential Filler Plug
Cap, Front Axle Hub Grease, RH
Cap, Front Axle Hub Grease, RH
1
1
1
Seal, Oil (For Differential Side Gear Shaft
1
Seal, Oil (For Differential Side Gear Shaft
Gasket, (For Front Differential Drain Plug
Cotter Pin
1
1
2
Part Number
Part Description
Quantity
04004-1940C
Parts Kit No.4 – USA Source Parts Kit 4WD
1
The kit listed above includes the following parts:
Part Number
43425-0C010
90105-A0193
90119-A0151
90464-00897
Part Description
Ring, Shaft Snap (For Front Drive Inner Shaft Outer)
Bolt
Bolt
Clamp
Quantity
2
1
2
1
Illustration Name
Front Suspension
Front Differential
Propeller Shaft
Front Differential
Page
11
19
20
19
8
D. PARTS ILLUSTRATION
Frame
9
Frame & Cab Mounting
10
Under Cover
Spare Tire Carrier
11
Front Suspension
12
Rear Suspension
13
Brake Tubes
14
Brake Tubes Continued…
15
Brake Tubes Continued…
16
Fuel Tank
17
Fuel Tubes
18
Wire Harness Clamps
ABS & VSC
19
Power Steering
Front Differential
Engine Mounting
20
Propeller Shaft
21
Exhaust System
22
Exhaust System Continued…
23
Exhaust System Continued…
24
Exhaust System Continued…
25
AT Shift Cable
Radiator
26
Air Conditioning
Front Bumper
27
Rear Bumper
Front Fender
28
Front Fender Apron
29
III.
FRAME INSPECTION
1. PERFORM INITIAL PRE-HOIST INSPECTION
1. INSPECT THE FRAME FOR EXCESSIVE FRAME CORROSION THAT COULD AFFECT THE
STRUCTURAL INTEGRITY OF THE FRAME
2. FRAME INSPECTION
All frame inspection must be performed using the NEW frame inspection
application on TIS. Ensure you inspect the frame and properly document the
inspection. Failure to perform this will result in denial of the claim.
1. ACCESS INSPECTION APPLICATION
a. Run the VIN in TIS and click on the Warranty Tab
b. Click on the “Frame Inspection” link on TIS
2. LOG INTO THE INSPECTION APPLICATION
a. Reenter your TIS password
30
3. ENTER VEHICLE INFORMATION
a. Enter the vehicle mileage.
b. Select the state from the drop-down menu that the vehicle is registered.
Note: Do NOT select the state the dealership is located.
c.
Inspect the frame for CRC compound that could have been previously applied:
CRC was Previously Applied: Select the CRC Bottle Button
NO CRC Previously Applied: Select Frame Button
Note: CRC could only be previously applied to 2005 to 2008 Tacoma vehicles.
4. INSPECT THE FRAME SECTIONS
a. Inspect the frame in the colored areas below and use the application to document the results of the
inspection.
Note: Crossmember mounting locations should be inspected 6” into the crossmember.
Tundra 07 to 08
b. Select Section A
Note: The frame inspection application must be completed in alphabetical order.
31
c.
Inspect the frame section and inspect all surfaces of the frame rail and crossmember. Select the photo
that best represents the frame condition. If perforation of 10mm or larger is identified select “Peroration
of the Frame”.
Note: You must click the bubble next to the image to select the condition.
d. If you selected Perforation of the Frame, the application will request more information about the
size of perforation(s) and location.
e. The section with perforation will split into 2 sub-sections to further identify the perforation location.
f. Select the size of the perforation in each sub-section.
g. Upload a photo for each area containing perforation and describe the location in the comments
section.
Note:
• If both sub-sections have perforation, it will require two pictures to be uploaded.
• If perforation was accidentally selected use the back button to reselect the correct frame
condition.
h. Select Next to move onto the next section.
32
i.
Once all sections have been completed, select the Submit button.
NO Perforation Found
j. If no perforation was not found, follow the directions as provided.
Perforation Found
k.
If perforation was found, this application will be submitted to your Regional Office for review. The
region office will review the inspection and provide feedback if the frame replacement is approved
for future repair.
DO NOT proceed with frame replacement or parts ordering until you are provided
with approval from the Regional Office. Approval will be sent to the TIS inbox for the
inspection, Service Manager and Parts Manager.
33
34
IV.
FRAME REPLACEMENT WORK PROCEDURE
A. PERFORM PRELIMINARY VEHICLE INSPECTION
1. Perform health check and record any preexisting DTCs
2. Test drive the vehicle and inspect the following vehicle functions/current operating conditions prior to vehicle
repair.
•
•
•
•
•
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
Etc.
3. Documents the current vehicle operating condition on the Frame Replacement Inspection Sheet.
B. 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 removing any fuel system part, drain all fuel to prevent spilling.
1. AIR VENTILATION
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
Fires and ignition sources are prohibited while working on the fuel system.
Clearly display the sign found on the next page stating “WORKING WITH GASOLINE, NO FIRES OR IGNITION SOURCES”.
Smoking is prohibited near the work area.
DO NOT work in areas where there are welders, grinders, drills, electric motors, heaters, etc.
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.
DO NOT use metal hammers while working, due to the risk of flying sparks.
DO NOT start any engines or perform any of the above in neighboring work bays.
3. FIRE EXTINGUISHER
Have a fire extinguisher ready and available before beginning work.
4. PREVENT STATIC ELECTRICITY
To help prevent static electricity, lightly wet the floor with water, but not to the point where it creates a hazardous working condition.
Place appropriate warning cones or stand signs around the area as a caution.
5. PRECAUTIONS WHEN USING A LIFT
For bays equipped with auto lifts, cover all access cover joints with duct tape.
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
When disconnecting any fuel tubes, pipes, hoses or connectors there may still be some pressure 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
Do not allow the fuel to come in contact with any parts made of rubber or leather.
8. ASSIGN A SAFETY SUPERVISOR
Assign a safety supervisor to be in charge of all safety precautions and fire hazards around the work area.
35
36
37
C. REMOVE THE REAR BED ASSY
•
•
•
•
•
If the frame is perforated, ONLY raise the vehicle high enough to remove the tires.
For added safety and support place jack stands under the front and rear portions of the frame.
DO NOT work directly underneath the vehicle when performing bed assy removal.
The actual vehicle specs, equipment and parts required may differ than what is shown. Please
use the correct specifications and parts for the model you are working on.
For additional repair information, please reference to the appropriate repair manual found on TIS
for the vehicle you are working on.
1. CENTER THE VEHICLE BETWEEN THE LIFT ARMS
a) Verify the vehicle is aligned with the center point of the lift to prevent interference and damage to the
frame and/or lift.
2. REMOVE THE FOLLOWING PARTS
•
•
•
•
•
License Plate Light Assy LH/RH
No.3 Frame Wire
Rear Quarter Panel Mudguard LH/RH (If Equipped)
Rear Bumper Assy
Side Step Assy LH/RH (If Equipped)
3. DISCONNECT THE FRAME WIRE HARNESS
a) Disconnect the clamps, connectors and the frame wire
harness from the bed assy.
NOTE:
• The number of connectors may differ depending on
the vehicle specification.
• Be careful not to damage the wire harness clamps
when removing them.
4. DISCONNECT THE FUEL TANK INLET PIPE SUB-ASSY
a) Remove the 2 nuts and disconnect the fuel tank inlet
pipe sub assy.
38
5. REMOVE THE REAR BED ASSY
a) Using a Torx® T55H Tamper Resistant Socket, remove the Torx ® bolts from the rear bed assy.
• Long Bed: 8 Torx® bolts
• Standard Bed and Crewmax (Short Bed): 6 Torx® bolts
NOTE:
• Use 4 or more people to remove the rear bed assy from the frame.
• Evenly support the rear bed assy when removing it.
•
If you find excessive corrision around the bed mounting bolts and believe the bed cannot
be securly reattached after removal, contact your FTS
39
D. DISCHARGE THE FUEL SYSTEM PRESSURE
•
•
•
DO NOT disconnect any part of the fuel system until you have discharged the fuel system
pressure.
Even after discharging the fuel system pressure, place a piece of cloth around the tubes, 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.
For additional repair information, please reference to the appropriate repair manual in TIS for the
vehicle you are working on.
1. CHECK FOR DTCs
2. RECORD THE RADIO STATION PRESETS
3. DISCONNECT THE NEGATIVE (-) BATTERY TERMINAL
NOTE:
Wait 90 seconds after the negative (-) terminal cable is disconnected from the battery before proceeding.
Doing so will prevent the SRS from being deployed (i.e. airbag, seat belt pretensioner, etc.).
4. DISCHARGE THE FUEL SYSTEM PRESSURE
a)
b)
c)
d)
Disconnect the 2 fuel pump ECU connectors.
Reconnect the cable to the negative (-) battery terminal.
Start the engine.
After the engine has stopped, turn the ignition switch
OFF.
e) Crank the engine again to check that it does not start.
f) Disconnect the negative (-) battery terminal.
NOTE:
Please make sure to follow the procedure listed above.
This will prevent a large amount of gasoline from
spilling out when high pressure fuel tube is
disconnected.
40
E. REMOVE THE CAB BODY ASSY
•
•
•
•
•
If the frame is perforated, ONLY raise the vehicle high enough to remove the tires.
For added safety and support place jack stands under the front and rear portions of the frame.
DO NOT work directly underneath the vehicle when performing 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 in TIS for the
vehicle you are working on.
1. REMOVE THE ENGINE UNDER COVER No.1
NOTE:
Use precaution when performing this step, as you will need to work underneath the vehicle.
2. EVACUATE THE REFRIGERANT FROM THE AIR CONDITIONING SYSTEM
3. DRAIN THE FOLLOWING FLUIDS
•
•
•
Coolant
Brake Fluid
Front Differential Fluid
NOTE:
DO NOT remove the radiator cap while the radiator and engine are hot, doing so may cause the
coolant to spray out causing potential injuries.
4. REMOVE THE FOLLOWING PARTS
•
•
•
•
•
•
•
•
•
•
•
•
Front Door Scuff Plate LH/RH
Cowl Side Trim Board LH/RH
No.2 Dash Panel Insulator Pad
No.3 Dash Panel Insulator Pad
Jack and Tool (Standard Tool)
No.1 w/ Box Speaker Assy (If Equipped)
Luggage Compartment Box LH (Regular Cab Only)
Upper Back Panel Garnish (Regular Cab Only)
Front Seat Outer Belt Assy LH (Regular Cab Only)
Lower LH Quarter Trim Panel Assy (Regular Cab Only)
Lift up the second seat and pull up the rear edge of the Floor Carpet (Double Cab Only)
Back Panel Trim LH/RH (Crewmax Only)
5. REMOVE THE FOLLOWING PARTS
•
•
•
•
•
•
•
•
•
•
Front Wheels
Front End Panel LH/RH
Front Fender Splash Shield Sub-Assy LH/RH
Front Bumper Assy
Front Bumper Reinforcement Sub-Assy
No.2 Front Bumper Extension Sub-Assy LH/RH
Front Fender Mudguard LH/RH (If Equipped)
Throttle Body Cover Sub- Assy (2UZ-FE Only)
V-Bank Cover Sub- Assy (1GR-FE, 3UR-FE Only)
Air Cleaner Hose and Air Cleaner Assy
41
6. DISCONNECT THE ENGINE WIRE HARNESS (LH SIDE)
a) Remove the nut and disconnect the 2 (+) positive
battery cables.
b) Remove the bolt and disconnect the ground wire.
c) Disconnect the clamp.
d) Remove the No.1 relay block cover.
e) Disconnect the 2 connectors and clamps.
f) Remove the nut and disconnect the (+) positive battery
cable.
g) Disconnect the 6 connectors and 2 clamps.
h) Remove the bolt and disconnect the ground wire.
7. DISCONNECT THE No.1 COOLER REFRIGERANT
SUCTION HOSE ASSY
a) Remove the nut and disconnect the suction hose.
8. DISCONNECT THE VACUUM HOSE ASSY
a) Disconnect the vacuum hose.
42
9. DISCONNECT THE ENGINE WIRE HARNESS (RH SIDE)
a) Disconnect the 3 connectors and 2 clamps.
b) Disconnect the 5 connectors and 2 clamps.
c) Remove the connector holder block cover upper.
d) Disconnect the skid control sensor connector and
clamp.
NOTE:
Disconnect the clamp of the sensor completely from
the Body.
e) Remove the bolt and disconnect the ground wire.
NOTE:
Disconnect on the engine side otherwise the bolt may
be broken.
10. DISCONNECT THE INLET HEATER HOSE AND OUTLET HEATER HOSE, ENGINE SIDE
43
1GR-FE
11. DISCONNECT THE AIR INJECTION SYSTEM HOSES
a) Disconnect the No.5 hose and No.4 hose. (1GR-FE)
b) Disconnect the No.2 hose and clamp. (2UZ-FE)
c) Disconnect the clamp, No.2 hose and No.3 hose.
(3UR-FE)
2UZ-FE
3UR-FE
44
1GR-FE
12. DISCONNECT THE AIR PUMP HARNESS
a) Disconnect the 2 connectors and 4 clamps. (1GR-FE)
b) Disconnect the connector and 2 clamps. (2UZ-FE)
c) Disconnect the 2 connectors and 3 clamps. (3UR-FE)
2UZ-FE
3UR-FE
13. REMOVE THE FOLLOWING PARTS
•
•
•
•
Upper Center Front Bumper Retainer (Air Oil Cooler Equipped Vehicles Only)
Oil Cooler Assy (Air Oil Cooler Equipped Vehicles Only)
Radiator Side Deflector LH
Radiator Side Deflector RH (If Equipped)
45
14. DISCONNECT THE No.1 COOLER REFRIGERANT
DISCHARGE HOSE
a) Remove the bolt and disconnect the discharge hose.
15. REMOVE THE FOLLOWING PARTS
•
•
•
•
•
Radiator Inlet Hose
Radiator Outlet Hose
Radiator Fan
Fan Shroud
Radiator Assy
16. DISCONNECT THE VANE PUMP OIL RESERVOIR ASSY
a) Remove the 3 bolts of the windshield washer jar assy
to make space for removal of the bolt.
b) Remove the 3 bolts and disconnect the vane pump oil
reservoir assy.
46
LH Side
17. REMOVE THE FRONT FENDER APRON SEALS
a) Remove the left side 11 clips and front fender apron
seal LH/RH.
b) Remove the right side 11 clips and front fender apron
seal LH/RH.
RH Side
LH Side
18. DISCONNECT THE FRONT BRAKE TUBES
a) Disconnect the front brake tube and remove the bolt.
b) Repeat the procedure on the opposite side.
RH Side
47
19. DISCONNECT THE FRONT DIFFERENTIAL VACUUM
HOSES (4WD ONLY)
a) Disconnect the clamp and vacuum hoses.
20. DISCONNECT THE No.2 STEERING INTERMEDIATE
SHAFT
a) Make sure the front wheels are in a straight-ahead
position and the steering wheel is centered.
b) Reconnect the front seat outer belt assy LH.
(Regular Cab Only)
c) Using the seat belt, hold the steering wheel in position
as shown in the illustration, in order to prevent damage
to the spiral cable.
d) Place matchmarks on the intermediate shaft and No.2
intermediate shaft.
e) Remove the bolt.
f) Disconnect the intermediate shaft from the No.2
intermediate shaft.
NOTE:
If the intermediate shaft cannot be pulled out
completely, spread the gap of the sliding yoke with a
flathead screwdriver or a wrench and pull out the
intermediate shaft.
48
21. DISCONNECT THE No.1 PARKING BRAKE CABLE
a) Remove the nut and No.1 wire adjusting nut.
NOTE:
If No.1 wire adjusting nut is too rusty to remove, then
separate parking brake mechanism from frame.
b) Remove the bolt and cable retainer.
c) Disconnect the No.1 parking brake cable.
NOTE:
Use precaution when performing this step, as you will
need to work underneath the vehicle.
22. DISCONNECT THE TRANSMISSION CONTROL CABLE
a) Remove the bolt and disconnect the ground wire.
b) Disconnect the 3 clamps.
NOTE:
Use precaution when performing this step, as you will
need to work underneath the vehicle.
c) Remove the nut.
d) Remove the 2 bolt and disconnect the transmission
control cable.
23. DISCONNECT THE REAR BRAKE TUBES
a) Disconnect the 2 rear brake tubes.
b) Remove the bolt and disconnect brake tube.
NOTE:
Use precaution when performing this step, as you will
need to work underneath the vehicle.
49
24. REINSTALL THE FRONT WHEELS
25. REMOVE THE CAB BODY ASSY USING AN ABOVE GROUND LIFT
a)
b)
c)
d)
e)
f)
g)
Remove the 6 bolts, 6 nuts, 4 washers and 2 No.1 lower cab mounting cushion sub-assy.
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 vehicle.
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.
• The center of gravity position of the cab body may become inappropriate depending on the
shape of the lift arm used and under such situation the cab body may fall when lifted. To prevent
falling off of the cab body, use some weights to establish right balance and secure the cab body
to the lift arm using ratchet tie down belts.
• DO NOT work directly underneath the vehicle when pulling the frame assy out from under.
• DO NOT remove the cab mount bolts, as they will be used as guides during cab assy
reinstallation process.
50
F. DISASSEMBLE THE FRAME
1. PLACE THE FRAME ON A LIFT
a) Place the 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 removed.
•
Ratcheting Tie Downs: Qty 1
° Length: 2 in X 27 ft
° Minimum Work Load Capacity: 3,000 lbs
2. REMOVE THE FOLLOWING PARTS
•
•
Spare Tire
Wheels
3. DISCONNECT THE OXYGEN SENSOR CONNECTORS
a) Disconnect the 4 oxygen sensor connectors.
4. REMOVE THE FOLLOWING PARTS
•
•
•
Propeller Shaft Heat Insulator (4WD Only)
Front Propeller Shaft Assy (4WD Only)
Rear Propeller Shaft Assy
° Insert SST 09325-40010 (A750E) or SST 09325-60010 (AB60E) into the transmission after the rear
propeller shaft is removed to prevent oil leakage (2WD Only)
NOTE:
Make sure to place matchmarks on the front (if equipped) and rear propeller shafts prior to removal.
5. REMOVE THE FOLLOWING PARTS
•
•
•
•
No.1 Fuel Tank Protector Sub-Assy (If Equipped)
Fuel Tank Strap
Fuel Tank Assy
Charcoal Canister Assy
51
6. DISCONNECT THE PARKING BRAKE SYSTEM
a) Remove the tension spring.
b) Remove the bolt and cable retainer.
c) Disconnect the 2 parking brake cables.
d) Remove the 3 bolts and cable support bracket (A).
e) Remove the 2 bolts and parking brake intermediate
lever (B).
f) Remove the 2 bolts and No.2 cable support bracket (C).
7. DISCONNECT THE FUEL PIPES
a) Remove the No.1 fuel pipe clamp.
b) Disconnect the 2 fuel pipes.
NOTE:
Put a shop towel under the fuel pipe to catch any spilled
fuel.
8. DISCONNECT THE FUEL VAPOR FEED HOSE ASSY
52
4WD Only
2UZ-FE, 3UR-FE
9. DISCONNECT THE ENGINE WIRE
(2UZ-FE, 3UR-FE ONLY)
10. DISCONNECT THE DIFFERENTIAL WIRE (4WD ONLY)
11. REMOVE AND SET ASIDE THE POWER STEERING PUMP ASSY
a)
b)
c)
d)
Remove the drive belt.
Disconnect the connectors.
Disconnect the harness clamp. (3UR-FE Only)
Remove the 2 bolts and nut (2UZ-FE Only) or the 2 bolts (1GR-FE, 3UR-FE Only) and the power
steering vane pump.
NOTE:
• DO NOT disconnect the power steering pump hoses or tubes.
• Make sure to keep the power steering pump reservoir in an upright position to prevent the fluid
from leaking out.
12. REMOVE THE INTAKE AIR SURGE TANK (1GR-FE ONLY)
1GR-FE
13. REMOVE THE ENGINE AND TRANSMISSION ASSY
a) Disconnect and remove the necessary items/parts to
prepare the engine and transmission assy for removal.
b) Install the engine hanger. (1GR-FE, 3UR-FE)
For 1GR-FE
12281-31060 = Engine Hanger No.1, Qty: 1
12282-31040 = Engine Hanger No.2, Qty: 1
90119-08A87 = Bolt, Qty: 4
3UR-FE
For 3UR-FE
12281-38150 = Engine Hanger No.1, Qty: 2
90119-14120 or 90119-A0166 = Bolt, Qty: 2
53
c) 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.
14. REMOVE THE FUEL TUBES
a) Remove the bolts, clamps and fuel tubes.
NOTE:
• The number of clamps will differ depending on the
vehicle specification.
• Take care not to damage or break the clamps
during removal.
15. DISCONNECT THE SKID CONTROL SENSOR WIRES
a) Remove the 2 bolts and disconnect the skid control
sensor wire. (LH Side)
b) Remove the bolt and disconnect the skid control sensor
wire. (RH Side)
16. DISCONNECT THE FRONT BRAKE HOSES
a)
b)
c)
d)
Disconnect the brake tube from the brake hose
Remove the clip.
Remove the bolt and disconnect the front brake hose.
Repeat the procedure on the opposite side.
54
17. REMOVE THE FOLLOWING PARTS
•
•
•
•
Front Stabilizer Bar
Front Axle Shaft Nut (4WD Only)
Tie Rod End Sub-Assy
° Remove the cotter pin and nut.
° Using the SST 09610-20012, disconnect the tie rod end.
Lower Ball Joint
° Remove the 2 bolts and disconnect the lower ball joint from the steering knuckle.
18. REMOVE THE FRONT SUSPENSION UPPER ARM AND
STEERING KNUCKLE ASSY
a) Remove the bolt, 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 the drive
shaft loose with a plastic hammer. (4WD Only)
19. REMOVE THE FOLLOWING PARTS
•
•
Front Shock Absorber Assy
Front Drive Shaft Assy (4WD Only)
° Using the SST 09520-24010 (09520-32040), 09520-01010, remove the front drive shaft
NOTE:
Be careful not to damage the dust cover and oil seal.
• Power Steering Link Assy w/ Power Steering Vane Pump
NOTE:
• When removing 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.
• Front Differential Carrier Assy (4WD Only)
• Front Suspension Lower Arm Sub-Assy
NOTE:
If the bolt is seized and the front suspension lower arm cannot be removed, remove the lower ball
joint with the front suspension lower arm left on the frame.
• Lower Ball Joint
NOTE:
When the front suspension arm can be removed, this work is not required.
° Remove the cotter pin and nut.
° Using the SST 09950-40011 (09951-04010,09953-04020,09954-04010,09955-04031,
09958-04011,09952-04010),09955-04090, remove the lower ball joint.
•
No.1 Front Spring Bumper (Qty: 4)
° Using the SST 09922-10010-01, remove the front spring bumper.
55
20. DISCONNECT THE PARKING BRAKE CABLE
a) Remove the 11 bolts, clamp and disconnect the parking
brake cable.
21. DISCONNECT THE REAR BRAKE TUBES
a) Disconnect the No.4 rear brake tube.
b) Disconnect the No.5 rear brake tube.
c) Remove the 2 clip and disconnect the flexible hose.
22. REMOVE THE FOLLOWING PARTS
•
•
•
Rear Shock Absorber Assy
Rear Differential Assy
Fuel Pump Control Computer Assy
56
23. REMOVE THE FRAME WIRE HARNESS
a) Remove the bolt and disconnect the ground wire.
(If Equipped)
b) Disconnect the clamps and remove the frame wire
harness.
NOTE:
• The number of wire harness clamps will differ
depending on the vehicle specification.
• Take care not to damage or break the wire harness
clamps during removal.
24. REMOVE THE No.6 FUEL TUBE CLAMP
a) Remove the bolt and No.6 fuel tube clamp.
25. REMOVE THE CLIPS
26. REMOVE THE FRONT DIFFERENTIAL SUPPORT ASSY
(4WD ONLY)
a) Remove the bolt, nut and differential support assy.
57
27. REMOVE THE ENGINE WIRE CLAMP
(2UZ-FE, 3UR-FE ONLY)
28. REMOVE THE FRAME WIRE CLAMP
29. REMOVE THE No.2 FRONT ENGINE MOUNTING
BRACKET LH
30. REMOVE THE EXHAUST SYSTEM
a)
b)
c)
d)
Remove the 6 nuts.
Remove the exhaust pipe and 4 exhaust pipe supports.
Remove the 2 exhaust pipe gaskets.
Remove the exhaust tail pipe and exhaust tail pipe support.
31. REMOVE THE FRAME FROM THE LIFT
a) Remove the ratcheting tie down strap and the frame from the lift.
58
G. 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.
•
H.
Ratcheting Tie Downs: Qty 1
° Length: 2 in X 27 ft
° Minimum Work Load Capacity: 3,000 lbs
INSTALLATION OF BODY PLUGS
1. REMOVE THE PLASTIC SHEET
2. INSTALL THE PLUGS AS SHOWN BELOW
1/2 PLUG INSTALLATION
FRONT
59
2/2 PLUG INSTALLATION
FRONT
60
NEW Replacement Parts
Part Number
04483-0C040
04483-0C040
90080-10138
or
90105-A0381
90178-A0050
94622-51400
Varies **
Varies **
2. INSTALL THE REAR LEAF SPRINGS
Part Description
Shackle Kit, Rear
Spring RH
Shackle Kit, Rear
Spring LH
Kit #
Quantity
2
1
2
1
a) Install the NEW rear leaf spring with all NEW parts
(shackle, bushings, bolts, washers & nuts) and torque
to spec.
Bolt
2
2
Torque Spec: 77 ft∙lbs (105 N∙m, 1071 kgf∙cm)
Nut
Washer
Rear Leaf Spring (LH)
Rear Leaf Spring (RH)
2
1
Na*
Na*
2
2
1
1
b) Repeat the procedure on the opposite side.
* Individual Part(s)
** Only 1 part is used. The part number depending on the list
61
3. REINSTALL THE CAB MOUNTS
NEW Replacement Parts
Part Number
90119-A0080
Part Name
Bolt
Kit #
2
Qty
8
a) Reinstall cab mounts No.1.
b) Reinstall cab mounts No.2 & No.3 with 8 NEW bolts
and torque to spec.
Torque Spec: 45 ft∙lbs (61 N∙m, 622 kgf∙cm)
4. INSTALL THE FRONT SUSPENSION LOWER ARMS
NEW Replacement Parts
Part Number
Part Name
Kit #
Arm, Sub-Assy, Front Suspension,
48068-09100
NA*
Lower No.1 RH
Arm, Sub-Assy, Front Suspension,
48069-09090
NA*
Lower No.1 LH
48190-34010
Cam Assy, Camber Adjust
1
48198-34010
Cam, Camber Adjust, No.2
1
Cam Sub-Assy, Front Suspension
48409-34041
1
Toe Adjust
Plate, Front Suspension Toe
48452-34011
1
Adjust, No.2
90119-A0204
Bolt
2
90178-18003
Nut
1
90201-19011
Washer
1
* Individual Part(s)
1
a) Install the NEW front suspension lower arm with NEW
bolt, NEW toe adjusting cam, NEW toe adjusting plate,
NEW nut, NEW washer, NEW No.2 camber adjusting
cam, NEW camber adjusting cam, then torque to spec.
2
2
Torque Spec: 207 ft∙lbs (280 N∙m, 2855 kgf∙cm)
2
b) Repeat the procedure on the opposite side.
Qty
1
2
2
2
2
62
5. REINSTALL THE LOWER BALL JOINTS
NOTE:
• If the front suspension lower arm is to be replaced with a new one, install the lower ball joint on
the new front suspension lower arm.
• If the holes for the cotter pin are not aligned, tighten the axle nut further, up to 60 degree.
a) Reinstall the lower ball joint with the nut and torque to spec.
Torque Spec: 123 ft∙lbs (167 N∙m, 1703 kgf∙cm)
b) Install the NEW cotter pin.
c) Repeat the procedure on the opposite side.
6. INSTALL THE No.1 SPRING BUMPERS
NEW Replacement Parts
Part Number
48304-0C030
48304-0C030
Part Name
Bumper, Front Spring, No.1 RH
Bumper, Front Spring, No.1 LH
Kit #
2
2
Qty
2
2
a) Install the 2 NEW front spring bumpers to the frame
and torque to spec.
Torque Spec: 23 ft∙lbs (31 N∙m, 316 kgf∙cm)
b) Repeat the procedure on the opposite side.
NEW Replacement Parts
Part Number
90105-A0179
90119-A0170
Part Name
Bolt**
Kit #
NA*
NA*
Qty
1
1
* Individual Part(s)
** Only 1 part used. The part number depending on the list.
7. REINSTALL THE ENGINE WIRE CLAMP
(2UZ-FE, 3UR-FE ONLY)
Torque Spec: 13 ft∙lbs (17.2 N∙m, 175 kgf∙cm)
8. REINSTALL THE FRAME WIRE CLAMP
Torque Spec: 23 ft∙lbs (31 N∙m, 316 kgf∙cm)
9. REINSTALL THE No.2 FRONT ENGINE MOUNTING
BRACKET LH
Torque Spec: 24 ft∙lbs (32 N∙m, 326 kgf∙cm)
63
10. REINSTALL THE FRONT DIFFERENTIAL SUPPORT
ASSY (4WD ONLY)
a) Reinstall the front differential support with the nut and
bolt, then torque to spec.
Torque Spec: 83 ft∙lbs (113 N∙m, 1152 kgf∙cm)
11. INSTALL THE CLIPS
NEW Replacement Parts
Part Number
52238-0C010
Part Name
Holder, Body Mounting, Rear
Kit #
2
Qty
2
12. INSTALL THE No.6 FUEL TUBE CLAMP
NEW Replacement Parts
Part Number
77414-0C010
90105-A0179
Part Name
Clamp, Fuel Tube, No.6
Bolt
* Individual Part(s)
Kit #
2
NA*
Qty
1
1
a) Install the NEW No.6 fuel tube clamp with the NEW
bolt, and torque to spec.
Torque Spec: 23 ft∙lbs (31 N∙m, 316 kgf∙cm)
64
13. INSTALL THE REAR BRAKE TUBES
NEW Replacement Parts
Part Number
47324-0C060
47324-0C080
47324-0C090
47325-0C090
47325-0C100
47325-0C110
90469-A0004
90469-A0004
90469-A0004
Part Name
Tube, Rear Brake, No.4**
Tube, Rear Brake, No.5**
Clamp, Brake Tube, No.7**
Kit #
NA*
NA*
NA*
NA*
NA*
NA*
NA*
NA*
NA*
Qty
1
1
1
1
1
1
7
8
9
a) Install the NEW rear brake tubes with the NEW
clamp(s).
NOTE:
The number of clamps will differ depending on the
vehicle spec.
* Individual Part(s)
** Only 1 part used. The part number depending on the list.
NEW Replacement Parts
Part Number
Varies**
Part Name
Kit # Qty
Wire, Frame
NA*
1
* Individual Part(s)
** Only 1 part used. The part number depending on the list.
14. INSTALL THE FRAME WIRE HARNESS
a) Connect the clamps to install the NEW frame wire
harness.
b) Connect the ground wire with the bolt and torque to
spec. (If Equipped)
Torque Spec: 22 ft∙lbs (29.3 N∙m, 299 kgf∙cm)
NOTE:
The number of wire harness clamps will differ
depending on the vehicle spec.
65
NEW Replacement Parts
Part Number
90119-A0169
51900-34050
Part Name
Bolt
Carrier Assy, Spare Wheel
* Individual Part(s)
15. INSTALL THE SPARE WHEEL CARRIER ASSY
Kit #
2
NA*
Qty
4
1
a) Install the NEW spare wheel carrier assy with the 4
NEW bolts and torque to spec.
Torque Spec: 15 ft∙lbs (20 N∙m, 204 kgf∙cm)
16. REINSTALL THE FUEL PUMP CONTROL COMPUTER
ASSY
a) Reinstall the fuel pump control computer with the 2 nuts
and torque to spec.
Torque Spec: 14 ft∙lbs (19.5 N∙m, 199 kgf∙cm)
b) Reconnect the 2 connectors.
17. REINSTALL THE FOLLOWING PARTS
•
Rear Differential Assy
° Reinstall the rear differential assy with the 4 NEW U
- bolts, 2 spring seats, 2 spring bumpers, 8 NEW
mounting nuts and 8 NEW washers, then torque to
spec.
° Torque Spec: 74 ft∙lbs (100 N∙m, 1020 kgf∙cm)
•
Rear Shock Absorber Assy
° Reinstall the rear shock absorber assy with the
NEW nut, retainer and 2 cushions, then torque to
spec.
° Torque Spec:
Nut (Upper Side) - 21 ft∙lbs (28 N∙m, 286 kgf∙cm)
° Reinstall with the bolt, 2 nuts and torque to spec.
° Torque Spec:
Nut (Lower Side) - 66 ft∙lbs (90 N∙m, 918 kgf∙cm)
° Repeat the procedure on the opposite side.
NEW Replacement Parts
Part Number
90117-A0003
90117-A0004
90178-A0050
94622-51400
90178-A0071
Part Name
Bolt, U (For Rear Spring) **
Kit #
NA*
NA*
2
1
2
Qty
4
4
8
8
2
Nut
Washer
Nut
* Individual Part(s)
** Only 1 part used. The part number depending on the list.
66
18. RECONNECT THE REAR BRAKE TUBES
NEW Replacement Parts
Part Number
90468-A0007
Part Name
Clip
Kit #
2
Qty
2
a) Reconnect the 2 flexible hose with a 2 NEW clips.
b) Reconnect the 2 rear brake tube and torque to spec.
Torque Spec: 11 ft∙lbs (15 N∙m, 153 kgf∙cm)
19. REINSTALL THE PARKING BRAKE CABLE
a) Reinstall the parking brake cables with the clamp and
11 bolts, then torque to spec.
Torque Spec:
Bolt A - 14 ft∙lbs (19 N∙m, 194 kgf∙cm)
Bolt B - 10 ft∙lbs (13.5 N∙m, 138 kgf∙cm)
20. REINSTALL THE FRONT DIFFERENTIAL CARRIER
ASSY (4WD ONLY)
a) Reinstall the front differential carrier assy with the 3
bolts, 2 stoppers and 2 nuts, then torque to spec.
Torque Spec: 83 ft∙lbs (113 N∙m, 1152 kgf∙cm)
67
b) Reinstall the breather tubes with the NEW bolt and torque to
spec.
NEW Replacement Parts
Part Number
90105-A0193
Part Name
Bolt
Kit #
4
Qty
1
Torque Spec: 12 ft∙lbs (16.6 N∙m, 169 kgf∙cm)
c) Reinstall the differential wire connector with the bolt
and clamp, then torque to spec.
Torque Spec: 13 ft∙lbs (17.2 N∙m, 175 kgf∙cm)
68
21. REINSTALL THE POWER STEERING LINK ASSY
W/ POWER STEERING VANE PUMP
a) Place the power steering link assy w/ power steering
vane pump on the frame as shown in the figure.
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.
• Take care not to deform the power steering tube
etc. during placement.
b) Install the 2 bolts (A) and 2 nuts, then torque to spec.
Torque Spec: Nut - 89 ft∙lbs (120 N∙m, 1224 kgf∙cm)
c) Install the bolts (b) (2UZ-FE: 5 bolts, 1GR-FE, 3UR-FE:
6 bolts) and torque to spec.
Torque Spec: Bolt - B 21 ft∙lbs (28 N∙m, 286 kgf∙cm)
22. REINSTALL THE FRONT DRIVE SHAFT ASSY
(4WD ONLY)
NEW Replacement Parts
Part Number
90311-47012
or
90311-47027
90311-47013
43425-0C010
Part Description
Kit #
Quantity
Seal, Oil (For Differential Side
Gear Shaft
3
1
3
1
4
2
Seal, Oil (For Differential Side
Gear Shaft
Ring, Shaft Snap (For Front
Drive Inner Shaft Outer)
a) Install a NEW snap ring.
b) Reinstall the front drive shaft assy.
c) Repeat the procedure on the opposite side.
NOTE:
• Be careful not to damage the dust cover and oil seal.
• If the oil seal is damaged, replace the NEW parts.
69
23. REINSTALL THE FRONT SHOCK ABSORBERS
NEW Replacement Parts
Part Number
90178-A0052
Part Name
Nut (For Front Suspension Support)
Kit #
2
Qty
8
a) Reinstall the front shock absorber assy with the 4 NEW
nuts (A) and torque to spec.
Torque Spec: Nut A - 33 ft∙lbs (45 N∙m, 459 kgf∙cm)
b) Reinstall the bolt and nut (B), then torque to spec.
Torque Spec: Nut B - 144 ft∙lbs (195 N∙m, 1988 kgf∙cm)
c) Repeat the procedure on the opposite side.
24. REINSTALL THE FRONT SUSPENSION UPPER ARM
AND STEERING KNUCKLES
a) Reinstall the front suspension upper arm w/ steering
knuckle assy with the bolt, nut and 2 washers, then
torque to spec.
Torque Spec: 173 ft∙lbs (235 N∙m, 2396 kgf∙cm)
b) Repeat the procedure on the opposite side.
25. REINSTALL THE FOLLOWING PARTS
•
•
NEW Replacement Parts
Part Number
90252-04003
90119-A0192
Part Name
Cotter Pin
Bolt
Kit #
1
2
Qty
2
4
•
•
Lower Ball Joint
° Reinstall the lower ball joint with the 2 bolts and
torque to spec.
° Torque Spec: 221 ft∙lbs (300 N∙m, 3059 kgf∙cm)
° Repeat the procedure on the opposite side.
Tie Rod End Sub-Assy
° Reinstall the tie rod end with the nut and torque to
spec.
° Torque Spec: 51 ft∙lbs (69 N∙m, 704 kgf∙cm)
° Install the NEW cotter pin.
° Repeat the procedure on the opposite side.
Front Axle Shaft Nut (4WD Only)
° Temporarily reinstall the front axle nut.
° This nut will be tightened when the vehicle is
completed.
° Repeat the procedure on the opposite side.
Front Stabilizer Bar
° Reinstall the stabilizer bar with the 2 brackets and 4
NEW bolts, then torque to spec.
° Torque Spec: 51 ft∙lbs (69 N∙m, 704 kgf∙cm)
° Reconnect the stabilizer links with the 2bolts and
torque to spec.
° Torque Spec: 89 ft∙lbs (120 N∙m, 1224 kgf∙cm)
70
26. RECONNECT THE FRONT BRAKE HOSES
NEW Replacement Parts
Part Number
90119-A0222
90468-A0007
Part Name
Bolt
Clip
a) Reinstall a bracket with a NEW bolt and torque to spec.
Kit #
2
2
Qty
2
2
Torque Spec: 21 ft∙lbs (29 N∙m, 296 kgf∙cm)
b) Reinstall the front brake hose with the NEW clip.
c) Repeat the procedure on the opposite side.
27. RECONNECT THE SKID CONTROL SENSOR WIRES
NEW Replacement Parts
Part Number
90105-A0064
Part Name
Bolt
Kit #
2
Qty
3
a) Reinstall the skid control sensor wire with the 2 NEW
bolts and torque to spec. (LH Side Connects to the
Frame)
b) Reinstall the skid control sensor wire with the NEW bolt
and torque to spec. (RH Side Connects to the Body)
Torque Spec: 9 ft∙lbs (12.5 N∙m 127 kgf∙cm)
71
NEW Replacement Parts
Part Number
77285-34380
77289-26010
77285-34370
77296-0C010
or
77296-0C020
77412-34010
77412-34010
77412-34010
77413-34010
90105-A0179
90105-A0179
90105-A0179
28. REINSTALL THE FUEL TUBES
Part Description
Clamp, Fuel Tube, No.1
Clamp, Fuel Tube, No.1
Clamp, Fuel Tube, No.2
Kit #
2
1
1
Quantity
3
1
3
Clamp, Fuel Tube, No.3
2
1
NA*
NA*
NA*
1
NA*
NA*
NA*
1
2
3
1
2
3
4
Clamp, Fuel Tube,
No.4**
Clamp, Fuel Tube, No.5
Bolt**
a) Reinstall the fuel tubes with the NEW clamps and NEW
bolts, then torque to spec.
Torque Spec: 21 ft∙lbs (29 N∙m, 296 kgf∙cm)
NOTE:
The number of clamps will differ depending on the
vehicle spec.
* Individual Part(s)
** Only 1 part is used. The part number depending on the list
29. REINSTALL THE ENGINE AND TRANSMISSION ASSY
a) Reinstall engine and transmission assy.
NOTE:
• When reinstalling 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.
72
b) Attach the engine mounts with the 4 NEW bolts and
torque to spec.
NEW Replacement Parts
Part Number
90119-A0224
Part Name
Bolt
Kit #
2
Qty
4
LH Side
Torque Spec: 58 ft∙lbs (79 N∙m, 806 kgf∙cm)
RH Side
c) Attach the transmission mount with 4 NEW bolts and
torque to spec.
NEW Replacement Parts
Part Number
90119-A0210
Part Name
Bolt
Kit #
2
Qty
4
Torque Spec: 12 ft∙lbs (16 N∙m, 163 kgf∙cm)
d) Remove the bolt(s) and the engine hangers.
(1GR-FE, 3UR-FE Only)
e) Reinstall the items/parts that were removed during the
engine and transmission assy removal.
73
30. REINSTALL THE INTAKE AIR SURGE TANK
(1GR-FE ONLY)
a) Install the NEW air surge tank to intake manifold
gasket.
b) Reinstall the intake air surge tank with the 4 bolts and
the 2 nuts, then torque to spec.
Torque Spec: 21 ft∙lbs (28 N∙m, 286 kgf∙cm)
NEW Replacement Parts
Part Number
17176-0P010
Part Name
Gasket, Airsurge Tank To Intake
Manifold
* Individual Part(s)
Kit #
Qty
NA*
1
c) Reinstall the 3 surge tank stays with the 6 bolts and
torque to spec.
Torque Spec: 15 ft∙lbs (21 N∙m, 214 kgf∙cm)
d) Reinstall the oil baffle plate with the bolt and torque to
spec.
Torque Spec: 80 in∙lbs (9.0 N∙m, 92 kgf∙cm)
e) Reinstall the 2 water by-pass hoses.
f) Reinstall the No.1 ventilation hose.
g) Reinstall the 3 connectors and 4clamps.
31. REINSTALL THE POWER STEERING PUMP ASSY
a) Reinstall the power steering vane pump with the 2 bolts and the nut (2UZ-FE Only) or the 2 bolts
(1GR-FE, 3UR-FE Only), then torque to spec.
Torque Spec: 21 ft∙lbs (28 N∙m, 286 kgf∙cm)
b) Reconnect the clamp. (3UR-FE Only)
c) Reconnect the connectors.
d) Reinstall the drive belt.
4WD Only
2UZ-FE, 3UR-FE
32. RECONNECT THE DIFFERENTIAL WIRE (4WD ONLY)
33. RECONNECT THE ENGINE WIRE
(2UZ-FE, 3UR-FE ONLY)
74
34. RECONNECT THE FUEL PIPES
a) Reconnect the 2 fuel pipes.
b) Reinstall the No.1 fuel pipe clamp.
35. RECONNECT THE FUEL VAPOR FEED HOSE ASSY
36. RECONNECT THE PARKING BRAKE SYSTEM
a) Reconnect the cable support bracket with the 3 bolts
and torque to spec (A).
b) Reconnect the parking brake intermediate lever with
the 2 bolts and torque to spec (B).
c) Reconnect the No.2 cable support bracket with the 2
bolts and torque to spec (C).
Torque Spec: 14 ft∙lbs (19 N∙m, 194 kgf∙cm)
d) Reconnect the 2 parking brake cables.
e) Reinstall the tension spring.
f) Reinstall the cable retainer with the bolt and torque to
spec.
Torque Spec: 9 ft∙lbs (12.5 N∙m, 127 kgf∙cm)
37. REINSTALL THE CHARCOAL CANISTER ASSY
a) Reinstall the charcoal canister assy with the 4 bolts and
2 nuts, then torque to spec.
Torque Spec:
Bolt - 21 ft∙lbs (29 N∙m, 296 kgf∙cm)
Nut – 9 ft∙lbs (12.5 N∙m, 127 kgf∙cm)
b) Reconnect the fuel hose, connector and clamp.
75
38. REINSTALL THE FUEL TANK STRAPS
a) Reinstall the fuel tank straps with the 2 pins and 2 clips.
NEW Replacement Parts
Part Number
90119-A0077
77272-0C030
Part Name
Bolt
Support, Breather Tube, No.1
39. REINSTALL THE FUEL TANK ASSY
Kit #
2
2
Qty
2
1
a) Reinstall the fuel tank assy with the 2 NEW bolts and
torque to spec.
Torque Spec: 30 ft∙lbs (40 N∙m, 408 kgf∙cm)
b) Reconnect the 2 fuel tubes.
c) Reconnect the connector and clamps.
d) Reconnect the NEW No.1 breather tube support and
hose.
40. REINSTALL THE No.1 FUEL TANK PROTECTOR ASSY
(IF EQUIPPED)
NEW Replacement Parts
Part Number
90080-11373
Part Name
Bolt
* Individual Part(s)
Kit #
NA*
Qty
2
a) Reinstall the No.1 fuel tank protector with the 2 NEW
bolts and the 2 nuts, then torque to spec.
Torque Spec: Bolt - 21 ft∙lbs (29 N∙m, 296 kgf∙cm)
Nut - 15 ft∙lbs (20 N∙m, 204 kgf∙cm)
76
41. REINSTALL THE REAR PROPELLER SHAFT ASSY
a) Remove the SST. (2WD Only)
b) Referencing the matchmarks, reinstall the propeller
shaft assy to the transmission / transfer case.
c) Reinstall the 4 nuts and torque to spec. (4WD Only)
Torque Spec: 52 ft∙lbs (70 N∙m, 714 kgf∙cm)
d) Reinstall the center support bearing to the frame as
shown in the illustration with 2 washer and 2 bolts, then
torque to spec. (3-Joint Type Only)
Torque Spec: 30 ft∙lbs (40.2 N∙m, 410 kgf∙cm)
e) Referencing the matchmarks, reinstall the propeller
shaft assy to the rear differential with 4 bolts, and 4
nuts, then torque to spec.
Torque Spec: 52 ft∙lbs (70 N∙m, 714 kgf∙cm)
42. REINSTALL THE FRONT PROPELLER SHAFT ASSY
a) Referencing the matchmarks, install the front propeller shaft assy to the transfer case and the front
differential with 8 nuts and 8 washers, then torque to spec.
Torque Spec: 59 ft∙lbs (80.3 N∙m, 819 kgf∙cm)
43. REINSTALL THE PROPELLER SHAFT HEAT
INSULATOR (4WD ONLY)
NEW Replacement Parts
Part Number
90119-A0151
Part Name
Bolt
Kit #
4
Qty
2
a) Reinstall the propeller shaft heat insulator with the 2
NEW bolts and torque to spec.
Torque Spec: 12 ft∙lbs (15.7 N∙m, 160 kgf∙cm)
77
44. REINSTALL THE EXHAUST SYSTEM
NEW Replacement Parts
Part Number
90917-A6002
90126-A0011
90126-A0011
90126-A0011
90080-17187
Part Name
Kit #
Gasket, Exhaust Pipe
2
Bolt, Stud (For Exhaust Manifold,
NA*
RH) 3UR#
Bolt, Stud (For Exhaust Manifold,
NA*
LH) 3UR#
Bolt, Stud (For Manifold To
NA*
Exhaust Pipe)
Nut
2
* Individual Part(s)
Qty
2
3
a) Install the 2 NEW exhaust pipe gaskets.
b) Reinstall the exhaust pipe and 4 exhaust pipe supports.
c) Install the 6 NEW nuts and torque to spec.
Torque Spec: 40 ft∙lbs (54.3 N∙m, 554 kgf∙cm)
3
6
6
45. RECONNECT THE OXYGEN SENSOR CONNECTORS
a) Reconnect the 4 oxygen sensor connectors.
78
46. REINSTALL THE EXHAUST TAIL PIPE ASSY
NEW Replacement Parts
Part Number
90917-06085
90917-06093
90119-A0380
90080-46263
90461-15017
Part Name
Gasket, Exhaust Pipe, Center**
Bolt
Clamp**
Kit #
NA*
NA*
2
NA*
NA*
Qty
1
1
1
1
1
* Individual Part(s)
** Only 1 part used. The part number depending on the list.
a) Install the NEW exhaust pipe gasket.
b) Reinstall the exhaust tail pipe and exhaust pipe
support.
c) Install the NEW bolt and NEW clamp, then torque to
spec.
Torque Spec: 24 ft∙lbs (32 N∙m, 326 kgf∙cm)
47. REINSTALL THE FOLLOWING PARTS
•
•
Spare Tire
Wheels
48. REMOVE THE FRAME FROM THE LIFT
a) Remove the ratcheting tie down strap from the frame.
b) Lower the frame to the ground.
79
I.
REINSTALL THE CAB BODY ASSY
1. REINSTALL THE CAB BODY ASSY
a)
b)
c)
d)
e)
Raise the cab assy high enough so that the top of the engine clears the lowest point of the cab.
Push the frame under the cab assy.
Lower the cab assy slowly, making sure it does not interfere with anything.
Adjust the vehicle’s frame as needed to align the cab mounts with the cab assy bolts.
Once the cab assy is set on the mounts, secure it to the frame with 6 bolts, 6 nuts, 4 washers and 2
No.1 lower cab mounting cushion sub-assy, then torque to spec.
Torque Spec: 40 ft∙lbs (54 N∙m, 551 kgf∙cm)
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 2 to 3 people checking for interference, slowly lower the cab body assy to the frame.
80
2. RECONNECT THE REAR BRAKE TUBES
NEW Replacement Parts
Part Number
90412-10268
90119-A0184
Part Name
Way (For Rear Brake Tube)
Bolt
Kit #
1
2
Qty
1
1
a) Reconnect the rear brake tubes with the NEW bolt and
torque to spec.
Torque Spec: 23 ft∙lbs (31 N∙m, 316 kgf∙cm)
b) Reconnect the 2 rear brake tubes and torque to spec.
Torque Spec: 11 ft∙lbs (15.2 N∙m, 155 kgf∙cm)
3. RECONNECT THE TRANSMISSION CONTROL CABLE
NEW Replacement Parts
Part Number
90080-17229
Part Name
Nut
* Individual Part(s)
Kit #
NA*
Qty
1
a) Reconnect the shift cable with the 2 bolts and NEW
nut, then torque to spec.
Torque Spec:
Bolt - 9 ft∙lbs (12 N∙m, 122 kgf∙cm)
Nut - 10 ft∙lbf (14 N∙m, 143 kgf∙cm)
b) Reconnect the ground wire with the bolt and torque to
spec.
Torque Spec: 73 in∙lbs (8.3 N∙m, 85 kgf∙cm)
c) Reconnect the 3 clamps.
81
4. RECONNECT THE No.1 PARKING BRAKE CABLE
a) Reconnect the No.1 parking brake cable.
b) Reinstall the cable retainer with the bolt and torque to
spec.
Torque Spec: Bolt - 9 ft∙lbs (12.5 N∙m, 127 kgf∙cm)
c) Reinstall the No.1 wire adjusting nut and nut, then
torque to spec.
Torque Spec: Nut - 11 ft∙lbs (15 N∙m, 153 kgf∙cm)
5. REMOVE THE FRONT WHEELS
6. RECONNECT THE No.2 STEERING INTERMEDIATE
SHAFT
NEW Replacement Parts
Part Number
90080-11555
Part Name
Bolt
Kit #
2
Qty
1
a) Make sure the front wheels are in a straight-ahead
position and the steering wheel is centered.
b) Referencing the matchmarks, connect the No.2
intermediate shaft to the intermediate shaft with the NEW
bolt.
c) Torque bolt to spec.
Torque Spec: 26 ft∙lbs (35 N∙m, 357 kgf∙cm)
d) Disconnect the seat belt that is holding the steering
wheel.
7. RECONNECT THE FRONT DIFFERENTIAL VACUUM
HOSE (4WD ONLY)
NEW Replacement Parts
Part Number
90464-00897
Part Name
Clamp
Kit #
4
Qty
1
a) Reconnect the NEW clamp and vacuum hose.
82
8. RECONNECT THE FRONT BRAKE TUBES
NEW Replacement Parts
Part Number
90412-10266
90412-10267
47314-0C020
47315-0C030
or
47315-0C031
90119-A0169
Part Description
Way, No.1
(For Front Brake Tube)
Way, No.2
(For Front Brake Tube)
Tube, Front Brake, No.4
Kit #
Quantity
1
1
1
1
2
1
Tube, Front Brake, No.5
2
1
Bolt
2
2
a) Reconnect the front brake tube with the NEW bolt and
torque to spec.
Torque Spec: 23 ft∙lbs (31 N∙m, 316 kgf∙cm)
b) Temporarily install the NEW front brake tube.
c) Torque the front NEW brake tube to spec.
LH Side
Torque Spec: 11 ft∙lbs (15.2 N∙m, 155 kgf∙cm)
d) Repeat the procedure on the opposite side.
RH Side
83
9. REINSTALL THE FRONT FENDER APRON SEALS
NEW Replacement Parts
Part Number
90080-46327
Part Name
Clip (For Front Fender Apron Seal)
LH Side
Kit #
2
Qty
22
a) Reinstall the left side 2 front fender apron seals LH /
RH with the 11 NEW clips.
b) Reinstall the right side 2 front fender apron seals LH /
RH with the 11 NEW clips.
RH Side
10. RECONNECT THE VANE PUMP OIL RESERVOIR ASSY
a) Reconnect the vane pump oil reservoir assy with the 3
bolts and torque to spec.
Torque Spec: 71 in∙lbs (8.0 N∙m, 82 kgf∙cm)
b) Reconnect the windshield washer jar assy with the 3
bolts and torque to spec.
Torque Spec: 31 in∙lbs (3.5 N∙m, 36 kgf∙cm)
84
11. REINSTALL THE FOLLOWING PARTS
•
NEW Replacement Parts
Part Number
16492-21050
Part Name
Packing (For Radiator Drain Cock)
Kit #
2
Qty
1
•
•
•
12. RECONNECT THE No.1 COOLER REFRIGERANT
DISCHARGE HOSE
NEW Replacement Parts
Part Number
90099-14120
Part Name
O-Ring
Radiator Assy
° Install the NEW radiator drain cock packing.
° Reinstall the radiator assy with the 4 bolts and
torque to spec.
° Torque Spec: 13 ft∙lbs (18 N∙m, 184 kgf∙cm)
Fan Shroud
° Reinstall the fan shroud with the 2 bolts and torque
to spec.
° Torque Spec: 58 in∙lbs (6.5 N∙m, 66 kgf∙cm)
Radiator Outlet Hose
Radiator Inlet Hose
Kit #
1
Qty
1
a) Install a NEW o-ring to the A/C discharge hose.
b) Reconnect the A/C discharge hose with the bolt and
torque to spec.
Torque Spec: 87 in∙lbs (9.8 N∙m, 100 kgf∙cm)
13. REINSTALL THE FOLLOWING PARTS
•
•
Radiator Side Deflector RH (If Equipped)
Radiator Side Deflector LH
14. REINSTALL THE OIL COOLER
(AIR OIL COOLER EQUIPPED VEHICLES ONLY)
a) Reinstall the oil cooler with the 3 bolts and torque to
spec.
Torque Spec: 10 ft∙lbs (14 N∙m, 143 kgf∙cm)
b) Reconnect the No.1 oil cooler inlet hose and No.1 oil
cooler outlet hose.
c) Reconnect the clamp.
85
15. REINSTALL THE UPPER CENTER FRONT BUMPER
RETAINER
(AIR OIL COOLER EQUIPPED VEHICLES ONLY)
NEW Replacement Parts
Part Number
90179-06178
Part Name
Nut
1GR-FE
Kit #
1
Qty
6
a) Reinstall the front bumper retainer upper center with
the 6 NEW nuts and torque to spec.
Torque Spec: 48 in∙lbs (5.4 N∙m, 55 kgf∙cm)
16. RECONNECT THE AIR PUMP HARNES
a) Reconnect the 2 connectors and 4 clamps.
(1GR-FE)
b) Reconnect the connector and 2 clamps.
(2UZ-FE)
c) Reconnect the 2 connectors and 3 clamps.
(3UR-FE)
2UZ-FE
3UR-FE
86
1GR-FE
17. RECONNECT THE AIR INJECTION SYSTEM HOSES
a) Reconnect the No.5 hose and No.4 hose. (1GR-FE)
b) Reconnect the No.2 Hose and clamp. (2UZ-FE)
c) Reconnect the No.2 hose and No.3 hose. (3UR-FE)
2UZ-FE
3UR-FE
18. RECONNECT THE INLET HEATER HOSE AND OUTLET HEATER HOSE, ENGINE SIDE
19. RECONNECT THE ENGINE WIRE HARNESS (RH SIDE)
a) Reconnect the ground wire with the bolt and torque to
spec.
Torque Spec: 73 in∙lbs (8.3 N∙m, 85 kgf∙cm)
b) Reconnect the skid control sensor connector and
clamp.
87
c) Reconnect the 2 clamps and 3 connectors.
d) Reconnect the 2 clamps and 5 connectors.
e) Reinstall the connector holder block cover upper.
20. RECONNECT THE VACUUM HOSE ASSY
NEW Replacement Parts
Part Number
90069-08009
Part Name
O-Ring
Kit #
2
Qty
1
a) Reconnect the vacuum hose assy.
21. RECONNECT THE No.1 COOLER REFRIGERANT
SUCTION HOSE
a) Install a NEW o-ring to the A/C suction hose.
b) Reconnect the A/C suction hose and torque to spec.
Torque Spec: 87 in∙lbs (9.8 N∙m, 100 kgf∙cm)
22. RECONNECT THE ENGINE WIRE HARNESS (LH SIDE)
a) Reconnect the ground wire with the bolt and torque to
spec.
Torque Spec: 73 in∙lbs (8.3 N∙m, 85 kgf∙cm)
b) Reconnect the 2 clamps and 6 connectors.
88
c) Reconnect the (+) positive battery cable with the nut
and torque to spec.
Torque Spec: 7 ft∙lbs (10 N∙m, 102 kgf∙cm)
d) Reconnect the clamp and 2 connectors.
e) Reinstall the No.1 relay block cover.
f)
Reconnect the clamp.
g) Reconnect the ground wire with the bolt and torque to
spec.
Torque Spec: 73 in∙lbs (8.3 N∙m, 85 kgf∙cm)
h) Reconnect the 2 positive (+) battery cables with the
nut and torque to spec.
Torque Spec: 9 ft∙lbs (12.7 N∙m, 130 kgf∙cm)
89
NEW Replacement Parts
Part Number
90178-A0044
90178-A0067
90189-06236
90080-11717
Part Name
Nut
Nut
Clip
Bolt
* Individual Part(s)
Kit #
2
2
NA*
NA*
Qty
8
6
4
16
23. REINSTALL THE FOLLOWING PARTS
• Air Cleaner Hose and Air Cleaner Assy
(1GR-FE Only)
° Torque Spec:
Air Cleaner Assy - 71 in∙lbs (8.0 N∙m, 82 kgf∙cm)
Air Cleaner Hose - 66 in∙lbs (7.5 N∙m, 76 kgf∙cm)
• Air Cleaner Hose and Air Cleaner Assy
(2UZ-FE, 3UR-FE Only)
° Torque Spec: 44 in∙lbs (5.0 N∙m, 51 kgf∙cm)
• Throttle Body Cover Sub- Assy (2UZ-FE Only)
° Torque Spec: 66 in∙lbs (7.5 N∙m, 76 kgf∙cm)
• V-Bank Cover Sub- Assy (1GR-FE, 3UR-FE Only)
° Torque Spec: 66 in∙lbs (7.5 N∙m, 76 kgf∙cm)
(1GR-FE Only)
• Front Fender Mudguard LH/RH (If Equipped)
• No.2 Front Bumper Extension Sub-Assy LH/RH
° Reinstall the No.2 front bumper extension Sub-Assy
with 8 NEW nuts and torque to spec.
° Torque Spec: 43 ft∙lbs (58 N∙m, 591 kgf∙cm)
• Front Bumper Reinforcement Sub-Assy
° Reinstall the front bumper reinforcement Sub-Assy
with 6 NEW nuts and torque to spec.
° Torque Spec: 52 ft∙lbs (71 N∙m, 724 kgf∙cm)
• Front Bumper Assy
(Steel Bumper Equipped Vehicles Only)
° Reinstall the front bumper bar with the 8 bolts and
4 NEW clips, then torque to spec.
° Torque Spec: Bolt 24 ft∙lbs (32 N∙m, 326 kgf∙cm)
° Reinstall the front bumper cover with the 16 NEW
bolts, 10 clips and 2 screws.
• Front Bumper Cover Assy
(Resin Bumper Equipped Vehicles Only)
° Reinstall with the 6 screws and 16 clips.
• Front Fender Splash Shield Sub-Assy LH/RH
• Front End Panel LH/RH
• Front Wheels
24. REINSTALL THE FOLLOWING PARTS
•
•
•
•
•
•
•
•
•
•
•
•
Lower LH Quarter Trim Panel Assy (Regular Cab Only)
Front Seat Outer Belt Assy LH (Regular Cab Only)
° Reconnect the front seat outer belt assy LH.
° Torque Spec: 31 ft∙lbs (42 N∙m, 428 kgf∙cm)
Upper Back Panel Garnish (Regular Cab Only)
Luggage Compartment Box LH (Regular Cab Only)
Floor Carpet is returned (Double Cab Only)
Back Panel Trim LH/RH (Crewmax Only)
No.1 w/ Box Speaker Assy (If Equipped)
Jack and Tool (Standard Tool)
No.2 Dash Panel Insulator Pad
No.3 Dash Panel Insulator Pad
Cowl Side Trim Board LH/RH
Front Door Scuff Plate LH/RH
90
J. REINSTALL THE REAR BED ASSY
1. REINSTALL THE REAR BED ASSY
a) Using a Torx® T55H Tamper Resistant Socket, reinstall the rear bed assy Torx ® bolts and torque to
spec.
• Long Bed: 8 Torx® bolts
• Standard Bed and Crewmax (Short Bed): 6 Torx® bolts
Torque Spec: 44 ft∙lbs (66 N∙m, 673 kgf∙cm)
NOTE:
• Use 4 or more people to install the rear bed assy from the frame.
• Evenly support the rear bed assy when reinstalling it.
• Be careful not to damage or hit the fuel inlet pipe when reinstalling the rear bed assy.
•
If you find excessive corrision around the bed mounting bolts and believe the bed
cannot be securly reattached after removal, contact your FTS
2. REINSTALL THE FUEL TANK INLET PIPE SUB-ASSY
NEW Replacement Parts
Part Number
90178-A0049
Part Name
Nut
Kit #
2
Qty
2
a) Reinstall the fuel inlet pipe sub-assy with the 2 NEW
nuts and torque to spec.
Torque Spec: 15 ft∙lbs (20 N∙m, 204 kgf∙cm)
91
3. RECONNECT THE FRAME WIRE HARNESS
a) Reconnect the clamps, connectors and the frame wire
harness to the rear bed assy.
NOTE:
The number of connectors will differ depending on
the vehicle spec.
• Use new clamps if the original ones are damaged.
•
4. REINSTALL THE FOLLOWING PARTS
NEW Replacement Parts
Part Number
90119-A0219
90119-A0219
90119-A0271
90119-A0271
Part Name
Bolt (w/o Towing Hitch)
Bolt (w/ Towing Hitch)
Bolt (w/o Towing Hitch)
Bolt (w/ Towing Hitch)
* Individual Part(s)
Kit #
NA*
NA*
NA*
NA*
Qty
4
10
4
2
•
•
•
•
•
•
•
No.1 Rear Wheel House Liner LH
Fuel Filler Opening Lid Sub- Assy
Side Step Assy LH/RH (If Equipped)
Rear Bumper Assy
° Reinstall the rear bumper assy with the 12 NEW
bolts and torque to spec.
(Trailer Hitch Equipped Vehicles Only)
° Reinstall the rear bumper assy with the 8 NEW bolts
and torque to spec.
° Torque Spec: 113 ft∙lbs (153 N∙m, 1560 kgf∙cm)
Rear Quarter panel Mudguard LH/RH (If Equipped)
No.3 Frame Wire
License Plate Light Assy LH/RH
92
K. FINAL ASSEMBLY
1. REINSTALL THE NEGATIVE (-) BATTERY TERMINAL
2. REFILL THE FOLLOWING FLUIDS
•
NEW Replacement Parts
Part Number
12157-10010
90430-24003
Part Name
Gasket, Front Differential Filler Plug
Gasket (For Front Differential
Drain Plug)
Kit #
3
Qty
1
3
1
•
•
Brake Fluid
° Remove the brake tubes from the master cylinder.
° Refill with Toyota Dot 3 Brake Fluid.
° Bleed the master cylinder.
° Reinstall the brake tubes to the master cylinder and
torque to spec.
° Torque Spec: 11 ft∙lbs (15.2 N∙m, 155 kgf∙cm)
° Refill with Toyota Dot 3 Brake Fluid.
° Bleed the brake system at each wheel and torque
the bleeder screws to spec.
° Torque Spec: 8 ft∙lbs (11 N∙m, 112 kgf∙cm)
Coolant
° Refill with Toyota Long Life Coolant.
° Bleed the cooling system.
Front Differential
° Install a NEW drain plug washer and torque to
spec.
° Torque Spec: 29 ft·lbs (39.2 N·m, 400 kgf·cm)
° Refill with Hypoid Gear Oil API GL-5 75W-90.
° Install a NEW filler plug washer and torque to spec.
° Torque Spec: 29 ft·lbs (39.2 N·m, 400 kgf·cm)
3. START THE VEHICLE AND INSPECT THE FOLLOWING FOR LEAKS
•
•
•
•
Fuel System
° Start the engine and let it run for 5 seconds, then stop the engine and inspect for leaks.
° If there are no leaks, restart the engine and re-inspect.
Cooling System
Brake System
Front Differential System
4. RECHARGE THE A/C SYSTEM AND CHECK FOR PROPER OPERATION AND REFRIGERANT LEAKS
5. CHECK THE OPERATION OF THE FOLLOWING SYSTEMS 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 systems
listed below. This is an important step, and must be performed thoroughly to ensure proper
operation of these systems.
•
•
Parking Brake Travel
Shift Control Lever
6. CHECK ALL FLUID LEVELS AND ADJUST AS NEEDED
93
7. TORQUE THE FRONT AXLE NUT (4WD ONLY)
NEW Replacement Parts
Part Number
95381-04050
43514-34020
43514-34020
Part Name
Kit #
Cotter Pin
3
Cap, Front Axle Hub Grease, RH
3
Cap, Front Axle Hub Grease, LH
3
Qty
2
1
1
a) Remove the front wheels.
b) Torque the front axle nut to spec.
Torque Spec: 249 ft∙lbs (338 N∙m, 3447 kgf∙cm)
c)
d)
e)
f)
Reinstall the lock cap with the NEW cotter pin.
Reinstall the NEW grease cap.
Repeat the procedure on the opposite side.
Reinstall the front wheels and torque to spec.
Torque Spec:
Aluminum Wheel - 97 ft∙lbs (131 N∙m, 1336 kgf∙cm)
Steel Wheel - 154 ft∙lbs (209 N∙m, 2131 kgf∙cm)
NOTE:
If the holes for the cotter pin are not aligned, tighten
the axle nut further, up to 60 degree.
8. PERFORM A WHEEL ALIGNMENT
9. CHECK THE HEADLIGHT AIM AND ADJUST AS NEEDED
10. REINSTALL THE ENGINE UNDER COVER No.1
NEW Replacement Parts
Part Number
90119-A0169
90119-A0169
Part Name
Bolt (Large TYPE)
Bolt (Small TYPE)
* Individual Part(s)
Kit #
NA*
NA*
Qty
5
2
a) Reinstall the engine under cover No.1 with 5 NEW bolts
and 3 screws, then torque to spec.
(Front Bumper Chrome Plated Type)
b) Reinstall the engine under cover No.1 with 2 NEW bolts
and 3 screws, then torque to spec.
(Front Bumper Resin Type)
Torque Spec: 21 ft∙lbs (29 N∙m, 296 kgf∙cm)
11. CHECK FOR DTC’S AND REPAIR AS NEEDED
12. PERFORM INITIALIZATION
1. FINAL INSPECTION
a) Check the operation of the following systems:
• 4WD System (4WD Only)
• Power Windows
• Interior Lights
• Power Door Locks
• Exterior Lights
• All Gauges, Indicators and Warning Lights
• HVAC System
• Cooling Fans
• Audio System
• Etc.
2. TEST DRIVE THE VEHICLE AND DOCUMENT FINAL REPAIR STATUS
a) Test drive the vehicle and perform final repair sign off with the Frame Replacement Inspection Sheet.
This must be performed and signed off by an MDT, Shop Foreman or Service Manager and retained
with Final R.O.
94
3. RECORD THE FRAME SERIAL NUMBER
a) Log into the frame tracker website using your dealer code and password.
URL: https://zh-frame-tracker.imagespm.info/
Default password: xxxxx
b) Select 2007 to 2008 Tundra ZH7 from the pick list.
c) Enter the VIN of the vehicle.
95
d) Enter the frame serial off of the case label along with the R.O. number and Approved Frame Inspection Case
Number.
e) Press submit and print a copy of the serial number and file with the R.O.
1. 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.
96