ZH6_05-10_Tacoma

TECHNICAL INSTRUCTIONS
FOR
WARRANTY ENHANCEMENT PROGRAM ZH6
*****************************
CERTAIN 2005 THROUGH 2010 MODEL YEAR TACOMA
*****************************
FRAME REPLACEMENT
UPDATED 3-1-2018
Update 3-1-18
- Frame part numbers corrected
Update 2-15-18
- Parts information updated
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 ELearning 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)
° 2TR-FE Engine
- 12281-75040 – Engine hanger no. 1 (Qty: 1)
- 12281-75040 – Engine hanger no. 2 (Qty: 1)
- 91552-A1020 – Bolt (Qty: 2)
Engine hoist (Qty: 2) or Hydraulic mini crane (Qty 2)
Engine sling (Qty: 2)
Protective eyewear
Protective gloves
Ratcheting tie down strap (2 in X 27 ft, minimum work load capacity: 3,000 lbs)
Special Service Tools (SST)
° 07110-58060 – Air conditioner service tool set or Commercially available air conditioning manifold
gauge set
° 09325-40010 – Transmission oil plug (Transmission A340E)
° 09610-20012 – Pitman arm puller (2WD)
° 09628-62011 – Ball joint puller (4WD, Pre-Runner)
° 09520-32040 – A component of SST 09520-24010, Differential side gear shaft puller
° 09520-01010 – Drive shaft remover attachment
° 09628-00011 – Ball joint puller
° 09922-10010-01 – Variable open wrench
Standard hand tools
Techstream
Torque wrench
Torx® T55H socket
Socket wrench 36mm
Hexagon wrench 8, 10
Deep socket wrench 10, 12, 14, 17, 19mm
Union Nut Wrench 10mm
Weights
Drill
B. SUPPLIES
•
•
•
•
•
•
•
Toyota Genuine ATF WS or DEXRON® lll (DEXRON® ll) – As needed
Hypoid gear oil API GL-5 SAE 75W-90 – 1.5 liter (4wd Only)
R134a refrigerant – As needed
Toyota DOT 3 brake fluid – 3 pints
Toyota long life coolant – 2 gallons
Paint Marker
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 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, confirm campaign completion status,
or confirm campaign applicability.
•
•
•
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
04001-76104
04001-76204
04001-76304
04001-76404
04001-76504
04001-76604
04001-76704
04001-77604
04001-76904
04001-77104
04001-77204
04001-77304
04001-77404
04001-77504
04006-63104
04006-63204
04006-63304
04006-63404
04006-63504
04006-63604
04006-63704
04006-63804
04006-63904
04006-64104
04006-64204
04006-64304
04006-64404
04006-64504
Part Description
(RCB 2WD 2TR 5MT or 4AT 05-08MY)
(ACB 2WD 2TR 5MT or 4AT 05-08MY)
(ACB 2WD 1GR 6MT 05-08MY)
(RCB 4WD 2TR 5MT 05-08MY)
(ACB 4WD 2TR 5MT 05-08MY)
(ACB 4WD 1GR 6MT or 5AT 05-08MY)
(DCB 4WD 1GR 6MT or 5AT 05-08MY)
(RCB Prerunner 4WD 2TR 5MT 05-08MY)
(ACB 2WD 2TR 5MT 05-08MY)
(ACB 2WD 1GR 5AT 05-08MY)
(ACB 2WD 1GR 6MT 05-08MY)
(DCB 2WD 1GR 5AT 05-08MY)
(DCB 2WD 1GR 5AT Super Long 05-08MY)
(DCB 2WD 1GR 5AT super long 05-08MY)
(RCB 2WD 2TR 5MT or 4AT 09 -10 MY)
(ACB 2WD 2TR 5MT or 4AT 09 -10 MY)
(ACB 2WD 1GR 6MT 09 -10 MY)
(RCB 4WD 2TR 5MT 09 -10 MY)
(ACB 4WD 2TR 5MT 09 -10 MY)
(ACB 4WD 1GR 6MT or 5AT 09 -10 MY)
(DCB 4WD 1GR 6MT or 5AT 09 -10 MY)
(RCB Prerunner 2WD 2TR 5MT 09-10 MY)
(ACB 2WD 2TR 5MT 09-10 MY)
(ACB 2WD 1GR 5AT 09-10 MY)
(ACB 2WD 1GR 6MT 09-10 MY)
(DCB 2WD 1GR 5AT 09-10 MY)
(DCB 2WD 1GR 5AT Super Long 09-10 MY)
(DCB 4WD 1GR 5AT Super Long 09-10 MY)
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
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
Page
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
3
Individual Parts (Continued):
Part Number
Part Description
Quantity
Illustration Name
Page
43425-04040
47323-04160
47324-04120
47325-04160
47325-04170
47325-04180
47325-04190
47325-04200
47325-04210
47326-04130
47326-04140
47326-04150
47326-04160
47326-04170
47326-04180
Ring, Drive Shaft Snap
Tube, RR Brake, No.3
Tube, RR Brake, No.4
Tube, RR Brake, No.5 (05-08MY)
Tube, RR Brake, No.5 (05-08MY)
Tube, RR Brake, No.5 (05-08MY)
Tube, RR Brake, No.5 (09-10MY)
Tube, RR Brake, No.5 (09-10MY)
Tube, RR Brake, No.5 (09-10MY)
Tube, RR Brake, No.6 (05-08MY)
Tube, RR Brake, No.6 (05-08MY)
Tube, RR Brake, No.6 (05-08MY)
Tube, RR Brake, No.6 (09-10MY)
Tube, RR Brake, No.6 (09-10MY)
Tube, RR Brake, No.6 (09-10MY)
Arm Sub-Assy, Suspension LWR RH w/ Bush
Arm Sub-Assy, Suspension LWR RH w/ Bush
Arm Sub-Assy, Suspension LWR LH w/ Bush
Arm Sub-Assy, Suspension LWR LH w/ Bush
Spring Assy, RR RH
Spring Assy, RR RH
Spring Assy, RR RH
Spring Assy, RR LH
Spring Assy, RR LH
Spring Assy, RR LH
Bumper Sub-Assy, FR Spring
Bumper Sub-Assy, FR Spring
Wire, Skid Control Sensor
Wire, Skid Control Sensor
Wire, Skid Control Sensor
Wire, Skid Control Sensor
Bolt, U
Bolt, U
Bolt, U
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Nut, Flange
Nut
Pin, w/ Hole
Clip
Clamp
Clamp
Clamp
Carrier Assy, Spare Wheel
Carrier Assy, Spare Wheel
Seal, Frame Side Rail, RH*
Seal, Frame Side Rail, LH*
Nut w/Flange*
Bolt with Washer*
Clip
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Front Suspension
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
10
12-14
12-14
12,15
13,16
14,17
1
1
1
1
Front Suspension
Front Suspension
Front Suspension
Front Suspension
9
10
9
10
1
1
1
1
1
1
2
2
1
1
1
1
4
4
4
4
2
4
9
2
4
4
1
1
2
3
4
1
1
1
1
2
2
2
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Front Suspension
Front Suspension
ABS
ABS
ABS
ABS
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Propeller Shaft
Front Suspension
Brake Tubes
Under Cover
Front Suspension
Fuel Tank
Shift Lever
Shift Lever
Brake Tubes
Brake Tubes
Brake Tubes
Spare Tire Carrier
Spare Tire Carrier
No Illustration
No Illustration
No Illustration
No Illustration
No Illustration
11
11
11
11
11
11
9
9
19
19
19
19
11
11
11
11
21
9
12-18
8
9
18
23
23
12,15
13,16
14,17
8
8
N/A
N/A
N/A
N/A
N/A
48068-04030
48068-04040
48069-04030
48069-04040
48210-04370
48210-04380
48210-AD020
48220-04160
48220-04170
48220-AD020
48304-04090
48304-AD010
89516-04010
89516-04020
89516-04040
89516-04090
90117-A0001
90117-A0002
90117-A0005
90119-08A91
90119-A0151
90119-A0161
90119-A0169
90119-A0193
90178-A0013
90179-08241
90240-08054
90468-14033
90469-A0004
90469-A0004
90469-A0004
51900-35410
51900-35420
5114A-04010
5114B-04010
90178-A0024
90119-A0170
90080-46327
12,15
13,16
14,17
*Note Frame seal and mounting hardware are only needed for frames that do not come with them previously installed.
4
Parts Kits:
Part Number
04001-71104
Part Description
Parts Kit No.1 – Common Replacement Kit A
Quantity
1
The kit listed above includes the following parts:
Part Number
77285-35760
90179-10201
90412-10247
90910-03001
91671-80814
94622-51400
Part Number
04001-71204
Part Description
Support, Fuel Return & Main Tube
Nut
Way, 2
Bolt, Engine Mount
Bolt, Flange w/ Washer
Washer, Plain
Qty
1
4
2
4
4
10
Illustration Name
Fuel Tubes
Engine Mounting
Brake Tubes
Engine Mounting
Engine Mounting
Rear Suspension
Part Description
Parts Kit No.2 – Common Replacement Kit B (2wd Non-PreRunner)
Page
18
20
12-17
20
20
11
Quantity
1
The kit listed above includes the following parts:
Part Number
04483-04080
17451-0A010
47355-04020
51719-04010
90069-08019
90080-10138
90080-11376
90080-11555
90080-17215
90119-A0169
90119-A0192
90171-A0005
90177-A0010
90178-A0044
90178-A0050
90210-A0002
90210-A0004
90412-10248
90468-A0007
90949-A1006
Part Number
04006-54104
Part Description
Shackle Kit, RR Spring
Gasket, Exhaust Pipe
Bracket, Flexible Hose, No. 5
Holder, Body Support Bracket
Ring, O
Bolt, Flange
Bolt, w/ Washer
Bolt, w/ Washer
Nut, Flange
Bolt, w/ Washer
Bolt, w/ Washer
Nut, Castle
Nut, Lock
Nut, Flange
Nut, Flange
Washer, Seal
Washer, Seal
Way, 2
Clip
Clamp
Qty
2
1
1
2
1
2
2
2
6
4
6
2
2
6
10
1
1
1
4
3
Illustration Name
Rear Suspension
Exhaust System
Brake Tubes
Cab Mounting
Radiator
Rear Suspension
Fuel Tank
Power Steering
Front Suspension
Spare Tire carrier
Rear Bumper
Front Suspension
Rear Suspension
Front Bumper
Rear Suspension
Air Conditioning
Air Conditioning
Brake Tubes
Brake Tubes
Brake Tubes
Part Description
Parts Kit No.2 – Common Replacement Kit C (4WD and PreRunner)
Page
11
22
12-17
8
23
11
18
20
9,10
8
23
9-10
11
23
11
23
23
12-17
12-18
12-17
Quantity
1
The kit listed above includes the following parts:
Part Number
17451-0A010
47355-04020
51719-04010
90069-08019
90080-10138
90080-A0249
90080-11555
90080-17215
90119-A0169
90119-A0192
90171-A0005
90177-A0010
90178-A0044
90178-A0050
90210-A0002
90210-A0004
90412-10248
90468-A0007
90949-A1006
Part Description
Gasket, Exhaust Pipe
Bracket, Flexible Hose, No. 5
Holder, Body Support Bracket
Ring, O
Bolt, Flange
Bolt, w/ Washer
Bolt, w/ Washer
Nut, Flange
Bolt, w/ Washer
Bolt, w/ Washer
Nut, Castle
Nut, Lock
Nut, Flange
Nut, Flange
Washer, Seal
Washer, Seal
Way, 2
Clip
Clamp
Qty
1
1
2
1
2
2
2
6
4
6
2
2
6
10
1
1
1
4
3
Illustration Name
Exhaust System
Brake Tubes
Cab Mounting
Radiator
Rear Suspension
Fuel Tank
Power Steering
Front Suspension
Spare Tire carrier
Rear Bumper
Front Suspension
Rear Suspension
Front Bumper
Rear Suspension
Air Conditioning
Air Conditioning
Brake Tubes
Brake Tubes
Brake Tubes
Page
22
12-17
8
23
11
18
20
9,10
8
23
9-10
11
23
11
23
23
12-17
12-18
12-17
5
Part Number
04001-71304
Part Description
Parts Kit No.3 – JPN Source Parts kit 1 (4WD 05-08MY)
Quantity
1
The kit listed above includes the following parts:
Part Number
12157-10010
43514-28010
90311-47027
90311-47013
90430-24003
95381-04045
Part Number
04006-46104
Part Description
Gasket, Drain Plug
Cap, FR Hub Grease
Seal, Type T Oil
Seal, Type T Oil
Gasket
Pin, Cotter
Qty
1
2
1
1
1
2
Illustration Name
Front Differential
Front Suspension
Front Differential
Front Differential
Front Differential
Front Suspension
Part Description
Parts Kit No.3 – JPN Source Parts kit 4 (4WD 09-10MY)
Page
20
10
20
20
20
10
Quantity
1
The kit listed above includes the following parts:
Part Number
12157-10010
43514-28010
90311-47026
90311-47027
90430-24003
95381-04045
Part Description
Gasket, Drain Plug
Cap, FR Hub Grease
Seal, Type T Oil
Seal, Type T Oil
Gasket
Pin, Cotter
Qty
1
2
1
1
1
2
Illustration Name
Front Differential
Front Suspension
Front Differential
Front Differential
Front Differential
Front Suspension
Page
20
10
20
20
20
10
Part Number
Part Description
Quantity
04001-71404
Parts Kit No.4 – JPN Source Parts kit 2
1
The kit listed above includes the following parts:
Part Number
48190-25010
48198-25010
95381-03025
95381-03230
Part Number
04001-71504
Part Description
Cam Assy, Camber Adjust
Cam, Camber Adjust, No. 2
Pin, Cotter
Pin, Cotter
Qty
4
4
2
2
Illustration Name
Front Suspension
Front Suspension
Power Steering
Front Suspension
Part Description
Parts Kit No.5 – JPN Source Parts kit 3
Page
9
9
20
9
Quantity
1
The kit listed above includes the following parts:
Part Number
48190-60020
48198-60011
48409-60020
48452-35020
95381-03225
95381-03230
Part Description
Cam Assy, Camber Adjust
Cam, Camber Adjust, No. 2
Cam Assy, Camber Adjust
Plate, Toe Adjust, No. 2
Pin, Cotter
Pin, Cotter
Qty
2
2
2
2
2
2
Illustration Name
Front Suspension
Front Suspension
Front Suspension
Front Suspension
Power Steering
Front Suspension
Page
10
10
10
10
20
10
Part Number
Part Description
Quantity
04001-71604
Parts Kit No.6 – USA Source Parts kit 1 (1GR)
1
The kit listed above includes the following parts:
Part Number
17176-0P010
90080-10291
90080-11180
90080-17187
90080-43036
90126-A0011
Part Description
Gasket, Air Surge Tank to INT Manifold
Bolt
Bolt, w/ Washer
Nut, Lock
Gasket, Exhaust Pipe
Stud, Hex Lobular
Qty
1
2
2
4
2
4
Illustration Name
Exhaust System
Exhaust System
Exhaust System
Exhaust System
Exhaust System
Exhaust System
Page
22
22
22
22
22
22
6
Part Number
04001-71704
Part Description
Parts Kit No.7 – USA Source Parts kit 2 (2TR)
Quantity
1
The kit listed above includes the following parts:
Part Number
90080-43033
90080-10064
90080-10291
90177-A0004
Part Number
04001-71804
Part Description
Gasket, Exhaust Pipe
Bolt, Flange
Bolt
Nut, Lock
Qty
1
2
2
2
Illustration Name
Exhaust System
Exhaust System
Exhaust System
Exhaust System
Part Description
Parts Kit No.8 – USA Source Parts kit 3
Page
22
22
22
22
Quantity
1
The kit listed above includes the following parts:
Part Number
48304-04100
75395-35070
75396-35020
90080-11373
90119-A0166
90119-A0192
90189-A0002
90189-A0002
Part Number
04001-71904
Part Description
Bumper Sub-Assy, FR Spring
Clip, Outside Molding, No. 1
Clip, Outside Molding, No. 2
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Grommet, Screw
Grommet, Screw
Qty
2
3
7
8
2
2
8
2
Illustration Name
Front Suspension
Molding
Molding
Under Cover
Front Suspension
Under Cover
Rear Wheel House Liner
Molding
Part Description
Parts Kit No.9 – USA Source Parts kit 4
Page
10
23
23
8
10
8
24
23
Quantity
1
The kit listed above includes the following parts:
Part Number
75395-04010
75395-35070
75396-04010
75396-35020
90189-A0002
90189-A0002
Part Number
04001-72104
Part Description
Clip, Outside Molding, No. 1
Clip, Outside Molding, No. 1
Clip, Outside Molding, No. 2
Clip, Outside Molding, No. 2
Grommet, Screw
Grommet, Screw
Qty
4
4
14
2
6
2
Illustration Name
Molding
Molding
Molding
Molding
Rear Wheel House Liner
Molding
Part Description
Parts Kit No.10 – Brake Tube kit 1 (without VSC)
Page
24
24
24
24
24
24
Quantity
1
The kit listed above includes the following parts:
Part Number
47313-04190
47315-04160
Part Number
04001-72204
Part Description
Tube, FR Brake, No.3
Tube, FR Brake, No.5
Qty
1
1
Illustration Name
Brake Tubes
Brake Tubes
Part Description
Parts Kit No.11 – Brake Tube kit 2 (with VSC)
Page
12-14
12-14
Quantity
1
The kit listed above includes the following parts:
Part Number
47313-04200
47315-04170
47323-04170
47324-04130
Part Description
Tube, FR Brake, No.3
Tube, FR Brake, No.5
Tube, RR Brake, No.3
Tube, RR Brake, No.4
Qty
1
1
1
1
Illustration Name
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Page
15-17
15-17
15-17
15-17
7
Part Number
04001-72304
Part Description
Parts Kit No.12 – Brake Tube kit 3 (for 2WD)
Quantity
1
The kit listed above includes the following parts:
Part Number
Part Description
Qty
Illustration Name
47314-04140
Tube, FR Brake, No.4
1
Brake Tubes
47316-04140
Tube, FR Brake, No.6
1
Brake Tubes
47351-04030
47352-04030
Bracket, Flexible Hose, RH
Bracket, Flexible Hose, LH
1
1
Brake Tubes
Brake Tubes
Part Number
04001-72404
Part Description
Parts Kit No.13 – Brake Tube kit 4 (for 4WD, PRE-RUNNER)
Page
12,13,
15,16
12,13,
15,16
18
18
Quantity
1
The kit listed above includes the following parts:
Part Number
47314-04150
47316-04150
47353-04010
47354-04010
90119-A0169
Part Number
04007-18135
Part Description
Tube, FR Brake, No.4
Tube, FR Brake, No.6
Bracket, Flexible Hose, No. 3
Bracket, Flexible Hose, No. 4
Bolt, w/ Washer
Qty
1
1
1
1
7
Illustration Name
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Part Description
Plug Hole Kit 4x4 and PreRunner (You may not use all plugs provided in the kit)
Page
12-17
12-17
18
18
12-18
Quantity
1
The kit listed above includes the following parts:
Part Number
90950-01983
90950-01984
90950-01987
90950-01989
90950-01991
90950-01990
90950-01992
90950-01A24
90950-01931
90950-01631
90333-20001
90333-30002
Part Number
04007-18235
Part Description
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
Qty
4
2
8
4
4
4
2
2
1
4
10
28
Illustration Name
Part Description
Plug Hole Kit 4x2 (You may not use all plugs provided in the kit)
Page
Quantity
1
The kit listed above includes the following parts:
Part Number
90950-01983
90950-01984
90950-01A09
90950-01987
90950-01989
90950-01991
90950-01990
90950-01992
90950-01A11
90950-01A24
90950-01931
90950-01631
90333-20001
90333-30002
Part Description
PLUG , HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
PLUG, HOLE
Qty
4
2
2
6
4
4
4
2
2
2
1
4
2
36
Illustration Name
Page
8
D. PARTS ILLUSTRATION
Frame
Cab Mounting
Under Cover
Spare Tire Carrier
9
Front Suspension
10
Front Suspension Continued…
11
Rear Suspension
12
Brake Tubes
13
Brake Tubes Continued…
14
Brake Tubes Continued…
15
Brake Tubes Continued…
16
Brake Tubes Continued…
17
Brake Tubes Continued…
18
Brake Tubes Continued…
Fuel Tank
90119-A0249
90119-A0249
Fuel Tubes
19
ABS
Wire Harness Clamps
20
Power Steering
Front Differential
Engine Mounting
Or
90311-47026
Or
90311-47027
21
Propeller Shaft
22
1GR-FE Exhaust System
2TR-FE Exhaust System
23
Shift Lever
Radiator
Air Conditioning
Front Bumper
Rear Bumper
Molding
24
Rear Wheel House Liner
Molding
Moulding Continued…
25
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
26
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.
Tacoma 05 to 10
b. Select Section A
Note: The frame inspection application must be completed in alphabetical order.
27
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.
28
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.
29
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.
30
31
32
C. REMOVE THE 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 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
•
•
•
•
•
Rear Bumper Assy
Rear Tail/Combination Light LH/RH
Rear Mudguard LH/RH (If Equipped)
Side Step Assy LH/RH (If Equipped)
Rocker Panel Molding LH/RH (If Equipped)
•
•
•
•
Body Rocker Panel Molding Assy LH (If Equipped)
Outside LH Back Door Molding Sub-Assy (If Equipped)
Quarter Panel Wheel Opening Molding LH
Left Rear Wheel Well Liner
NOTE: Be careful not to damage the rear tail/combination lights when removing them.
3. REMOVE THE 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 INLET PIPE SUB-ASSY
a) Remove the bolt and disconnect the fuel inlet pipe subassy.
5. REMOVE THE BED ASSY
a) Using a Torx® T55H Socket, remove the 6 Torx ® bolts
from the bed assy.
NOTE:
• Use 4 or more people to remove the bed assy from
the frame.
• Evenly support the bed assy when removing it.
• Be careful not to damage the filler tubes when
removing the bed.
33
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 the appropriate repair manual in TIS for the
vehicle you are working on.
1. CHECK FOR DTCs
2. RECORD THE RADIO STATION PRESETS
3. DISCHARGE THE FUEL SYSTEM PRESSURE
a) Remove the No. 2 fuel tank protector. (If Equipped)
b)
c)
d)
e)
Disconnect the fuel pump connector.
Start the engine.
After the engine, has stopped, turn the ignition switch OFF.
Crank the engine again to check that it does not start.
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.
4. 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.).
34
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 vehicle when performing cab 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 the appropriate repair manual in TIS for the
vehicle you are working on.
1. REMOVE THE ENGINE UNDER COVERS
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 (including engine block)
Brake Fluid
•
•
Clutch Fluid (Manual Transmission Vehicles Of 1GR-FE Only)
Front Differential Fluid (4WD Only)
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 BODY COMPONENTS
•
•
•
Radiator Grille
Front Bumper Filler LH/RH
Front Fender Mudguard LH/RH
•
•
•
Front Bumper Assy
Front Bumper Reinforcement
Front No.2 Bumper Extension Sub-assy LH/RH
5. REMOVE THE FOLLOWING INTERIOR COMPONENTS
•
•
Front Door Scuff Plate LH/RH
Front Floor Footrest
•
Cowl Side Trim Board LH/RH
6. REMOVE THE INSTRUMENT PANEL BOX
35
7. DISCONNECT THE FRAME WIRE HARNESS
a) Disconnect the 5 clamps.
b) Disconnect the connector(s).
c) Remove the frame wire harness grommet from the cab
assy.
d) Pull out the frame wire harness from the vehicle cab
assy.
NOTE: The number of connectors may differ
depending on the model.
8. REMOVE THE GLOVE BOX AND LOWER INSTRUMENT
PANEL FINISH PANEL
a) Remove the glove box.
b) Remove the bolt and the lower instrument panel finish
panel.
9. DISCONNECT THE ENGINE WIRE HARNESS
a) Disconnect each connector and clamp from the ECM
and remove the engine wire harness.
NOTE: The number of connectors may differ
depending on the model.
10. REMOVE THE FOLLOWING PARTS
• Rear Console Box (for Separate Seat Type)
• Front Console Box
•
•
Voltage Inverter Assy (If Equipped)
Manual Transmission Shift Lever (Manual Trans Vehicles Only)
36
11. DISCONNECT THE PARKING BRAKE CABLES
For Separate Seat Type:
a) Remove the 2 clips.
b) Disconnect the 2 parking brake cables.
For Bench Seat Type:
c) Turn back the floor carpet.
d) Remove the 3 bolts and the parking brake cable joint
protector.
e) Remove the 2 clips.
f) Disconnect the 2 parking brake cables.
12. REMOVE THE FOLLOWING PARTS
•
V-Bank Cover (1GR-FE Only)
•
Air Cleaner Hose and Air Cleaner Assy
13. DISCONNECT THE NO.2 ENGINE WIRE HARNESS
a) Remove the nut and disconnect the (+) positive battery
cable.
b) Remove the bolt and disconnect the ground wire.
c) Disconnect the 2 clamps.
d) Remove the No.1 upper relay block cover.
e) Disconnect the 3 connectors.
f) Remove the nut and disconnect the fuse box wire
harness.
37
LH Side
14. DISCONNECT THE SKID CONTROL SENSOR WIRE
HARNESS
a) Disconnect the harness clamp and front skid control
sensor connector.
b) Repeat the procedure on the opposite side.
RH Side
15. DISCONNECT THE FRONT DIFFERENTIAL BREATHER
TUBES (4WD ONLY)
a) Disconnect the front differential breather tubes.
NOTE: There may be 2 front differential breather tubes
depending on the vehicle model.
16. DISCONNECT THE FUEL PIPES AND VAPOR FEED
HOSE
a) Remove the 2 fuel pipe clamps.
b) Disconnect the No. 1 and No. 2 fuel pipe.
NOTE: Put a shop towel under the fuel pipe to catch
any spilled fuel.
17. DISCONNECT THE VACUUM HOSE
a) Disconnect the vacuum hose.
38
18. REMOVE THE FOLLOWING PARTS
• Radiator Support to Frame Seal
• Radiator Inlet Hose
• Radiator Outlet Hose
•
•
Fan Shroud
Radiator Assy
19. DISCONNECT THE NO.1 HOSE (2TR-FE ONLY)
a) Disconnect the No.1 hose.
20. DISCONNECT THE GROUND WIRE (2TR-FE ONLY)
a) Remove the bolt and disconnect the ground wire.
21. DISCONNECT POWER STEERING PUMP OIL
RESERVOIR ASSY (1GR-FE ONLY)
a) Disconnect power steering pump oil reservoir assy.
22. DISCONNECT THE GROUND WIRE (1GR-FE ONLY)
a) Remove the bolt and disconnect the clamp and the
ground wire.
23. DISCONNECT THE ENGINE WIRE HARNESS
a) Disconnect the clamp.
b) Remove the engine wire harness container from the
cowl panel.
24. DISCONNECT THE WATER / HEATER HOSES, ENGINE SIDE
LH Side
25. REMOVE THE FRONT FENDER APRON SEALS
4WD, Pre-Runner Only (Shown):
a) Remove the 20 clips and 4 front fender apron seals.
2WD Only:
b) Remove the 22 clips and 4 front fender apron seals.
RH Side
39
26. DISCONNECT THE AIR CONDITIONING DISCHARGE AND SUCTION HOSES FROM THE
COMPRESSOR
LH Side
27. DISCONNECT THE FRONT BRAKE TUBES
a) Disconnect the front brake tube.
b) Repeat the procedure on the opposite side.
RH Side
28. DISCONNECT THE STEERING SLIDING YOKE
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
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, to prevent damage to the
spiral cable.
c) Place match marks on the steering sliding yoke and
No.2 intermediate shaft.
d) Loosen bolt (A) and remove bolt (B).
e) Disconnect the steering sliding yoke from the No.2
intermediate shaft.
NOTE: If the steering sliding yoke is stuck, tap it from
below with a brass hammer to disconnect it.
29. DISCONNECT THE SHIFT CABLE (AUTO TRANS ONLY)
Cable Type:
a) Remove the clip.
b) Remove the nut and disconnect the shift cable.
Rod Type:
c) Remove the pin and clip, disconnect the shift cable.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
40
30. DISCONNECT THE CLUTCH RELEASE CYLINDER ASSY
(2TR –FE MANUAL TRANS ONLY)
a) Remove the bolt and disconnect the clutch hose.
b) Remove the 2 bolts and disconnect the clutch release
cylinder.
NOTE: Use precaution when performing this step, as you
will need to work underneath the vehicle.
31. DISCONNECT THE NO.1 CLUTCH HOSE
(1GR-FE MANUAL TRANS ONLY)
a) Disconnect the clutch release cylinder tube from the
clutch hose.
b) Remove the clip and disconnect the clutch hose.
32. DISCONNECT THE NO.2 FUEL HOSE
a) Remove the clip and disconnect the No.2 fuel hose.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
33. DISCONNECT THE FUEL TANK TUBES
a) Remove the fuel pipe clamp.
b) Disconnect the 2 fuel tank tubes.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
34. DISCONNECT THE REAR BRAKE TUBES
a) Disconnect the 2 rear brake tubes.
b) Remove the bolt and disconnect the 2 way.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
35. DISCONNECT THE PARKING BRAKE CABLES
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
41
36. REMOVE THE FOLLOWING PARTS
• Floor Board No.1/No.2 (Access Cab Only)
• Seat Floor Box (Access Cab Only)
• Rear Floor Side Service Hole Cover LH/RH
•
•
Luggage Compartment Side Tray (Double Cab Only)
No.1 w/ Box Speaker Assy (If Equipped)
(Access Cab Only)
37. REMOVE THE CAB BODY ASSY USING AN ABOVE GROUND LIFT
a)
b)
c)
d)
e)
f)
g)
h)
Remove the 6 nuts and 6 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.
Mark the location of the tires so it will be easier to install the cab onto the new frame.
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 of the cab body may become nose heavy depending on placement of the lift
arm which could cause the cab to fall when lifted. To prevent this, use weights to establish a
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, they will be used as guides during cab assy reinstallation.
42
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 and Min. Work Load Capacity: 3,000 lbs)
2. REMOVE THE FOLLOWING PARTS
• Wheels
• Propeller Shaft Heat Insulator (If Equipped)
• Front Propeller Shaft Assy (4WD Only)
• Exhaust Pipe Stopper Bracket (If Equipped)
• Rear Propeller Shaft Assy
• Insert SST 09325-40010 into trans after the Rear Prop Shaft is removed to prevent oil leakage (2WD Only)
NOTE: Place match marks on the front (if equipped) and rear propeller shafts prior to removal.
3. REMOVE THE EXHAUST SYSTEM (1GR-FE ONLY)
a) Remove the 2 bolts and 4 exhaust pipe supports.
b) Remove the center exhaust pipe assy and exhaust pipe
supports.
c) Remove the exhaust pipe gasket.
d) Disconnect the 2 oxygen sensor connectors.
e) Remove the 6 nuts and 2 exhaust pipe supports.
f) Remove the front exhaust pipe assy and exhaust pipe
supports.
g) Remove the 2 exhaust pipe gaskets.
4. REMOVE THE EXHAUST SYSTEM (2TR-FE ONLY)
a)
b)
c)
d)
e)
f)
g)
h)
Remove the 2 bolts and 4 exhaust pipe supports.
Remove the center exhaust pipe assy and exhaust pipe supports.
Remove the exhaust pipe gasket.
Disconnect the 2 oxygen sensor connectors.
Disconnect the 2 oxygen sensor wire harness clamps.
Remove the 2 bolts and exhaust pipe support.
Remove the front exhaust pipe assy and exhaust pipe supports.
Remove the 2 exhaust pipe gaskets.
43
5. REMOVE THE FOLLOWING PARTS
• No.1 Fuel Tank Protector Assy (If Equipped)
• Fuel Tank Strap
• Fan /V-belt
• Fuel Tank
• Charcoal Canister Assy
6. REMOVE AND SET ASIDE THE POWER STEERING PUMP ASSY
a) Disconnect the connector.
b) Disconnect the clamp. (1GR-FE Only)
c) Remove the bolt and disconnect the ground wire. (1GR-FE Only)
d) Remove the 2 bolts and the power steering vane pump.
NOTE:
• DO NOT disconnect the power steering pump hoses or tubes.
• Keep the power steering pump reservoir upright to prevent the fluid from leaking out.
7. REMOVE THE FOLLOWING PARTS
•
•
Intake Air Surge Tank (1GR-FE Only)
Intake Air Connector (2TR-FE Only)
8. DISCONNECT THE OIL COOLER TUBE (AUTO TRANS
ONLY)
a) Remove the bolts and disconnect the oil cooler tube.
LH Side
9. REMOVE THE ENGINE AND TRANSMISSION ASSY
a) Remove the bolt and disconnect the ground wire.
(LH Side)
b) Disconnect the connector and clamp. (4WD Only)
c) Disconnect and remove the necessary items/parts to
prepare the engine and transmission assy for removal.
d) Install the engine hanger.
4WD Only
For 1GR-FE:
12281-31060 = No.1 Engine Hanger
12282-31040 = No.2 Engine Hanger
90119-08A87 = 4 Bolts
For 2TR-FE:
12281-75040 = No.1 Engine Hanger
12281-75040 = No.2 Engine Hanger
91552-A1020 = 2 Bolts
44
e) Remove the engine and transmission assy.
NOTE:
• ALWAYS use 2 engine hoists/cranes to lift it.
• DO NOT use 1 engine hoist/crane to lift the engine
& transmission assy, as the unbalanced weight
may lead to an accident or injury.
• ONLY use engine hoists/cranes that can properly
support the weight of the engine and transmission
assy.
• Carefully adjust the 2 engine hoists/cranes used so
that the engine and transmission assy is properly
balanced.
10. DISCONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS (2WD ONLY)
a) Remove the bolt, disconnect the clamp and skid control
sensor wire harness.
b) Repeat the procedure on the opposite side.
11. DISCONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS (4WD, PRE-RUNNER ONLY)
a) Remove the bolt and disconnect the skid control sensor
wire harness.
b) Repeat the procedure on the opposite side.
12. DISCONNECT THE FRONT BRAKE HOSE (2WD ONLY)
a) Disconnect the front brake tube from the brake hose.
b) Remove the 2 bolts and disconnect the front brake
hose and flexible hose bracket.
c) Repeat the procedure on the opposite side.
13. DISCONNECT THE FRONT BRAKE HOSE
(4WD, PRE-RUNNER ONLY)
a) Disconnect the front brake tube from the brake hose.
b) Remove the bolt and disconnect the front brake hose
and flexible hose bracket.
c) Repeat the procedure on the opposite side.
45
14. REMOVE THE FOLLOWING PARTS
•
•
•
•
Front Axle Hub Grease Cap (4WD Only)
Front Axle Shaft Nut (4WD Only)
Tie Rod End*
Front Stabilizer Link Assy
* SST 09610-20012 (2WD), SST 09628-62011 (4WD, Pre-Runner) disconnect the tie rod end.
15. REMOVE THE FRONT SUSPENSION UPPER ARM AND
STEERING KNUCKLE ASSY (2WD ONLY)
a) Remmove the 2 bolts (A).
b) Remove the 2 bolts (B), 2 nuts, 2 washers and front
suspension upper arm w/ steering knuckle.
c) Repeat the procedure on the opposite side.
16. REMOVE THE FRONT SUSPENSION UPPER ARM AND
STEERING KNUCKLE ASSY (4WD, PRE-RUNNER ONLY)
a) Remove the 2 bolts (A).
b) Remove the bolt (B), nut, 2 washers and front
suspension upper arm w/ steering knuckle.
c) 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.
17. REMOVE THE FOLLOWING PARTS
•
•
•
•
Front Drive Shaft Assy (4WD Only) *
Front Suspension Member Brace Sub-Assy
Front Stabilizer Bar
Front Shock Absorber Assy
°
°
°
•
•
•
•
Power Steering Link Assy w/ Pump
Front Differential Carrier (4WD Only)
Lower Ball Joint**
Front Spring Bumper***
*SST 09520-24010 (09520-32040),09520-01010
**SST 09628-00011
***SST 09922-10010-01
NOTE:
• When removing the power steering link with the pump, have one person support the power
steering link and the other support the pump and keep it upright to avoid fluid leakage.
• 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.
18. REMOVE THE PARKING BRAKE CABLES
a) Remove the 8 bolts and parking brake cables.
46
19. 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.
Front Side
20. REMOVE THE HARNESS BRACKETS
a) Remove the 2 bolts and 2 brackets.
Rear Side
21. DISCONNECT THE BRAKE HOSE
a) Disconnect the No.5 rear brake tube.
b) Disconnect the No.6 rear brake tube.
c) Remove the 2 clips and 2 bolts, disconnect the brake
hose and the No.2 flexible hose bracket.
22. REMOVE THE FOLLOWING PARTS
• Rear Stabilizer Bar (If Equipped)
• Rear Shock Absorber Assy
•
•
Rear Differential Assy
No.1 Rear Spring Bumper (2WD Only)
4WD and PreRunner vehicles will not have leaf springs replaced or will have them replaced
under E02. If the vehicle already had E02 performed there is no need to separate the rear
differential from the leaf springs, remove the leaf springs and rear diff as an assembly.
23. REMOVE THE NO.2 CHARCOAL CANISTER PIPE
a) Disconnect the clamps and remove the No.2 charcoal
canister pipe.
47
24. REMOVE THE FRAME AUXILIARY CROSSMEMBER
EXTENSIONS (IF EQUIPPED)
a) Remove the 2 bolts and frame auxiliary crossmember
extensions.
25. REMOVE THE HOOK
a) Remove the 2 bolts and hook.
26. REMOVE THE REAR ENGINE MOUNTING
REINFORCES (1GR-FE ONLY)
a) Remove the 2 bolts and 2 rear engine mounting
reinforces.
27. REMOVE THE PARKING BRAKE CABLE HEAT
INSULATOR (IF EQUIPPED)
a) Remove the 2 bolts and parking brake cable heat
insulator.
28. REMOVE THE OXYGEN SENSOR BRACKETS
(2TR-FE ONLY)
a) Remove the 2 bolts and 2 brackets.
29. REMOVE THE NO.1 RECEIVER HITCH ATTACHMENT
REINFORCEMENT (IF EQUIPPED)
a) Remove the 2 bolts and No.1 receiver hitch attachment
reinforcement.
48
30. REMOVE THE CLIPS
31. REMOVE THE FOLLOWING PARTS
•
•
•
Front Suspension Lower Arm
Cab Mounts (QTY:6)
Rear Leaf Spring Assy
32. REMOVE THE FRAME FROM THE LIFT
a) Remove the ratcheting tie down strap and the frame from the lift.
49
G. PLUG HOLES IN REPLACEMENT FRAME
1. PLACE THE NEW FRAME ON THE LIFT
Place the NEW frame on the lift, and secure it with a ratcheting tie down strap.
• Ratcheting Tie Downs: Qty 1 (Length: 2 in X 27 ft and Min. Work Load Capacity: 3,000 lbs)
a)
2. INSTALL THE BODY PLUGS (YOU MAY NOT USE ALL THE BODY PLUGS DEPENDING ON THE
FRAME DESIGN)
Note: The illustration shows only the right side if the body plug installation points are positioned similarly for both sides.
Step 4 & 7
Step 3, 5, & 6
Front
STEP ③
Front
90080-46327
Step 3 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.
90950-01983
90950-01987
4WD ONLY
90950-01983×4 90950-01989×2
TLL: 6 or 8 plugs
90950-01989
STEP ④
Front
Front
90950-01992
90950-01990
90950-01989
STEP ⑥
90950-01987×2
90080-46327x2
Step 4 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.
90950-01987×4
TLL: 4 plugs
90950-01987
STEP ⑤
4WD ONLY
Front
Step 5 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.
90950-01989×2
TLL: 6 plugs
90950-01990×2
90950-01992×2
Step 6 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.
90950-01991×2
TLL: 2 plugs
90950-01991
50
STEP ⑦
Front
90950-01991
Step 7 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.
2WD ONLY
2WD ONLY
90950-01A09
90950-01A09×2
90950-01991×2
TLL: 2 or 4 plugs
Step 8 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.
90950-01631×4
TLL: 4 plugs
Step 8 (refer to the following illustration):
b) Install the body plugs as follows into the side-rail.
90950-01984×2
TLL: 4 plugs
90950-01987
TTL: 2 plugs
Step 9 (refer to the following illustration):
c) Install the body plugs as follows into the side-rail.
90950-01931×1
*1) RH is for 2TR engine.
LH is for 1GR engine
TLL: 1 plug
51
Step 10 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.
NOTE:
DO NOT INSTALL THE LOWER TWO PLUGS IF THE VEHICLE HAS
A 120V OUTLET OPTION IN THE BED
90333-20001 (Stickers)
TLL: 10 plugs (4WD and PreRunner) or 2 plugs (2WD)
Step 11 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.
90333-30002 (Stickers)
TLL: 28 plugs (4WD) or 36 plugs (2WD)
Step 12 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.
90950-01990×2
TLL: 2 plugs
Step 13 (refer to the following illustration):
a) Install the one way plug with the channel opening the sides of the
vehicle so that water cannot enter the frame form tire spray.
90950-01A24×2
TLL: 2 plugs
52
Step 14 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.
2WD ONLY
90950-01A09×2
TLL: 2 plugs
Step 15 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.
2WD ONLY
90950-01A11×2
TLL: 2 plugs
3. INSTALL FRAME RAIL SEAL
a) Inspect the replacement frame on both sides with the
frame seal temporally installed as identified in the
picture. Depending on when the service frame was
produced will determine if the following are present:
•
•
•
Predrilled hole w/weld nut: Proceed to step b)
Predrilled hole w/o weld nut: Proceed to step c)
No hole is present: Proceed to step d)
Note: Both sides of the frame must be inspected
because the hole status may differ from side to
side.
b) Install Frame Seal with Predrilled Hole with Weld Nut
1. Install the frame seal with the bolt.
Torque Spec: 29 N∙m (21.5 ft∙lbf)
Part #
90119-A0170
Part Name
Bolt, Flange
Qty
2
2. Skip to step #4 on page 55
53
c) Install Frame Seal with Predrilled Hole w/o Weld Nut
1. Using tape secure bolt and washer to the back
of the frame as shown.
Note: Using the tape will prevent the bolt from falling back
into the frame rail when installing the seal and will
prevent the bolt from spinning when torqueing the
nut.
Part #
90119-A0170
90178-A0024
Part Name
Bolt, Flange
Nut
Qty
2
2
2. Install the frame seal and torque the nut to spec
Torque Spec: 18.5 N∙m (14.0 ft∙lbf)
3. Skip to Step #4 on page 55
d) Install Frame Seal with No Hole in Frame
1. Using the template in the appendix of this TI
mark the hole on the inner frame rail for both
the left and right side frame rail.
2. Use a center punch to give the drill bit a pilot to
prevent wandering while drilling.
3. Drill the frame with a 10mm bit (3/8”).
4. Debur the hole to remove all the sharp metal
burrs.
Note: A deburring tool was previously provided
for safety recall D0C. This tool works well to
remove these sharp burrs.
5. Using tape secure bolt and washer to the back
of the frame as shown.
Note: Using the tape will prevent the bolt from
spinning when torqueing the nut.
Part #
90119-A0170
90178-A0024
Part Name
Bolt, Flange
Nut
Qty
2
2
6. Install the frame seal and torque the nut to
spec.
Torque Spec: 18.5 N∙m (14.0 ft∙lbf)
54
H. ASSEMBLE THE FRAME
NEW Replacement Parts
Part Name
Holder, Body Support
51719-04010
Bracket
Part #
1. INSTALL THE NEW CLIPS
Kit #
Qty
2
2
2. REINSTALL THE NO.1 RECEIVER HITCH ATTACHMENT
REINFORCEMENT (IF EQUIPPED)
a) Reinstall the No.1 receiver hitch attachment
reinforcement with the 2 bolts and torque to spec.
Torque Spec: 45 N∙m (459 kgf∙cm, 33 ft∙lbf)
3. REINSTALL THE NO.1 REAR SPRING BUMPER
(2WD ONLY)
a) Reinstall the rear spring bumper with the 2 nuts and
torque to spec.
b) Repeat the procedure on the opposite side.
Torque Spec: 15 N∙m (153 kgf∙cm, 11 ft∙lbf
NEW Replacement Parts
Part #
90119-A0151
Part Name
Bolt, w/ Washer
*Individual Part(s)
4. REINSTALL THE PROPELLER SHAFT HEAT INSULATOR
(IF EQUIPPED)
Kit #
NA*
Qty
2
a) Reinstall the propeller shaft heat insulator with the 2
NEW bolts and torque to spec.
Torque Spec: 15.7 N∙m (160 kgf∙cm, 12 ft∙lbf)
5. REINSTALL THE PARKING BRAKE CABLE HEAT
INSULATOR (IF EQUIPPED)
a) Reinstall the parking brake cable heat insulator with
the 2 bolts and torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
55
6. REINSTALL THE OXYGEN SENSOR BRACKETS
(2TR-FE ONLY)
a) Reinstall the 2 brackets with the 2 bolts and torque to
spec.
Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft∙lbf)
7. REINSTALL THE REAR ENGINE MOUNTING
REINFORCES (1GR-FE ONLY)
a) Reinstall the rear engine mounting reinforces with
the 2 bolts and torque to spec.
Torque Spec: 31 N∙m (316 kgf∙cm, 23 ft∙lbf)
NEW Replacement Parts
Part #
90119-A0192
90119-A0193
Part Name
Bolt, w/ Washer
Bolt, w/ Washer
*Individual Part(s)
8. REINSTALL THE HOOK
Kit #
8
NA*
Qty
2
2
a) Reinstall the hook with the 2 NEW bolts and torque
to spec.
Torque Spec: 70 N∙m (714 kgf∙cm, 52 ft∙lbf)
9. REINSTALL THE FRAME AUXILIARY CROSSMEMBER
EXTENSION (IF EQUIPPED)
a) Reinstall the 2 frame auxiliary crossmember
extensions with the 2 bolts and torque to spec.
Torque Spec: 45 N∙m (459 kgf∙cm, 33 ft∙lbf)
10. REINSTALL THE CAB MOUNTS
a) Reinstall cab mounts No.1
b) Reinstall cab mounts No.2 and No.3 with the 8 bolts
and torque to spec.
Torque Spec: 61 N∙m (622 kgf∙cm, 45 ft∙lbf)
56
11. INSTALL THE NEW FRONT SUSPENSION LOWER ARM (2WD ONLY)
a) Install the NEW front suspension lower arm with the 2 NEW nuts, 2 NEW No.1 camber adjust cams and 2
NEW No.2 camber adjust cams, then torque to spec. 2WD Only
Torque Spec: 210 N∙m (2141 kgf∙cm, 155 ft∙lbf)
b) Repeat the procedure on the opposite side.
Part #
48068-04030
48069-04030
48190-25010
48198-25010
90178-A0013
NEW Replacement Parts
Part Name
Arm Sub-Assy, Suspension
LWR RH w/Bush
Arm Sub-Assy, Suspension
LWR LH w/Bush
Cam Assy, Camber Adjust
Cam, Camber Adjust No. 2
Nut, Flange
*Individual Part(s)
Kit #
Qty
NA*
1
NA*
1
4
4
NA*
4
4
4
12. INSTALL THE NEW FRONT SUSPENSION LOWER ARM (4WD, PRE-RUNNER ONLY)
a) Install the NEW front suspension lower arm with the NEW bolt, nut, NEW toe adjust cam, NEW No.2 toe
adjust cam, NEW No.1 camber adjust cam and NEW No.2 camber adjust cam, then torque to spec.
Torque Spec: 135 N∙m (1377 kgf∙cm, 100 ft∙lbf)
b) Repeat the procedure on the opposite side.
4WD, Pre-Runner Only
NEW Replacement Parts
Part #
48068-04040
48069-04040
48190-60020
48198-60011
48409-60020
48452-35020
90119-A0166
Part Name
Kit #
Arm Sub-Assy, Suspension
NA*
LWR RH w/Bush
Arm Sub-Assy, Suspension
NA*
LWR LH w/Bush
Cam Assy, Camber Adjust
5
Cam, Camber Adjust No. 2
5
Cam Sub- Assy, Toe Adjust
5
Plate, Toe Adjust, No. 2
5
Bolt, w/ Washer
8
*Individual Part(s)
Qty
1
1
2
2
2
2
2
NEW Replacement Parts (2WD Only)
Part #
Part Name
Kit # Qty
48304-04090
NA*
2
Bumper, Sub-Assy FR
Spring**
48304-AD010
NA*
2
*Individual Part(s)
**Only 1 part used, part number varies by vehicle type.
13. INSTALL THE NEW FRONT SPRING BUMPER
a) Using the SST 09922-10010-01, install the NEW front
spring bumpers and torque to spec.
Torque Spec: 31 N∙m (316 kgf∙cm, 23 ft∙lbf)
b) Repeat the procedure on the opposite side.
NEW Replacement Parts
( 4WD, Pre-Runner Only )
Part #
Part Name
Bumper, Sub-Assy FR
48304-04100
Spring
Kit #
Qty
8
2
57
14. INSTALL THE NEW REAR BRAKE TUBES
a) Install the NEW rear brake tubes with the NEW clamp(s).
Part #
47325-*****
47326-*****
90469-A0004
90469-A0004
90469-A0004
90949-A1006
NEW Replacement Parts
Part Name
Tube, RR Brake, No.5**
Tube, RR Brake, No.6**
Clamp (Regular Cab)
Clamp (Access Cab)
Clamp (Double Cab)
Clamp
*Individual Part(s)
Kit #
NA*
NA*
NA*
NA*
NA*
2
Qty
1
1
2
3
4
3
Kit #
Qty
1
1
15. REINSTALL THE NO. 2 CHARCOAL CANISTER PIPE
NEW Replacement Parts
Part #
77285-35760
Part Name
Support, Fuel Return &
Main Tube
NEW Replacement Parts
Part #
90119-A0169
51900-35410
81900-35420
Part Name
Kit # Qty
Bolt, w/ Washer
2
4
NA*
1
Carrier Assy, Spare
Wheel**
NA*
1
*Individual Part(s)
**Only 1 part used, part number varies by vehicle type.
a) Install the NEW fuel return and main tube support.
b) Reinstall the No.2 charcoal canister pipe.
16. INSTALL THE NEW SPARE TIRE CARRIER ASSY
a) Install the NEW spare tire carrier assy with the 4 NEW
bolts and torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
17. INSTALL LEAF SPRINGS
4WD and PreRunner
a) Reinstall leaf springs and shacke and torque to spec.
Torque Spec: 120 N∙m (1224 kgf∙cm, 89 ft∙lbf)
2WD
b) Install the NEW rear leaf springs with the all NEW parts
(shackle, bushings, bolts, washers and nuts) and torque
to spec.
Torque Spec: 120 N∙m (1224 kgf∙cm, 89 ft∙lbf)
Part #
04483-04080
90080-10138
90178-A0050
94622-51400
Varies**
Varies**
Part Name
Shackle Kit, RR Spring
Bolt, Flange
Nut, Flange
Washer, Plain
Spring Assy, RR RH
Spring Assy, RR LH
Kit #
2
2
2
1
NA*
NA*
Qty
2
2
2
2
1
1
c) Repeat the procedure on the opposite side.
58
18. REINSTALL THE FOLLOWING PARTS
•
NEW Replacement Parts
Rear Differential Assy
Part #
90117-A0001
90117-A0002
90117-A0005
90178-A0050
90178-51400
Part Name
Bolt, U**
Kit #
NA*
NA*
NA*
2
1
Qty
4
4
4
8
8
Kit #
2
Qty
2
•
Nut, Flange
Washer, Plain
*Individual Part(s)
**Only 1 part used, part number varies by vehicle type.
Rear Shock Absorber Assy
Part #
90117-A0010
Part Name
Nut, Lock
•
Rear Stabilizer Bar
Part #
90119-08A91
Part Name
Bolt, w/ Washer
*Individual Part(s)
Kit #
NA*
Qty
4
Kit #
Qty
2
1
NEW Replacement Parts
Part #
47355-04020
90119-A0169
90468-A0007
Front Side
Part Name
Bracket, Flexible Hose,
No. 2
Bolt, W/ Washer
Clip
*Individual Part(s)
Rear Differential Assy
° Reinstall with the 4 NEW U -bolts (2WD), 2 spring
seats, 2 spring bumpers (If Equipped), 8 NEW flange
nuts and 8 NEW plain washers, then torque to spec.
° Torque Spec: 50 N∙m (510 kgf∙cm, 37 ft∙lbf)
Rear Shock Absorber Assy
° Reinstall rear shock absorber assy with the bolt, nut
and washer. (Lower side)
° Torque Spec: Nut - 58 N∙m (591 kgf∙cm, 43 ft∙lbf)
° Reinstall the 3 retainers, 2 cushions and NEW nut,
then torque to spec. (Upper side)
° Torque Spec: Nut - 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
° Repeat the procedure on the opposite side.
Rear Stabilizer Bar (If Equipped)
° Reinstall with the 2 brackets and NEW 4 bolts, then
torque to spec.
° Torque Spec: 27 N∙m (275 kgf∙cm, 20 ft∙lbf)
° Reconnect the 2 stabilizer bar links with the 4 nuts,
then torque to spec.
Torque Spec: 65 N∙m (663 kgf∙cm, 48 ft∙lbf)
19. RECONNECT THE BRAKE HOSE
13
or
NA*
2
2
2
a) Install the NEW No.2 flexible hose bracket with the 2
NEW bolts.
b) Reconnect the 2 brake hoses with the 2 NEW clips.
c) Reconnect the No.5, No.6 rear brake tubes and torque to
spec.
Torque Spec:
Flexible hose bracket - 29 N∙m (296 kgf∙cm, 21 ft∙lbf)
Rear brake tube - 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
Rear Side
20. REINSTALL THE HARNESS BRACKETS
a) Reinstall the 2 brackets with the 2 bolt and torque to
spec.
Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft∙lbf)
21. REINSTALL THE FRAME WIRE HARNESS
a) Reconnect the clamps to install the frame wire harness.
b) Reconnect the ground wire with the bolt and torque to
spec.
Torque Spec: 12.7 N∙m (130 kgf∙cm, 9 ft∙lbf)
NOTE: The number of wire harness clamps will differ
depending on the vehicle spec.
59
22. REINSTALL THE PARKING BRAKE CABLES
a) Reinstall the 2 parking brake cables with the 8 bolts, then
torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
23. REINSTALL THE LOWER BALL JOINT
NEW Replacement Parts
Part #
90171-A0005
95381-03230
Part Name
Nut, Castle
Pin, Cotter
Kit #
2
4-5
Qty
2
2
a) Reinstall the lower ball joint with the NEW nut and torque
to spec.
Torque Spec: 160 N∙m (1632 kgf∙cm, 118 ft∙lbf)
b) Install the NEW cotter pin.
c) Repeat the procedure on the opposite side.
24. REINSTALL FRONT DIFFERENTIAL CARRIER (4WD ONLY)
a) Reinstall the front differential carrier with the 2 bolts, 4
stoppers and 3 nuts, then torque to spec.
Torque Spec: Except TMMTX Made
Bolt - 137.3 N∙m (1400 kgf∙cm, 101 ft∙lbf)
Nut – 87.2 N∙m (889 kgf∙cm, 64 ft∙lbf)
Torque Spec: TMMTX Made
Bolt - 128.5 N∙m (1310 kgf∙cm, 95 ft∙lbf)
Nut - 81.5 N∙m (831 kgf∙cm, 60 ft∙lbf)
2TR-FE
25. REINSTALL THE POWER STEERING LINK ASSY W/
POWER STEERING VANE PUMP
a) Reinstall the power steering link assy w/ power steering
vane pump with the bolts and nuts, then torque to spec.
Torque Spec:
Bolt A - 92 N∙m (938 kgf∙cm, 68 ft∙lbf)
Bolt B - 28 N∙m (286 kgf∙cm, 21 ft∙lbf)
1GR-FE
NOTE:
• When reinstalling the power steering link with the
pump, have one person support the power steering
link and the other support the pump.
• Keep the power steering pump reservoir upright to
prevent the fluid from leaking out.
26. RECONNECT THE FRONT DIFFERENTIAL BREATHER
TUBE (4WD ONLY)
a) Reconnect the front differential breather tube with the
bolt and 2 clamps, then torque to spec.
Torque Spec: 12.7 N∙m (130 kgf∙cm, 9 ft∙lbf)
60
NEW Replacement Parts
Part #
90080-17215
Part Name
Nut, Flange
27. REINSTALL THE FRONT SHOCK ABSORBER ASSY
Kit #
2
Qty
6
a) Install the 3 NEW nuts (A) and torque to spec.
b) Reinstall the front shock absorber assy with the bolt and
nut (B), then torque to spec.
Torque Spec:
Nut A - 64 N∙m (653 kgf∙cm, 47 ft∙lbf)
Nut B - 83 N∙m (846 kgf∙cm, 61 ft∙lbf)
c) Repeat the procedure on the opposite side.
28. REINSTALL THE FRONT STABILIZER BAR
NEW Replacement Parts (2WD Only)
Part #
90119-A0161
Part Name
Bolt, w/ Washer
*Individual Part(s)
Kit #
NA*
Qty
4
a) Reinstall the stabilizer bar with 2 brackets and 4 NEW
bolts, then torque to spec. (2WD Only)
b) Reinstall the stabilizer bar with 2 brackets and 4 bolts,
then torque to spec. (4WD, Pre-Runner Only)
Torque Spec:
2WD - 21 N∙m (214 kgf∙cm, 15 ft∙lbf)
4WD, Pre-Runner - 40 N∙m (408 kgf∙cm, 30 ft∙lbf)
2WD Only
29. REINSTALL THE SUSPENSION MEMBER BRACE SUBASSY
a) Reinstall the suspension member brace sub-assy with 8
bolts (2WD Only) or 7 bolts (4WD, Pre-Runner Only), then
torque to spec.
Torque Spec: 45 N∙m (459 kgf∙cm, 33 ft∙lbf)
4WD, Pre-Runner Only
NEW Replacement Parts
Part #
43425-04040
90311-47012
90311-47013
Part Name
Ring, Drive Shaft Snap
Seal, Type T Oil (LH)
Seal, Type T Oil (RH)
*Individual Part(s)
Kit #
NA*
3
3
Qty
2
1
1
30. REINSTALL THE FRONT DRIVE SHAFT ASSY (4WD ONLY)
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.
61
31. REINSTALL THE FRONT SUSPENSION UPPER ARM
AND STEERING KNUCKLE ASSY (2WD ONLY)
a) Reinstall the front suspension upper arm w/ steering
knuckle with the 2 bolts (A), 2 nuts and 2 washers, then
torque to spec.
Torque Spec: Bolt A - 82 N∙m (836 kgf∙cm, 60 ft∙lbf)
b) Reinstall the 2 bolts (B), then torque to spec.
Torque Spec: Bolt B - 160 N∙m (1632 kgf∙cm, 118 ft∙lbf)
c) Repeat the procedure on the opposite side.
32. REINSTALL THE FRONT SUSPENSION UPPER ARM AND
STEERING KNUCKLE ASSY (4WD, PRE-RUNNER ONLY)
a) Reinstall the front suspension upper arm w/ steering
knuckle with the bolt (A), nut and 2 washers, then torque
to spec.
Torque Spec: Nut - 115 N∙m (1173 kgf∙cm, 85 ft∙lbf)
b) Reinstall the 2 bolts (B), then torque to spec.
Torque Spec: Bolt B - 160 N∙m (1632 kgf∙cm, 118 ft∙lbf)
c) Repeat the procedure on the opposite side.
33. REINSTALL THE FOLLOWING PARTS
•
NEW Replacement Parts
Tie Rod End
Part #
Part Name
Kit # Qty
95381-03025
4
2
Pin, Cotter**
95381-03225
5
2
**Only 1 part used, part number varies by vehicle type.
NEW Replacement Parts
Part #
47314-04140
47316-04140
90119-A0169
90412-10247
Part Name
Tube, FR Brake No. 4
Tube, FR Brake No. 6
Bolt, w/ Washer
Way, 2
*Individual Part(s)
Kit #
12
12
NA*
1
Qty
1
1
2
2
Front Stabilizer Link (2WD Only)
° Reinstall with 2 retainers, 2 cushions and nut, torque
to spec.
° Torque Spec: 19 N∙m (194 kgf∙cm, 14 ft∙lbf)
° Reinstall the nut, then torque to spec.
° Torque Spec: 69 N∙m (704 kgf∙cm, 51 ft∙lbf)
° Repeat the procedure on the opposite side.
• Front Stabilizer Link (4WD, Pre-Runner Only)
° Reinstall front stabilizer link with 2 nuts, torque to spec.
° Torque Spec: 70 N∙m (714 kgf∙cm, 52 ft∙lbf)
° Repeat the procedure on the opposite side.
• Tie Rod End
° Reinstall tie rod end with nut and torque to spec.
° Torque Spec:
2WD - 49 N∙m (500 kgf∙cm, 36 ft∙lbf)
4WD, Pre-Runner - 91 N∙m (928 kgf∙cm, 67 ft∙lbf)
° Install the NEW cotter pin.
° Repeat the procedure on the opposite side.
• Front Axle Shaft Nut (4WD Only)
° Temporarily reinstall the front axle nut.
° Nut will be tightened when the vehicle is completed.
° Repeat the procedure on the opposite side.
34. INSTALL THE NEW FRONT BRAKE TUBE AND NEW
WAY (2WD ONLY)
a) Temporarily install the NEW front brake tube and NEW
way.
b) Install the NEW bolt to the NEW front way and torque to
spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
c) Repeat the procedure on the opposite side.
62
NEW Replacement Parts
Part #
47314-04150
47316-04150
90119-A0169
90412-10247
Part Name
Tube, FR Brake No. 4
Tube, FR Brake No. 6
Bolt, w/ Washer
Way, 2
*Individual Part(s)
Kit #
12
12
13
1
Qty
1
1
2
2
35. INSTALL THE NEW FRONT BRAKE TUBE AND NEW
WAY (4WD, Pre-Runner ONLY)
a) Temporarily install the NEW front brake tube and NEW
way.
b) Install the NEW bolt to the NEW front way and torque to
spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
c) Repeat the procedure on the opposite side.
Part #
47351-04030
47352-04030
90119-A0169
90468-A0007
NEW Replacement Parts
Part Name
Bracket, Flexible Hose, RH
Bracket, Flexible Hose, LH
Bolt, w/ Washer
Clip
*Individual Part(s)
36. REINSTALL THE FRONT BRAKE HOSE (2WD ONLY)
Kit #
12
12
NA*
2
Qty
1
1
4
2
a) Reinstall the flexible hose bracket with the NEW bolt and
torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
b) Reconnect the front brake hose with a NEW clip.
c) Reconnect the front brake tube and torque to spec.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
d) Reinstall the NEW bolt and torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
e) Repeat the procedure on the opposite side.
NEW Replacement Parts
Part #
Part Name
Kit #
47353-04010 Bracket, Flexible Hose, No. 3 13
47354-04010 Bracket, Flexible Hose, N0. 4 13
90119-A0169
Bolt, w/ Washer
13
90468-A0007
Clip
2
Qty
1
1
4
2
37. REINSTALL THE FRONT BRAKE HOSE (4WD, PRE-RUNNER
ONLY)
a) Reinstall the flexible hose bracket with the bolt and
torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
b) Reconnect the front brake hose with a NEW clip.
c) Reconnect the front brake tube and torque to spec.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
d) Repeat the procedure on the opposite side.
Part #
89516-04010
89516-04020
NEW Replacement Parts
Part Name
Wire, Skid Control Sensor RH
Wire, Skid Control Sensor LH
*Individual Part(s)
Kit #
NA*
NA*
Qty
1
1
38. RECONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS (2WD ONLY)
a) Reconnect the clamp.
b) Reinstall the front skid control sensor wire harness with
bolt and torque to spec.
Torque Spec: 5.0 N∙m (51 kgf∙cm, 44 in∙lbf)
c) Repeat the procedure on the opposite side.
NOTE: If the front skid control sensor wire harness and
clamp are damaged, replace the NEW parts.
63
Part #
89516-04040
89516-04090
NEW Replacement Parts
Part Name
Wire, Skid Control Sensor RH
Wire, Skid Control Sensor LH
*Individual Part(s)
Kit #
NA*
NA*
Qty
1
1
39. RECONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS (4WD, PRE-RUNNER ONLY)
a) Reinstall the front skid control sensor wire harness with
bolt and torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
b) Repeat the procedure on the opposite side.
NOTE: If the front skid control sensor wire harness and
clamp are damaged, replace the NEW parts.
40. REINSTALL THE WHEELS
41. REINSTALL THE ENGINE AND TRANSMISSION ASSY
a) Reinstall engine and transmission assy.
NOTE:
• Use 2 engine hoists/cranes to lift engine & trans assy.
• DO NOT use 1 engine hoist/crane to lift the engine &
trans assy, the unbalanced weight may lead to an
accident or injury.
• ONLY use engine hoists/cranes that can properly
support the weight of the engine & trans.
• Carefully adjust the 2 engine hoists/cranes used so
that the engine & trans assy is balanced.
Part #
90179-10201
90910-03001
NEW Replacement Parts
Part Name
Nut
Bolt, Engine Mount
Kit #
1
1
Qty
4
4
Kit #
1
Qty
4
b) Attach the engine mounts with the 4 NEW bolts and 4
NEW nuts, then torque to spec.
Torque Spec: 38 N∙m (387 kgf∙cm, 28 ft∙lbf)
LH Side
RH Side
NEW Replacement Parts
Part #
91671-80814
Part Name
Bolt, Flange w/ Washer
c) Attach the transmission mount with 4 NEW bolts and
torque to spec.
Torque Spec: 18.5 N∙m (189 kgf∙cm, 14 ft∙lbf)
d) Remove the bolt(s) and the engine hangers.
e) Reinstall the items/parts that were removed during the
engine and transmission assy removal.
64
LH Side
f)
Reinstall the bolt and reconnect the ground wire. (LH Side)
Torque Spec: 12.7 N∙m (130 kgf∙cm, 9 ft∙lbf)
g) Reconnect the connector and clamp. (4WD Only)
4WD Only
42. RECONNECT THE OIL COOLER TUBE (AUTO TRANS ONLY)
a) Reconnect the oil cooler tube with the 2 bolts and torque
to spec.
Torque Spec: 28 N∙m (286 kgf∙cm, 21 ft∙lbf)
43. REINSTALL THE INTAKE AIR SURGE TANK (1GR-FE ONLY)
a) Install a NEW gasket onto the intake air surge tank.
b) Using a 8mm hexagon socket, reinstall the intake air
surge tank with the 4 bolts and torque to spec.
Torque Spec: 28 N∙m (286 kgf∙cm, 21 ft∙lbf)
c) Reinstall the 2 intake air surge tank nuts and torque to
spec.
Torque Spec: 28 N∙m (286 kgf∙cm, 21 ft∙lbf)
NEW Replacement Parts
Part #
17176-0P010
Part Name
Gasket, Air Surge Tank INT
Manifold
Kit #
Qty
6
1
d) Reinstall the 2 surge tank stays with the 4 bolts, then
torque to spec.
Torque Spec: 21 N∙m (214 kgf∙cm, 15 ft∙lbf)
e) Reinstall oil baffle plate with the bolt and torque to spec.
Torque Spec: 9.0 N∙m (92 kgf∙cm, 80 in∙lbf)
f)
Reinstall the throttle body bracket with the 2 bolts, then
torque to spec.
Torque Spec: 21 N∙m (214 kgf∙cm, 15 ft∙lbf)
g)
h)
i)
j)
k)
l)
Reconnect the 3 wire harness clamps and hose clamp.
Reconnect the throttle body w/ motor connector.
Reconnect the 2 VSV connectors.
Reconnect the ventilation hose.
Reconnect the fuel vapor feed hose.
Reconnect the 2 water by-pass hoses.
65
44. REINSTALL THE INTAKE AIR CONNECTOR (2TR-FE ONLY)
a) Reinstall the intake air connector with the 3 bolts, then torque to spec.
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
b)
c)
d)
e)
f)
g)
Tighten the hose clamp bolts.
Reconnect the vacuum hose.
Reconnect the No.2 ventilation hose.
Reconnect the vacuum hose.
Reconnect the wire harness clamp.
Reconnect the pressure sensor connector.
45. REINSTALL THE POWER STEERING PUMP ASSY
a) Reinstall the bolt and reconnect the ground wire and torque to spec. (1GR-FE Only)
Torque Spec: 8.0 N∙m (82kgf∙cm, 71 in∙lbf)
b) Reinstall the power steering vane pump with the 2 bolts, then torque to spec.
Torque Spec: 21 N∙m (214 kgf∙cm, 15 ft∙lbf)
c) Reconnect the connector.
d) Reconnect the clamp. (1GR-FE Only)
46. REINSTALL THE FAN AND GENERATOR V-BELT
47. REINSTALL THE FUEL TANK STRAPS
a) Reinstall the fuel tank straps with the 2 pins and 2 clips.
48. REINSTALL THE FUEL TANK
NEW Replacement Parts
Part #
90080-11376
Part Name
Bolt, W/ Washer
Kit #
2
Qty
2
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 2 fuel tubes.
c) Reconnect the connector.
49. REINSTALL THE NO.2 FUEL TANK PROTECTOR (IF EQUIPPED)
50. REINSTALL THE NO.1 FUEL TANK PROTECTOR ASSY
(IF EQUIPPED)
NEW Replacement Parts
Part #
90179-08241
Part Name
Nut
*Individual Part(s)
Kit #
NA*
Qty
4
a) Reinstall the No.1 fuel tank protector assy with the 4
NEW nuts and torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
66
51. REINSTALL THE CHARCOAL CANISTER ASSY
a) Reinstall the charcoal canister assy with the bolt and 3
nuts, then torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
b) Reconnect the fuel tank vent hose.
c) Reconnect the fuel hose.
d) Reconnect the main tube support and reconnect the filter
hose.
e) Reconnect the connector.
f) Reinstall the bolt and reconnect the skid control sensor
wire and torque to spec.
Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft∙lbf)
52. REINSTALL THE EXHAUST SYSTEM (1GR-FE ONLY)
NEW Replacement Parts
Part #
90080-17187
90080-43036
90126-A0011
Part Name
Nut, Lock
Gasket, Exhaust Pipe
Stud, Hex lobular
Kit #
6
6
6
Qty
4
2
4
a) Install the 2 NEW exhaust pipe gaskets.
b) Reinstall the front exhaust pipe assy and 2 exhaust pipe
supports.
c) Install the 4 NEW nuts and torque to spec.
d) Reconnect the 2 oxygen sensor connectors.
Torque Spec: 54.3 N∙m (554 kgf∙cm, 40 ft∙lbf)
NOTE: If the stud bolt is damaged, replace the NEW
parts.
Part #
17451-0A010
90080-10291
NEW Replacement Parts
Part Name
Gasket, Exhaust Pipe
Bolt
Kit #
2
6
Qty
1
2
e) Install the NEW exhaust pipe gasket.
f) Reinstall the center exhaust tail pipe and 4 exhaust pipe
supports.
g) Install the 2 NEW bolts and 2 springs, then torque to
spec.
Torque Spec: 43 N∙m (438 kgf∙cm, 32 ft∙lbf)
67
53. REINSTALL THE EXHAUST SYSTEM (2TR-FE ONLY)
NEW Replacement Parts
Part #
17451-0A010
90080-10064
90080-10291
90080-43033
90177-A0004
Part Name
Gasket, Exhaust Pipe
Bolt. Flange
Bolt. Flange
Gasket, Exhaust Pipe
Nut, Lock
Kit #
2
7
7
7
7
Qty
1
2
2
1
2
a) Install the NEW exhaust pipe gasket.
b) Reinstall the front exhaust pipe assy and exhaust pipe
support.
c) Install the 2 NEW bolts and 2 springs, then torque to
spec.
Torque Spec: 43 N∙m (438 kgf∙cm, 32 ft∙lbf)
d) Reconnect the 2 oxygen sensor connectors and 2 wire
harness clamps.
e) Install the NEW exhaust pipe gasket.
f) Reinstall the center exhaust tail pipe and 4 exhaust pipe
supports.
g) Install the 2 NEW bolts and torque to spec.
Torque Spec: 48 N∙m (489 kgf∙cm, 35 ft∙lbf)
54. REINSTALL THE EXHAUST PIPE STOPPER BRACKET
(IF EQUIPPED)
NEW Replacement Parts
Part #
90080-11180
Part Name
Bolt, w/ Washer
Kit #
6
Qty
2
a) Reinstall the exhaust pipe stopper bracket with the 2
bolts and torque to spec.
Torque Spec: 19 N∙m (194 kgf∙cm, 14 ft∙lbf)
55. REINSTALL THE REAR PROPELLER SHAFT ASSY
a) Remove the SST. (2WD Only)
b) Referencing the matchmarks, reinstall the propeller shaft
assy to the the transmission / transfer case.
c) Reinstall the 4 washers and 4 nuts, then torque to spec.
(4WD Only)
Torque Spec: 88.2 N∙m (899 kgf∙cm, 65 ft∙lbf)
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: 36.2 N∙m (369 kgf∙cm, 27 ft∙lbf)
e) Referencing the matchmarks, reinstall the propeller shaft
assy to the rear differential with 4 bolts, 4 washers and 4
nuts, then torque to spec.
Torque Spec: 88.2 N∙m (899 kgf∙cm, 65 ft∙lbf)
68
56. 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 4 bolts, 8 washers and 8 nuts, then torque to spec.
Torque Spec: 88.2 N∙m (899 kgf∙cm, 65 ft∙lbf)
57. REINSTALL THE FOLLOWING PARTS
•
•
Spare Tire
Wheels
58. REMOVE THE FRAME FROM THE LIFT
a) Remove the ratcheting tie down strap from the frame.
b) Lower the frame to the ground.
I.
REINSTALL THE CAB BODY ASSY
Before lowering the cab assembly ensure that you install the NEW brakelines onto the
bulk head.
Part #
47313-04190
47313-04200
47315-04160
47315-04170
47323-04160
47323-04170
47324-04120
47324-04130
NEW Replacement Parts
Part Name
Tube, FR Brake No. 3**
Tube, FR Brake No. 5**
Kit #
10
11
10
11
NA*
11
NA*
11
Qty
1
1
1
1
1
1
1
1
Tube, RR Brake No. 3
Tube, RR Brake No. 3
Tube, RR Brake No. 4
Tube, RR Brake No. 4
*Individual Part(s)
**Only 1 part used, part number varies by vehicle type.
1. INSTALL THE NEW ENGINE COMPARTMENT BRAKE
TUBES
a) Install the NEW No.3 and NEW No.5 front brake tubes.
b) Install the NEW No.3 and NEW No.4 rear brake tubes.
c) Torque all brake tubes to spec.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
69
2. REINSTALL THE CAB BODY ASSEMBLY
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 and line the tires up with the alignment marks.
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 6 bolts, 6 nuts, 6 washers and torque to spec.
Torque Spec:
No.1 - 37.5 N∙m (382 kgf∙cm, 28 ft∙lbf)
No.2, No.3 - 45 N∙m (459 kgf∙cm, 33 ft∙lbf)
NOTE:
• DO NOT work directly underneath the vehicle when pushing the frame under the cab assy.
• Slowly lower the cab assy making sure the wire harness, steering shaft & hoses don’t interfere.
• With 2 to 3 people checking for interference, slowly lower the cab body assembly to the frame.
3. RECONNECT THE PARKING BRAKE CABLE
Part #
90412-10248
90119-A0169
NEW Replacement Parts
Part Name
Kit #
Qty
Way, 2
2
1
Bolt, w/ Washer
13 or NA* 1
*Individual Part(s)
4. RECONNECT THE REAR BRAKE TUBES
a) Temporarily install the 4 rear brake tubes and NEW 2 way.
b) Install the NEW bolt to the 2 way and torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
c) Reconnect the 4 rear brake tubes and torque to spec.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
70
5. RECONNECT THE FUEL TANK TUBES
a) Reconnect the 2 fuel tank tubes.
b) Reinstall the fuel pipe clamp.
NOTE:
• Align the connector with the pipe, and push into
the connector until the connector makes a "click"
sound. If the connection is tight, apply a little
amount of fresh engine oil on the tip of the pipe.
• Ensure the pipe and the connector are securely
connected by pulling them.
6. RECONNECT THE NO.2 FUEL HOSE
a) Reconnect the No.2 fuel hose with the clip
Cable Type
7. RECONNECT THE SHIFT CABLE (AUTO TRANS ONLY)
Cable Type:
a) Reconnect the shift cable with the nut and torque to
spec.
Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft∙lbf)
b) Reinstall the clip.
NEW Replacement Parts (Rod Type)
Part #
Part Name
Kit #
90240-08054
Pin, W/ Hole
NA*
90468-14033
Clip
NA*
*Individual Part(s)
Qty
1
1
Rod Type:
c) Reconnect the shift cable with the NEW pin and NEW
clip.
8. CONNECT THE CLUTCH RELEASE CYLINDER ASSY
(2TR-FE MANUAL TRANS ONLY)
a) Reconnect the clutch release cylinder with the 2 bolts
and torque to spec.
Torque Spec: 11.8 N∙m (120 kgf∙cm, 9 ft∙lbf)
b) Reconnect the clutch hose with the bolt and torque to
spec.
Torque Spec: 37 N∙m (377 kgf∙cm, 27 ft∙lbf)
9. RECONNECT THE NO.1 CLUTCH HOSE
(1GR-FE MANUAL TRANS ONLY)
a) Reconnect the clutch hose with the clip.
b) Reconnect the clutch release cylinder tube to the clutch
hose.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
71
NEW Replacement Parts
Part #
90080-11555
Part Name
Bolt, w/ Washer
Kit #
2
Qty
2
10. RECONNECT THE STEERING SLIDING YOKE
a) Make sure the front wheels are in a straight-ahead
position and the steering wheel is centered.
b) Referencing the match marks, connect the steering
sliding yoke to the control valve shaft with the NEW bolt
(B).
c) Remove bolt (A) and install the NEW bolt (A).
d) Torque all bolts to spec.
Torque Spec: 35 N∙m (357 kgf∙cm, 26 ft∙lbf)
e) Disconnect the seat belt that is holding the steering
wheel.
LH Side
11. RECONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS
a) Reconnect the harness clamp and front skid control
sensor connector.
b) Repeat the procedure on the opposite side.
RH Side
LH Side
12. RECONNECT THE FRONT BRAKE TUBES
a) Reconnect the front brake tube and torque to spec.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
b) Repeat the procedure on the opposite side.
RH Side
72
13. RECONNECT THE AIR CONDITIONING DISCHARGE
AND SUCTION HOSES TO THE COMPRESSOR
NEW Replacement Parts
Part #
90210-A0002
90210-A0004
Part Name
Washer, Seal
Kit #
2
2
Qty
1
1
a) Install a NEW o-ring to the A/C discharge and suction
hoses.
b) Reconnect the A/C discharge and suction hoses to the
compressor, then torque to spec.
Torque Spec: 19 N∙m (194 kgf∙cm, 14 ft∙lbf)
c) Reconnect the cooler bracket with the bolt and torque
to spec.
Torque Spec: 7.5 N∙m (76 kgf∙cm, 66 in∙lbf)
LH Side
14. REINSTALL THE FRONT FENDER APRON SEAL
4WD, Pre-Runner Only (Shown):
a) Reinstall the 4 front fender apron seals with the 20
clips.
2WD Only:
b) Reinstall the 4 front fender apron seals with the 22
clips.
RH Side
15. RECONNECT THE WATER / HEATER HOSES, ENGINE SIDE
16. RECONNECT THE ENGINE WIRE HARNES
a) Reinstall the engine wire harness container to the cowl
panel.
b) Reconnect the clamp.
17. RECONNECT THE NO.1 HOSE (2TR-FE ONLY)
a) Reconnect the No.1 hose.
18. RECONNECT THE GROUND WIRE (2TR-FE ONLY)
a) Reconnect the ground wire with the bolt.
Torque Spec: 8.3 N∙m (85 kgf∙cm, 73 in∙lbf)
73
19. RECONNECT THE POWER STEERING PUMP
RESERVOIR ASSY (1GR-FE ONLY)
a) Reconnect the power steering pump reservoir assy.
20. RECONNECT THE GROUND WIRE (1GR-FE ONLY)
a) Reconnect the ground wire with the bolt.
b) Reconnect the clamp.
Torque Spec: 8.3 N∙m (85 kgf∙cm, 73 in∙lbf)
21. REINSTALL THE FAN SHROUD
22. REINSTALL THE RADIATOR
a) Install the NEW o-ring to the drain plug.
b) Tighten the radiator drain plug.
c) Reinstall the radiator with 4 bolts and torque to spec.
NEW Replacement Parts
Part #
90069-08019
Part Name
Ring, O
Kit #
2
Qty
1
Torque Spec: 18 N∙m (184 kgf∙cm, 13 ft∙lbf)
d) Reinstall the automatic transmission cooler lines (Auto
Trans Only).
e) Reinstall the fan shroud with the 2 bolts.
Torque Spec: 5.0 N∙m (51 kgf∙cm, 44 in∙lbf)
23. REINSTALL THE SUPPORT TO FRAME SEAL
24. RECONNECT THE VACUUM HOSE
a) Reconnect the vacuum hose.
25. RECONNECT THE FUEL PIPES
a) Reconnect the No.1 and No.2 fuel pipe.
b) Reinstall the 2 fuel pipe clamps.
26. RECONNECT THE FUEL VAPOR FEED HOSE
27. RECONNECT THE FRONT DIFFERENTIAL BREATHER
TUBES (4WD ONLY)
a) Reconnect the front differential breather tubes.
NOTE: There may be 2 different breather tubes
depending on the vehicle spec.
74
28. RECONNECT THE NO.2 ENGINE WIRE HARNESS
a) Reinstall fuse box wire harness with the nut and torque
to spec.
Torque Spec: 12.7 N∙m (130 kgf∙cm, 9 ft∙lbf)
b) Reconnect the 3 connectors.
c) Reinstall the No.1 upper relay block cover.
d) Reconnect the No.2 engine wire harness to the clip.
e) Reinstall the (+) positive battery cable with the nut and
torque to spec.
Torque Spec: 12.7 N∙m (130 kgf∙cm, 9 ft∙lbf)
f)
Reinstall the ground wire with the bolt and torque to
spec.
Torque Spec: 8.3 N∙m (85 kgf∙cm, 73 in∙lbf)
29. REINSTALL THE FOLLOWING PARTS
•
•
•
Air Cleaner Hose and Air Cleaner Assy (1GR-FE Only)
° Torque Spec:
Air Cleaner Assy - 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
Air Cleaner Hose - 12 N∙m (122 kgf∙cm, 9 ft∙lbf)
Air Cleaner Hose and Air Cleaner Assy (2TR-FE Only)
° Torque Spec: 12 N∙m (122 kgf∙cm, 9 ft∙lbf)
V-Bank Cover (1GR-FE Only)
° Torque Spec: 7.5 N∙m (76 kgf∙cm, 66 in∙lbf)
30. REINSTALL THE FOLLOWING PARTS
• Rear Floor Side Service Hole Cover LH/RH (Access Cab) • No.1 w/ Box Speaker Assy (If Equipped)
• Seat Floor Box (Access Cab)
• Luggage compartment Side Tray (Double Cab)
• Floor Board No.1/No.2 (Access Cab)
31. RECONNECT THE PARKING BRAKE CABLES
For Separate Seat Type:
a) Reconnect the 2 parking brake cables.
b) Reinstall the 2 clips.
For Bench Seat Type:
c) Reconnect the 2 parking brake cables.
d) Reinstall the 2 clips.
e) Reinstall the parking brake cable joint protector with the
3 bolts and torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
f)
Turn back the floor carpet.
75
32. REINSTALL THE FOLLOWING PARTS
•
•
•
Manual Transmission Shift Lever (Manual Trans)
Voltage Inverter Assy (If Equipped)
Front Console Box
•
•
Front Console Box
Rear Console Box (for Separate Seat Type)
33. RECONNECT THE ENGINE WIRE HARNESS
a) Reconnect each connector and clamp to the ECM and
engine wire harness.
NOTE: The number of connectors may differ
depending on the model.
34. REINSTALL THE GLOVE BOX AND THE LOWER
INSTRUMENT PANEL FINISH PANEL
a) Reinstall the lower instrument panel finish panel with
the bolt.
b) Reinstall the glove box.
35. RECONNECT THE FRAME WIRE HARNESS
a) Insert the frame wire harness into the cab assy.
b) Reinstall the frame wire harness grommet to the cab
assy.
c) Reconnect the 3 connectors.
d) Reconnect the 3 harness clamps.
e) Reconnect the 2 clamps.
76
36. REINSTALL THE FOLLOWING PARTS
•
•
•
•
Instrument Panel Box
Cowl Side Trim Board LH/RH
Front Floor Footrest
Front Door Scuff Plate LH/RH
37. REINSTALL THE FOLLOWING PARTS
•
NEW Replacement Parts
•
Front No.2 Bumper Extension Sub-Assy LH/RH
Part #
90176-A0044
Part Name
Nut, Flange
Kit #
2
Qty
6
•
•
•
•
Front No.2 Bumper Extension Sub-assy LH/RH
° Reinstall the No.2 front bumper extension with 6
NEW nuts and torque to spec.
° Torque Spec: 58 N∙m (591 kgf∙cm, 43 ft∙lbf)
Front Bumper Reinforcement
° Reinstall the front bumper reinforcement with 6 nuts
and torque to spec.
° Torque Spec: 58 N∙m (591 kgf∙cm, 43 ft∙lbf)
Front Bumper Assy
° Reinstall with the 6 screws and 9 clips.
Front Fender Mudguard LH/RH
Front Bumper Filler LH/RH
Radiator Grille
77
J. REINSTALL THE BED ASSY
1. REINSTALL THE BED ASSY
a) Using a Torx® T55 Socket, reinstall the bed assy Torx ®
bolts and torque to spec.
Torque Spec: 49 N∙m (500 kgf∙cm, 36 ft∙lbf)
NOTE:
• Use 4 or more people to lift the bed assy.
• Evenly support the bed assy when reinstalling it.
• Be careful not to damage or hit the fuel inlet pipe
when reinstalling the bed assy.
2. REINSTALL THE FUEL INLET PIPE SUB-ASSY
a) Reinstall the fuel inlet pipe sub-assy with the 2 nuts and
torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
3. RECONNECT THE FRAME WIRE HARNESS
a) Reconnect the 6 wire harness clamps to the bed assy.
NOTE:
• The number of connectors will differ depending on
the vehicle spec.
• Use new clamps if the original ones are damaged.
NEW Replacement Parts
Part #
90189-A0002
90189-A0002
Left Rear Wheel Well Liner
Part Name
Grommet, Screw (X-Runner)
Grommet, Screw
4. REINSTALL THE FOLLOWING PARTS
Kit #
9
8
Qty
6
8
Quarter Panel Wheel Opening Molding
Part #
Part Name
Kit #
75395-35070
Clip, Outside Molding, No. 1
8
75396-35020
Clip, Outside Molding, No. 2
8
90189-A0002
Grommet, Screw
8
Qty
3
7
2
Body Rocker Panel Molding Assy LH
Part #
Part Name
Kit #
75395-35070
Clip, Outside Molding, No. 1
9
75396-35020
Clip, Outside Molding, No. 2
9
90189-A0002
Grommet, Screw
9
Qty
2
1
1
Outside LH Back Door Molding Sub-Assy
Part #
Part Name
Kit #
75395-35070
Clip, Outside Molding, No. 1
9
75396-35020
Clip, Outside Molding, No. 2
9
90189-A0002
Grommet, Screw
9
Qty
2
1
1
Part #
75395-04010
75396-04010
Rocker Panel Molding LH/RH
Part Name
Clip, Outside Molding, No. 1
Clip, Outside Molding, No. 2
Kit #
9
9
Qty
4
14
Rear Bumper Assy
Part Name
Bolt, w/ Washer
Kit #
2
Qty
6
Part #
90119-A0192
•
•
•
•
•
•
•
•
•
Left Rear Wheel Well Liner
Quarter Panel Wheel Opening Molding LH
Body Rocker Panel Molding Assy LH (If Equipped)
Outside LH Back Door Molding Sub-Assy (If Equipped)
Side Step Assy LH/RH (If Equipped)
Rocker Panel Molding LH/RH (If Equipped)
Rear Mudguard LH/RH (If Equipped)
Rear Tail/Combination Light LH/RH
Rear Bumper Assy
° Reinstall the rear bumper assy with the 10 bolts and
torque to spec. (Trailer Hitch Equipped Vehicles Only)
° Reinstall the rear bumper assy with the 6 NEW bolts
and torque to spec.
° Torque Spec: 90 N∙m (918 kgf∙cm, 66 ft∙lbf)
78
K. FINAL ASSEMBLY
1. REINSTALL THE NEGATIVE (-) BATTERY TERMINAL
2. REFILL THE FOLLOWING FLUIDS
•
NEW Replacement Parts
Front Differential
Part #
12157-10010
90430-24003
Part Name
Gasket, Drain Plug
Gasket
Kit #
3
3
Qty
1
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: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
° Refill with Toyota Dot 3 Brake Fluid.
° Bleed the brake system at each wheel and torque
the bleeder screws to spec.
° Torque Spec: 10.8 N∙m (110 kgf∙cm, 8 ft∙lbf)
• Clutch Fluid (1GR-FE Manual Trans Only)
° Refill with Toyota Dot 3 Brake Fluid.
° Bleed the clutch system and torque the bleeder
screws to spec.
° Torque Spec: 10.8 N∙m (110 kgf∙cm, 8 ft∙lbf)
NOTE: 2TR Manual Trans uses master cylinder
reservoir for clutch.
• Coolant
° Refill with Toyota Long Life Coolant.
° Bleed the cooling system.
• Front Differential
° Install NEW drain plug washer and torque to spec.
° Torque Spec: 64.7 N·m (660 kgf·cm, 48 ft·lbf)
° Refill with Hypoid Gear Oil API GL-5 75W-90.
° Install a NEW filler plug washer and torque to spec.
° Torque Spec: 39.2 N·m (400 kgf·cm, 29 ft·lbf)
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
Clutch System (1GR-FE Manual Trans Only)
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 thouroughly to ensure proper
operation of these systems.
• Parking Brake Travel
• Shift Control Lever (Automatic Transmission Vehicles Only)
• Clutch Pedal (Manual Transmission Vehicles Only)
6. CHECK ALL FLUID LEVELS AND ADJUST AS NEEDED
79
Part #
43514-28010
95381-04045
NEW Replacement Parts
Part Name
Cap, FR Hub Grease
Pin, Cotter
Kit #
3
3
Qty
2
2
7. TORQUE THE FRONT AXLE NUT (4WD ONLY)
a) Remove the front wheels.
b) Torque the front axle nut 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 NEW grease cap.
Repeat the procedure on the opposite side.
Reinstall the front wheels and torque to spec.
Torque Spec: 113 N∙m (1152 kgf∙cm, 83 ft∙lbf)
NOTE: If the holes for the cotter pin are not aligned,
tighten the axle nut further, up to 60°.
8. PERFORM A WHEEL ALIGNMENT
9. CHECK THE HEADLIGHT AIM AND ADJUST AS NEEDED
10. REINSTALL THE ENGINE UNDER COVERS
NEW Replacement Parts
Purt Number
90080-11373
Purt Name
Bolt, w/ Washer
Kit #
8
Qty
8
a) Reinstall the engine under cover with 8 NEW bolts and
torque to spec.
Torque Spec: 30 N∙m (306 kgf∙cm, 22 ft∙lbf)
11. CHECK FOR DTC’S AND REPAIR AS NEEDED
12. PERFORM INITIALIZATION
13. FINAL INSPECTION
a) Check the operation of the following systems:
•
•
•
•
•
14.
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.
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.
15. 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
80
b) Select 2005 to 2010 Tacoma ZH6 from the pick list.
c) Enter the VIN of the vehicle.
d) Enter the frame serial off of the case label along with the R.O. number and Approved Frame Inspection Case
Number.
Sample Case Label
e) Press submit and print a copy of the serial number and file with the R.O.
81
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.
82
(100)
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(100)
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