ZKA_TI-11_15MY-D

TECHNICAL INSTRUCTIONS
FOR
CUSTOMER SUPPORT PROGRAM ZKA
*****************************
CERTAIN 2011 THROUGH 2015 MODEL YEAR TACOMA
*****************************
COVERAGE FOR VEHICLE FRAME CORROSION PERFORATION
The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians
performing this CSP 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 CSP 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.
1
OPERATION FLOWCHART
Verify Vehicle Eligibility
1. Confirm vehicle VIN matches the R.O.
2. Check the TIS Vehicle Inquiry System
Not Covered
No further action required
Frame Rail Seal
ALREADY INSTALLED
No further action required
Covered
Perform pre-hoist inspection
Inspect for Frame Rail Seal
Frame Rail Seal
NOT FOUND
Please see to the K0D Technical
Instructions and Dealer Letter for
the next steps
Perform Frame Inspection utilizing the Inspection
application
Yes (to either question)
Was perforation 10mm or larger found in the
locations identified in Green below?
No
Are you located in a Cold Climate
State, or is the vehicle eligible for
K0D?
No (to both questions)
Yes
Inspection Application submits report for FTS
approval
No
No further action required
Was approval received from the FTS?
Yes
Order parts and complete frame replacement
Campaign completed, return the vehicle
to the customer
Cold Climate States Include - CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, WV
and District of Columbia
Background
Toyota has received a number of reports regarding vehicle frame corrosion perforation on certain
2011-2017 model year Tacoma vehicles. These reports have indicated that these vehicles, when
operated in specific cold climate areas (Cold Climate States1) with high road salt usage, or exposed
to other environmental factors, may exhibit more-than-normal corrosion to the vehicle’s frame.
2
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
− 12281-75050 – Engine hanger (Qty: 2)
− 91672-81025 – 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)

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 35mm
Hexagon wrench 8, 10
Deep socket wrench 10, 12, 14, 17, 19mm
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 – 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
3
THE PARTS SHOWN BELOW WERE INCLUDED IN ZH6 2005-2010MY FRAME
REPLACEMENT PARTS BUT WILL NOT BE INCLUDED IN ZKA 2011-2015
• When removing the reusable parts, be careful to NOT damage and make them non-reusable.
Judge if the following parts are reusable or not on the actual vehicle, and order the part
individually as needed.
4
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 https://tacoma-2011-2017-frames.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
04006-63304
04008-15104
04006-63704
04008-15204
04006-63604
04008-15304
04006-64504
04008-15404
04006-64304
04008-15504
04006-64104
04008-15604
04006-64404
04008-15704
04006-63104
04008-16504
04008-16604
04008-16704
04006-63204
04008-16804
04008-16904
04008-17104
04006-63404
04008-17204
04008-17404
04008-17504
04006-63504
04008-17604
04008-17804
04008-17904
04008-18204
04008-18304
Part Description
(GRN225 2011-2012MY)
(GRN225 2013-2015MY)
(GRN245 DCB 2011-2012MY)
(GRN245 DCB 2013-2015MY)
(GRN245 LCB 2011-2012MY)
(GRN245 LCB 2013-2015MY)
(GRN250 2011-2012MY)
(GRN250 2013-2015MY)
(GRN265 DCB 2011-2012MY)
(GRN265 DCB 2013-2015MY)
(GRN265 LCB 2011-2012MY)
(GRN265 LCB 2013-2015MY)
(GRN270 2011-2012MY)
(GRN270 2013-2015MY)
(TRN220 2011-2012MY)
(TRN220 2013-2014MY)
(TRN225 DCB 2011-2012MY)
(TRN225 DCB 2013-2015MY)
(TRN225 LCB 2011-2012MY)
(TRN225 LCB 2013-2015MY)
(TRN240 4AT 2011-2012MY)
(TRN240 4AT 2013-2014MY)
(TRN240 5MT 2011-2012MY)
(TRN240 5MT 2013-2014MY)
(TRN245 4AT 2011-2012MY)
(TRN245 4AT 2013-2015MY)
(TRN245 5MT 2011-2012MY)
(TRN245 5MT 2013-2015MY)
(TRN265 DCB 2011-2012MY)
(TRN265 DCB 2013-2015MY)
(TRN265 LCB 2011-2012MY)
(TRN265 LCB 2013-2015MY)
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
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
Frame
Page
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
5
Individual Parts (Continued):
Part Number
Part Description
43425-04040
47313-04210
47313-04241
47315-04180
47315-04191
47323-04180
47323-04191
47324-04140
47324-04151
47325-04190
47325-04191
47325-04200
47325-04201
47325-04210
47325-04211
47326-04160
47326-04161
47326-04170
47326-04171
47326-04180
47326-04181
48068-04030
48068-04040
48069-04030
48069-04040
48304-04090
48304-04090
48304-AD010
48304-AD010
51900-35410
51900-35420
82711-16830
82715-04160
82715-04200
82715-04200
82715-04220
82715-04230
82715-04240
82715-04290
82715-04290
82715-04350
82715-3D680
82715-04250
82715-04260
90105-A0064
90105-A0066
90119-08A91
90119-A0141
90119-A0148
90119-A0151
90119-A0161
90119-A0169
90119-A0169
90119-A0169
90119-A0169
90119-A0193
90178-A0001
90178-A0013
90179-08241
90240-08054
90468-14033
90469-A0004
90469-A0004
90469-A0004
Ring, Shaft Snap (For Front Drive Inner Shaft Outer)
Tube, Front Brake, No.3
Tube, Front Brake, No.3
Tube, Front Brake, No.5
Tube, Front Brake, No.5
Tube, Rear Brake, No.3
Tube, Rear Brake, No.3
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
Tube, Rear Brake, No.5
Tube, Rear Brake, No.5
Tube, Rear Brake, No.5
Tube, Rear Brake, No.6
Tube, Rear Brake, No.6
Tube, Rear Brake, No.6
Tube, Rear Brake, No.6
Tube, Rear Brake, No.6
Tube, Rear Brake, No.6
Arm Sub-Assy, Front Suspension, Lower No.1 RH
Arm Sub-Assy, Front Suspension, Lower No.1 RH
Arm Sub-Assy, Front Suspension, Lower No.1 LH
Arm Sub-Assy, Front Suspension, Lower No.1 LH
Bumper, Front Spring, LH
Bumper, Front Spring, RH
Bumper, Front Spring, LH
Bumper, Front Spring, RH
Carrier Assy, Spare Wheel
Carrier Assy, Spare Wheel
Clamp (For Rear Differential Lock)
Bracket (For 2TR-FE 4WD Front Differential Wire)
Bracket (For 2TR-FE A/F Sensor Wiring)
Bracket (For Frame Wire No.2)
Bracket (For Frame Wire)
Bracket (For Frame Wire)
Bracket (For Frame Wire No.2)
Bracket (For Frame Wire No.2)
Bracket (For 2TR-FE A/F Sensor Wiring)
Bracket (For Frame Wire No.2)
Bracket (For 1GR-FE 4WD Front Differential Wire)
Bracket (For Rear Differential Lock)
Bracket (For Rear Differential Lock)
Bolt (For Skid Control Sensor)
Bolt (For Rear Differential Lock)
Bolt (For Rear Stabilizer Bracket Cover)
Bolt (For Front Differential Wire Bracket)
Bolt (For W/ Frame Wire No.2)
Bolt (For Heat Insulator of Propeller Shaft)
Bolt (For Front Stabilizer Bracket)
Bolt (For Brake Tube)
Bolt (For 1GR-FE W/O Frame Wire No.2)
Bolt (For 2TR-FE W/O Frame Wire No.2)
Bolt (For W/ Frame Wire No.2)
Bolt (For Front Hook, No.1 W/ Fuel Tank Protector)
Nut (For 4WD, Pre-Runner Front Suspension Camber Adjust Cam)
Nut (For 2WD Front Suspension Camber Adjust Cam)
Nut (For Fuel Tank Protector)
Pin, W/ Hole (For Transmission Control Rod)
Clip (For Transmission Control Rod)
Clamp, Brake Tube, No.11 (For Regular Cab)
Clamp, Brake Tube, No.11 (For Access Cab)
Clamp, Brake Tube, No.11 (For Double Cab)
Quantity
Illustration Name
Page
2
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
2
4
1
2
2
4
9
2
4
6
2
2
4
4
1
1
2
3
4
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
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Front Suspension
Front Suspension
Front Suspension
Front Suspension
Front Suspension
Front Suspension
Front Suspension
Front Suspension
Spare Tire Carrier
Spare Tire Carrier
Wire Harness Brackets
Wire Harness Brackets
Wire Harness Brackets
Wire Harness Brackets
Wire Harness Brackets
Wire Harness Brackets
Wire Harness Brackets
Wire Harness Brackets
Wire Harness Brackets
Wire Harness Brackets
Wire Harness Brackets
Wire Harness Brackets
Wire Harness Brackets
ABS
Wire Harness Brackets
Rear Suspension
Wire Harness Brackets
Wire Harness Brackets
Propeller Shaft
Front Suspension
Brake Tubes
Wire Harness Brackets
Wire Harness Brackets
Wire Harness Brackets
Under Cover
Front Suspension
Front Suspension
Fuel Tank
Shift Lever
Shift Lever
Brake Tubes
Brake Tubes
Brake Tubes
15
17,18,20
17,18,20
17,18,20
17,18,20
17,18,20
17,18,20
17,18,20
17,18,20
17
17
18-21
18-21
20
20
17
17
18-21
18-21
20
20
14
15
14
15
14
14
14
14
13
13
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
16
23
23
25
14
17-20,22
23
23
23
13
15
14
22
26
26
17
18,19
20,21
6
Parts Kits:
Part Number
Part Description
Quantity
04008-07235
Parts Kit No.1 – Common Replacement Kit D
1
The kit listed above includes the following parts:
Part Number
90910-03001
91671-80814
94151-21001
90412-10289
77285-35760
Part Number
04008-22104
Part Description
Bolt (For Front Engine Mount)
Bolt (For Rear Engine Mount)
Nut (For Front Engine Mount)
Way (For Front Brake Tube)
Clamp, Fuel Tube, No.1
Qty
4
4
4
2
1
Illustration Name
Engine Mounting
Engine Mounting
Engine Mounting
Brake Tubes
Fuel Tubes
Part Description
Parts Kit No.2 – Common Replacement Kit E
Page
24
24
24
17-21
22
Quantity
1
The kit listed above includes the following parts:
Part Number
90069-08019
90080-11555
90412-10276
90949-A1006
90468-A0007
90171-A0005
90171-A0005
90080-17215
90177-A0010
90119-A0169
51719-04010
90178-A0044
90119-A0192
90119-A0249
90210-A0002
90210-A0004
Part Number
04006-46104
Part Description
Packing (For Radiator Drain Cock)
Bolt (For Steering Intermediate Shaft)
Way, 2 (For Rear Brake Tube)
Clamp, Brake Tube, No.10
Clip (For Brake Tube)
Nut, Castle (For Front Lower Ball Joint RH)
Nut, Castle (For Front Lower Ball Joint LH)
Nut (For Front Suspension Support)
Nut (For Rear Shock Absorber)
Bolt (For Spare Tire Carrier)
Holder, Body Support Bracket
Nut (For Front Bumper Extension)
Bolt (For Rear Bumper)
Bolt (For Fuel Tank Band)
O Ring (For Discharge Hose Sub-Assy)
O Ring (For Suction Hose Sub-Assy)
Qty
1
2
1
3
4
1
1
6
2
4
2
6
6
2
1
1
Illustration Name
Radiator
Power Steering
Brake Tubes
Brake Tubes
Brake Tubes
Front Suspension
Front Suspension
Front Suspension
Rear Suspension
Spare Tire Carrier
Cab Mounting
Front Bumper
Rear Bumper
Fuel Tank
Air Conditioning
Air Conditioning
Part Description
Parts Kit No.3 – JPN Source Parts Kit 4 (4WD)
Page
26
24
17-21
17-21
17-22
14,15
14,15
14,15
16
13
13
26
26
22
26
26
Quantity
1
The kit listed above includes the following parts:
Part Number
12157-10010
90430-24003
90311-47027
90311-47026
43514-28010
43514-28010
95381-04045
Part Description
Gasket, Front Differential Filler Plug
Gasket, Front Differential Drain Plug
Seal, Oil (For Differential Side Gear Shaft)
Seal, Oil (For Differential Side Gear Shaft)
Cap, Front Axle Hub Grease, RH
Cap, Front Axle Hub Grease, LH
Cotter Pin (For Front Drive Shaft)
Qty
1
1
1
1
1
1
2
Illustration Name
Front Differential
Front Differential
Front Differential
Front Differential
Front Suspension
Front Suspension
Front Suspension
Page
24
24
24
24
15
15
15
7
Parts Kits (Continued):
Part Number
04001-71404
Part Description
Parts Kit No.4 – JPN Source Parts Kit 2 (2WD)
Quantity
1
The kit listed above includes the following parts:
Part Number
95381-03025
48190-25010
48190-25010
48198-25010
48198-25010
95381-03230
Part Number
04001-71504
Part Description
Cotter Pin (For Tie Rod End)
Cam, Front Suspension Camber Adjust, No.1 RH
Cam, Front Suspension Camber Adjust, No.1 LH
Cam, Front Suspension Camber Adjust, No.2 RH
Cam, Front Suspension Camber Adjust, No.2 LH
Cotter Pin (For Front Suspension Lower Arm)
Qty
2
2
2
2
2
2
Illustration Name
Power Steering
Front Suspension
Front Suspension
Front Suspension
Front Suspension
Front Suspension
Part Description
Parts Kit No.5 – JPN Source Parts Kit 3 (4WD and Pre-Runner)
Page
24
14
14
14
14
14
Quantity
1
The kit listed above includes the following parts:
Part Number
95381-03225
48190-60020
48190-60020
48198-60011
48198-60011
48409-60020
48452-35020
95381-03230
Part Number
04008-22304
Part Description
Cotter Pin (For Tie Rod End)
Cam, Front Suspension Camber Adjust, No.1 RH
Cam, Front Suspension Camber Adjust, No.1 LH
Cam, Front Suspension Camber Adjust, No.2 RH
Cam, Front Suspension Camber Adjust, No.2 LH
Cam Sub-Assy, Front Suspension Toe Adjust
Plate, Front Suspension Toe Adjust, No.2
Cotter Pin (For Front Suspension Lower Arm)
Qty
2
1
1
1
1
2
2
2
Illustration Name
Power Steering
Front Suspension
Front Suspension
Front Suspension
Front Suspension
Front Suspension
Front Suspension
Front Suspension
Part Description
Parts Kit No.6 – USA Source Parts Kit 5 (1GR)
Page
24
15
15
15
15
15
15
15
Quantity
1
The kit listed above includes the following parts:
Part Number
Part Description
Qty
17176-0P030
Gasket, Air Surge Tank to Intake Manifold
1
17451-0D020
Gasket, Exhaust Pipe
1
90080-10291
Bolt (For Exhaust Pipe)
2
90080-11180
Bolt (For Exhaust Pipe Stopper Bracket)
2
Part Number
04008-22504
Illustration Name
1GR-FE Exhaust
System
1GR-FE Exhaust
System
1GR-FE Exhaust
System
1GR-FE Exhaust
System
Part Description
Parts Kit No.7 – USA Source Parts Kit 7 (2TR)
Page
25
25
25
25
Quantity
1
The kit listed above includes the following parts:
Part Number
Part Description
Qty
90080-43033
Gasket (Exhaust Pipe)
1
90080-10064
Bolt (Exhaust Pipe)
2
90177-A0004
Nut (Exhaust Pipe)
2
Illustration Name
2TR-FE Exhaust
System
2TR-FE Exhaust
System
2TR-FE Exhaust
System
Page
25
25
25
8
Parts Kits (Continued):
Part Number
04001-71804
Part Description
Parts Kit No.8 – USA Source Parts Kit 3 (Except For X-Runner)
Quantity
1
The kit listed above includes the following parts:
Part Number
90119-A0166
48304-04100
48304-04100
90119-A0192
90080-11373
90080-11373
Part Description
Bolt (For Front Suspension Toe Adjust Cam)
Bumper, Front Spring, LH
Bumper, Front Spring, RH
Bolt (For Hook No.1)
Bolt (For Engine Under Cover Sub-Assy No.1)
Bolt (For Engine Under Cover Sub-Assy No.2)
Qty
2
1
1
2
4
4
90189-A0002
Clip (For Left Rear Wheel Well Liner)
8
90189-A0002
75395-35070
75396-35020
Clip (For Quarter Panel Wheel Opening Moulding)
Clip (For Quarter Panel Wheel Opening Moulding)
Clip (For Quarter Panel Wheel Opening Moulding)
2
3
7
Part Number
04001-71904
Illustration Name
Front Suspension
Front Suspension
Front Suspension
Under Cover
Under Cover
Under Cover
Rear Wheel
House Liner
Moulding
Moulding
Moulding
Part Description
Parts Kit No.9 – USA Source Parts Kit 4 (X-Runner)
Page
15
15
15
13
13
13
26
27
27
27
Quantity
1
The kit listed above includes the following parts:
Part Number
Part Description
Qty
90189-A0002
Clip (For Left Rear Wheel Well Liner)
6
75395-04010
75396-04010
75395-35070
75395-35070
75396-35020
75396-35020
90189-A0002
90189-A0002
Clip (For Rocker Panel Moulding)
Clip (For Rocker Panel Moulding)
Clip (For Body Rocker Panel Moulding)
Clip (For Back Door Moulding)
Clip (For Body Rocker Panel Moulding)
Clip (For Back Door Moulding)
Clip (For Body Rocker Panel Moulding)
Clip (For Back Door Moulding)
4
14
2
2
1
1
1
1
Part Number
04001-72204
Illustration Name
Rear Wheel
House Liner
Moulding
Moulding
Moulding
Moulding
Moulding
Moulding
Moulding
Moulding
Part Description
Parts Kit No.10 – Brake Tube Kit 2 (GRN245 with Off Road Package 2011MY)
Page
26
27
27
27
27
27
27
27
27
Quantity
1
The kit listed above includes the following parts:
Part Number
47313-04200
47315-04170
47323-04170
47324-04130
Part Description
Tube, Front Brake, No.3
Tube, Front Brake, No.5
Tube, Rear Brake, No.3
Tube, Rear Brake, No.4
Qty
1
1
1
1
Illustration Name
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Page
19,21
19,21
19,21
19,21
9
Parts Kits (Continued):
Part Number
04008-22704
Part Description
Prats Kit No.11 – Brake Tube Kit 5
(GRN245 with Off Road or TRD Package 2012-2015MY)
Quantity
1
The kit listed above includes the following parts:
Part Number
47313-04231
47315-04171
47323-04171
47324-04131
Part Number
04008-22904
Part Description
Tube, Front Brake, No.3
Tube, Front Brake, No.5
Tube, Rear Brake, No.3
Tube, Rear Brake, No.4
Qty
1
1
1
1
Illustration Name
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Part Description
Parts Kit No.12 – Brake Tube Kit 10 (2WD 2011MY)
Page
19,21
19,21
19,21
19,21
Quantity
1
The kit listed above includes the following parts:
Part Number
47314-04140
47316-04140
Part Number
04008-23104
Part Description
Tube, Front Brake, No.4
Tube, Front Brake, No.6
Qty
1
1
Illustration Name
Brake Tubes
Brake Tubes
Part Description
Parts Kit No.13 – Brake Tube Kit 6 (2WD 2012-2015MY)
Page
17,18,20
17,18,20
Quantity
1
The kit listed above includes the following parts:
Part Number
47314-04141
47316-04141
Part Number
04008-23204
Part Description
Tube, Front Brake, No.4
Tube, Front Brake, No.6
Qty
1
1
Illustration Name
Brake Tubes
Brake Tubes
Part Description
Parts Kit No.14 – Brake Tube Kit 11 (4WD and Pre-Runner 2011MY)
Page
17,18,20
17,18,20
Quantity
1
The kit listed above includes the following parts:
Part Number
47314-04150
47316-04150
90119-A0169
Part Number
04008-23304
Part Description
Tube, Front Brake, No.4
Tube, Front Brake, No.6
Bolt (For Brake Tube)
Qty
1
1
7
Illustration Name
Brake Tubes
Brake Tubes
Brake Tubes
Part Description
Parts Kit No.15 – Brake Tube Kit 7 (4WD and Pre-Runner 2012-2015MY)
Page
17-21
17-21
17-22
Quantity
1
The kit listed above includes the following parts:
Part Number
47314-04151
47316-04151
90119-A0169
Part Description
Tube, Front Brake, No.4
Tube, Front Brake, No.6
Bolt (For Brake Tube)
Qty
1
1
7
Illustration Name
Brake Tubes
Brake Tubes
Brake Tubes
Page
17-21
17-21
17-22
10
Parts Kits (Continued):
Part Number
04008-07535
Part Description
Plug Hole Kit Frame Replacement 1 (4WD and Pre-Runner)
Quantity
1
The kit listed above includes the following parts:
Part Number
90333-20001
90333-30002
90950-01631
90950-01931
90950-01983
90950-01984
90950-01987
90950-01989
90950-01990
90950-01991
90950-01992
90950-01A24
Part Number
04007-18235
Part Description
Plug, Plate
Plug, Plate
Plug, Hole
Plug, Hole
Plug, Hole
Plug, Hole
Plug, Hole
Plug, Hole
Plug, Hole
Plug, Hole
Plug, Hole
Plug, Hole
Qty
10
29
4
1
4
2
8
4
4
4
2
2
Illustration Name
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Part Description
Plug Hole Kit (2WD)
Page
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Quantity
1
The kit listed above includes the following parts:
Part Number
90333-20001
90333-30002
90950-01631
90950-01931
90950-01983
90950-01984
90950-01987
90950-01989
90950-01990
90950-01991
90950-01992
90950-01A09
90950-01A11
90950-01A24
Part Description
Plug, Plate
Plug, Plate
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
2
36
4
1
4
2
6
4
4
4
2
2
2
2
Illustration Name
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Page
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
11
D. PARTS ILLUSTRATION
Frame
Cab Mounting
Under Cover
Spare Tire Carrier
12
Front Suspension
13
Front Suspension Continued…
14
Rear Suspension
15
Brake Tubes
16
Brake Tubes Continued…
17
Brake Tubes Continued…
18
Brake Tubes Continued…
19
Brake Tubes Continued…
20
Brake Tubes Continued…
Fuel Tank
Fuel Tubes
21
ABS
Wire Harness Brackets
22
Power Steering
Front Differential
Engine Mounting
23
Propeller Shaft
1GR-FE Exhaust System
2TR-FE Exhaust System
24
Shift Lever
Radiator
Air Conditioning
Front Bumper
Rear Bumper
Rear Wheel House Liner
25
Moulding
Moulding Continued…
Moulding Continued…
26
FRAME INSPECTION
PERFORM INITIAL PRE-HOIST INSPECTION
1. INSPECT THE FRAME FOR EXCESSIVE FRAME CORROSION THAT COULD AFFECT THE STRUCTURAL
INTEGRITY OF THE FRAME
FRAME INSPECTION
All frame inspection must be performed using the 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. INSPECT FOR FRAME RAIL SEAL
a. Inspect if the frame already has a frame rail seal installed as shown in the image below
Is the frame rail seal already
installed?
YES
No further action required. Campaign is
complete
NO
Proceed to the next step in the
frame inspection
27
2. ACCESS INSPECTION APPLICATION
a. Run the VIN in TIS and click on the Warranty Tab.
b. Click on the “Frame Inspection” link on TIS.
3. LOG INTO THE INSPECTION APPLICATION
a. Reenter your TIS password
28
4. 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.
Select NO CRC Previously Applied: Select Frame Button
5. INSPECT THE FRAME SECTIONS
a. Inspect the frame in the colored areas below and use the application to document the results of the
inspection.
Tacoma 11 to 17
b. Select Section A
Note: The frame inspection application must be completed in alphabetical order.
29
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
“Perforation of the Frame”.
Note: You must click the bubble next to the image to select the condition.
c.
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:
• Include the R.O in the image of at least one of the perforation holes.
• If both sub-sections have perforation, it will require two pictures to be uploaded.
• If perforation was accidentally selected, use the back button to reset section.
h. Select Next to move onto the next section.
30
Each image attached has a size limit of 3 MB and all images cannot exceed
15 MB total. If 3MB is uploaded the system will display the error shown below.
User using Chrome browser may receive intermittent errors when uploading
several high-quality images, IE is recommended.
i. Once all sections have been completed, select the Submit button.
Note: When completed it will be indicated by all sections being grayed out and the submit button will
appear.
31
NO Perforation Found
j. If no perforation was 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 inspection technician’s
TIS inbox and Service and Parts Manager email.
32
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.
•
•
•
•
•
3.
4WD System (4WD Only)
Interior Lights
Exterior Lights
HVAC System
Audio System
•
•
•
•
Power Windows
Power Door Locks
All Gauges, Indicators and Warning Lights
Etc.
Documents the current vehicle operating condition on the Frame Replacement Inspection Sheet.
B. SAFETY CHECKLIST & PRECAUTIONS WHEN DRAINING THE FUEL SYSTEM
•
•
•
•
1.
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.
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.
smell is gone.
6.
Dissipate fuel vapors until the
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.
33
34
35
C. 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.
3.
RECORD THE RADIO STATION PRESETS
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
Remove the upper relay block cover.
Remove the circuit opening relay.
Connect the negative (-) battery terminal.
Start the engine.
Turn the ignition switch to ON after the engine stops.
NOTE: DTC P0171 (system too lean) may be present.
Crank the engine again, and check that the engine stops.
Remove the fuel tank cap, and discharge the pressure in
the fuel tank completely.
Disconnect the negative (-) battery terminal.
Reinstall the circuit opening relay.
Reinstall the upper relay block cover.
NOTE: Reinstall the No.1 upper relay block cover to not let foreign
objects enter.
36
D. 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
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 Tail/Combination Light LH/RH
Rear Bumper Assy
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 (If Equipped)
Left Rear Wheel Well Liner
Power Outlet Socket Assy (If Equipped)
When removing the parts, be careful not to damage them and surrounding
components.
3.
DISCONNECT THE FRAME WIRE HARNESS
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
Remove the bolt and disconnect the fuel inlet pipe subassy.
5.
REMOVE THE BED ASSY
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.
• Protect the front side of the bed assy to not
damage the cab assy.
37
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
• Brake Fluid
• Clutch Fluid (1GR-FE Manual Trans 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 (Except 2011MY)
• Front Fender Mudguard LH/RH
5.
• Front Bumper Assy
• Front Bumper Reinforcement
• Front No.2 Bumper Extension Sub-assy LH/RH
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
7.
DISCONNECT THE FRAME WIRE HARNESS
Disconnect the 5 clamps.
Disconnect the connector(s).
NOTE: The number of connectors may differ depending
on the model.
Remove the frame wire harness grommet from the cab
assy.
Pull out the frame wire harness from the vehicle cab assy.
38
8.
DISCONNECT THE NO.2 FRAME WIRE HARNESS
(IF EQUIPPED)
For Frame Connecting Type:
Remove the 2 bolts and cover.
Disconnect the 2 connectors and clamp.
For Floor Connecting Type:
Remove all 4 passenger side seat rail bolts.
Tilt the passenger side seat backwards.
Turn back the floor carpet.
Remove the bolt and wiring harness protector.
Disconnect the 2 connectors.
Remove the No.2 frame wire harness grommet from the
cab assy.
Pull out the No.2 frame wire harness from the cab assy.
9.
REMOVE THE GLOVE BOX AND LOWER INSTRUMENT
PANEL FINISH PANEL
Remove the glove box.
Remove the bolt and the lower instrument panel finish
panel.
Disconnect the radio setting condenser connector. (If Equipped)
10. DISCONNECT THE ENGINE WIRE HARNESS
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.
39
11. REMOVE THE FOLLOWING PARTS
• Rear Console Box (for Separate Seat Type)
• Front Console Box (Manual Trans Only)
• Voltage Inverter Assy (If Equipped)
• Manual Transmission Shift Lever (Manual Trans Only)
12. DISCONNECT THE PARKING BRAKE CABLES
For Separate Seat Type:
Remove the 2 clips.
Disconnect the 2 parking brake cables.
For Bench Seat Type:
Turn back the floor carpet.
Remove the 3 bolts and the parking brake cable joint
protector.
Remove the 2 clips.
Disconnect the 2 parking brake cables.
13. REMOVE THE FOLLOWING PARTS
• V-Bank Cover (1GR-FE Only)
• Air Cleaner Hose and Air Cleaner Assy (2TR-FE Only)
• Air Cleaner Assy (1GR-FE Only)
14. DISCONNECT THE NO.2 ENGINE WIRE HARNESS
Remove the nut and disconnect the (+) positive battery
cable.
Remove the bolt and disconnect the ground wire.
Disconnect the 2 clamps.
Remove the upper relay block cover.
Disconnect the 3 connectors.
Remove the nut and disconnect the fuse box wire harness.
Reinstall the upper relay block cover.
40
LH Side
15. DISCONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS
Disconnect the harness clamp and front skid control sensor
connector.
Repeat the procedure on the opposite side.
RH Side
RH Side
16. DISCONNECT THE NO.2 FRAME WIRE HARNESS
(IF EQUIPPED)
Disconnect the harness clamp and connector.
17. DISCONNECT THE FRONT DIFFERENTIAL BREATHER
TUBES (4WD ONLY)
Disconnect the front differential breather tubes.
NOTE: There may be 2 front differential breather tubes
depending on the vehicle model.
18. DISCONNECT THE FUEL PIPES AND VAPOR FEED HOSE
Remove the 2 fuel pipe clamps.
Disconnect the No. 1 and No. 2 fuel pipe.
Remove the clip and disconnect the fuel vapor feed hose.
NOTE: Put a shop towel under the fuel pipe to catch
any spilled fuel.
19. DISCONNECT THE VACUUM HOSE
Disconnect the vacuum hose.
41
20. DISCONNECT THE RADIATOR HOSES AND AUTO TRANS COOLING LINES (Auto Trans Only)
Disconnect the inlet and outlet radiator hoses from engine.
Disconnect the inlet and outlet auto transmission cooling lines from the radiator
Be careful not to damage the radiator hoses.
21. REMOVE THE FOLLOWING PARTS
• Radiator Support to Frame Seal
• Fan Shroud
• Radiator Assy
22. DISCONNECT THE NO.1 HOSE
2TR-FE Only (Shown):
Disconnect the No.1 hose from the air pump assy.
Remove the bolt and disconnect the ground wire.
2012-2015MY (1GR-FE Only):
Disconnect the No.1 hose from the air pump assy.
23. DISCONNECT THE POWER STEERING PUMP OIL
RESERVOIR ASSY (1GR-FE ONLY)
Disconnect power steering pump oil reservoir assy.
24. DISCONNECT THE GROUND WIRE (1GR-FE ONLY)
Remove the bolt and disconnect the clamp and the ground
wire.
25. DISCONNECT THE ENGINE WIRE HARNESS
Disconnect the clamp.
Remove the engine wire harness container from the cowl
panel.
26. DISCONNECT THE WATER / HEATER HOSES, ENGINE
SIDE
LH Side
27. REMOVE THE FRONT FENDER APRON SEALS
4WD, Pre-Runner Only (Shown):
Remove the 20 clips and 4 front fender apron seals.
2WD Only:
RH Side
Remove the 22 clips and 4 front fender apron seals.
42
28. DISCONNECT THE AIR CONDITIONING DISCHARGE AND
SUCTION HOSES FROM THE COMPRESSOR
29. DISCONNECT THE SUCTION HOSE BRACKET
LH Side
30. DISCONNECT THE FRONT BRAKE TUBES
Disconnect the front brake tube.
Repeat the procedure on the opposite side.
RH Side
31. DISCONNECT THE STEERING SLIDING YOKE
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
Make sure the front wheels are in a straight-ahead position
and the steering wheel is centered.
Using the seat belt, hold the steering wheel in position as
shown in the illustration, to prevent damage to the spiral
cable.
Place match marks on the steering sliding yoke and No.2
intermediate shaft.
Loosen bolt (A) and remove bolt (B).
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.
32. DISCONNECT THE SHIFT CABLE (AUTO TRANS ONLY)
Cable Type (Shown):
Remove the clip.
Remove the nut and disconnect the shift cable.
Rod Type:
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.
43
33. DISCONNECT THE CLUTCH RELEASE CYLINDER ASSY
(2TR –FE MANUAL TRANS ONLY)
Remove the bolt and disconnect the clutch hose.
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.
34. DISCONNECT THE NO.1 CLUTCH HOSE
(1GR-FE MANUAL TRANS ONLY)
Disconnect the clutch release cylinder tube from the clutch
hose.
Remove the clip and disconnect the clutch hose.
35. DISCONNECT THE NO.2 FUEL HOSE
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.
36. DISCONNECT THE FUEL TANK TUBES
Remove the fuel pipe clamp.
Disconnect the 2 fuel tank tubes.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
37. DISCONNECT THE REAR BRAKE TUBES
Disconnect the 2 rear brake tubes.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
38. DISCONNECT THE PARKING BRAKE CABLES
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
39. REMOVE THE FOLLOWING PARTS (ACCESS CAB ONLY)
• Floor Board No.1/No.2
• Seat Floor Box
• Rear Floor Side Service Hole Cover LH/RH)
• Rear Lower Console Box
• Rear Seat Cushion Assy
• No.1 w/ Box Speaker Assy (If Equipped)
44
40. REMOVE THE CAB BODY ASSY USING AN ABOVE GROUND LIFT
Remove the 4 hole plugs.
Remove the 6 nuts, 6 washers and 6 bolts.
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.
Reinstall the 6 bolts, they will be used as guides during cab assy reinstallation.
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.
F. DISASSEMBLE THE FRAME
1. PLACE THE FRAME ON A LIFT
Place the frame on the lift, and secure it with a ratcheting tie down strap.
tilting or falling off as parts are removed.
This will prevent the frame from
• Ratcheting Tie Downs: Qty 1 (Length: 2 in X 27 ft and Min. Work Load Capacity: 3,000 lbs)
2.
DISCONNECT THE FRONT PROPELLER SHAFT ASSY
(4WD ONLY)
Remove the 4 nuts from transfer case side of the front
propeller shaft assy.
3.
REMOVE THE FOLLOWING PARTS
• Wheels
• Propeller Shaft Heat Insulator (If Equipped)
• Rear Propeller Shaft Assy
• Exhaust Pipe Stopper Bracket (If Equipped)
• Insert SST 09325-40010 into trans after the Rear Prop Shaft is removed to prevent oil leakage (2WD Only)
45
NOTE: Place match marks on the front (if equipped) and rear propeller shafts prior to removal.
4.
REMOVE THE EXHAUST SYSTEM (1GR-FE ONLY)
Remove the 2 bolts and 2 springs.
Disconnect the 4 exhaust pipe supports from the frame and
remove the center exhaust pipe assy.
Remove the exhaust pipe gasket.
Disconnect the 2 exhaust pipe supports from the frame.
5.
REMOVE THE EXHAUST SYSTEM (2TR-FE ONLY)
Remove the 2 bolts and 2 nuts.
Disconnect the 4 exhaust pipe supports from the frame and remove the center exhaust pipe assy.
Remove the exhaust pipe gasket.
Disconnect the 2 oxygen sensor wire harness clamps.
Disconnect the exhaust pipe support from the frame.
6.
REMOVE THE FOLLOWING PARTS
• No.2 Fuel Tank Protector (If Equipped)
• No.1 Fuel Tank Protector Assy (If Equipped)
• Fuel Tank Straps
• V-belt
• Fuel Tank
• Charcoal Canister Assy
7.
REMOVE AND SET ASIDE THE POWER STEERING VANE PUMP
Disconnect the connector.
Disconnect the clamp. (1GR-FE Only)
Remove the bolt and disconnect the ground wire. (1GR-FE Only)
Remove the 2 bolts and the power steering vane pump.
NOTE:
• DO NOT disconnect the power steering vane pump hoses or tubes.
• Keep the power steering pump reservoir upright to prevent the fluid from leaking out.
8.
REMOVE THE FOLLOWING PARTS
• Intake Air Surge Tank (1GR-FE Only)
• Intake Air Connector (2TR-FE Only)
46
9.
LH Side
DISCONNECT THE OIL COOLER TUBE (AUTO TRANS ONLY)
Remove the bolts and disconnect the oil cooler tube.
10. REMOVE THE ENGINE AND TRANSMISSION ASSY
Remove the bolt and disconnect the ground wire. (LH Side)
Disconnect the connector and clamp. (4WD Only)
Disconnect the clamp. (2TR-FE Only)
Disconnect and remove the necessary items/parts to
prepare the engine and transmission assy for removal.
Install the engine hanger.
RH Side (4WD Only)
For 1GR-FE:
12281-31060 = No.1 Engine Hanger
12282-31040 = No.2 Engine Hanger
90119-08A87 = 4 Bolts
RH Side (2TR-FE Only)
For 2TR-FE:
12281-75050 = 2 Engine Hangers
91672-81025 = 2 Bolts
Remove the engine and transmission assy.
NOTE:
• Hang up the front exhaust pipe with string to avoid
applying pressure at the joint part. (2TR-FE only)
• 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.
47
Be careful not to damage exhaust system while removing the engine and trans mission assy.
11. REMOVE THE FRONT PROPELLER SHAFT ASSY (4WD ONLY)
12. DISCONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS (2WD ONLY)
2011MY RH Side:
Remove the bolt, disconnect the clamp and skid control
sensor wire harness.
Except 2011MY RH Side:
Remove the 2 bolts and skid control sensor wire harness.
Repeat the procedure on the opposite side.
13. DISCONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS (4WD, PRE-RUNNER ONLY)
Remove the bolt and disconnect the skid control sensor
wire harness.
Repeat the procedure on the opposite side.
14. DISCONNECT THE FRONT BRAKE HOSE (2WD ONLY)
Disconnect the front brake tube from the brake hose.
Remove the 2 bolts and disconnect the front brake hose
and flexible hose bracket.
Repeat the procedure on the opposite side.
15. DISCONNECT THE FRONT BRAKE HOSE
(4WD, PRE-RUNNER ONLY)
Disconnect the front brake tube from the brake hose.
Remove the bolt and disconnect the front brake hose and
flexible hose bracket.
Repeat the procedure on the opposite side.
16. REMOVE THE FOLLOWING PARTS
• Front Axle Hub Grease Cap (4WD Only)
• Front Axle Shaft Nut (4WD Only)
• Tie Rod End*
• Front Stabilizer Link Assy
• Lower Ball Joint Attachment**
48
* SST 09610-20012 (2WD), SST 09628-62011 (4WD, Pre-Runner) disconnect the tie rod end.
**SST 09628-00011
17. REMOVE THE FRONT SUSPENSION UPPER ARM AND
STEERING KNUCKLE ASSY (2WD ONLY)
Remove the 2 bolts, 2 nuts, 2 washers and front
suspension upper arm w/ steering knuckle.
Repeat the procedure on the opposite side.
18. REMOVE THE FRONT SUSPENSION UPPER ARM AND
STEERING KNUCKLE ASSY (4WD, PRE-RUNNER ONLY)
Remove the bolt, nut, 2 washers and front suspension
upper arm w/ steering knuckle.
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.
19. REMOVE THE FOLLOWING PARTS
• Front Drive Shaft Assy (4WD Only) *
• Front Shock Absorber Assy
• Front Suspension Member Brace Sub-Assy
• Power Steering Link Assy w/ Pump
• Front Stabilizer Bar
• Front Differential Carrier (4WD Only)
*SST 09520-24010 (09520-32040),09520-01010
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.
20. DISCONNECT THE PARKING BRAKE CABLES
Remove the 6 bolts and parking brake cables.
21. REMOVE THE FRAME WIRE HARNESS
Remove the bolt and disconnect the ground wire
(If Equipped).
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.
49
22. REMOVE THE NO.2 FRAME WIRE HARNESS (IF EQUIPPED)
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.
23. REMOVE THE NO.2 FLEXIBLE HOSE BRACKET
Disconnect the No.5 rear brake tube.
Disconnect the No.6 rear brake tube.
Remove the 2 clips and disconnect the 2 brake hoses.
Remove the 2 bolts and No.2 flexible hose bracket.
24. REMOVE THE FOLLOWING PARTS
• Spare Tire Carrier Assy (2012-2015MY)
• No.1 Rear Spring Bumper (2WD Only)
• Rear Stabilizer Bar (If Equipped)
25. REMOVE THE LEAF SPRINGS AND SHOCK ABSORBER
ASSY
For this campaign, the leaf springs will not be replaced. However, if eligible, replace leaf springs
under E02. If the vehicle is not eligible for E02, or 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.
26. REMOVE THE SKID CONTROL SENSOR WIRE BRACKET
(W/ REAR DIFFERENTIAL LOCK ONLY)
Remove the bolt.
Cut the clamp (A) using nippers.
Disconnect the 2 clamps and 2 connectors to remove the 2
brackets.
Remove the clamp (A) from the bracket.
27. REMOVE THE NO.2 CHARCOAL CANISTER PIPE
Disconnect the clamps and remove the No.2 charcoal
canister pipe.
50
28. REMOVE THE FRAME AUXILIARY CROSSMEMBER
EXTENSIONS (IF EQUIPPED)
Remove the 2 bolts and frame auxiliary crossmember
extensions.
29. REMOVE THE HOOK
Remove the 2 bolts and hook.
30. REMOVE THE REAR ENGINE MOUNTING REINFORCES
(1GR-FE ONLY)
Remove the 2 bolts and 2 rear engine mounting reinforces.
31. REMOVE THE PARKING BRAKE CABLE HEAT
INSULATOR (IF EQUIPPED)
Remove the 2 bolts and parking brake cable heat insulator.
32. REMOVE THE NO.1 RECEIVER HITCH ATTACHMENT
REINFORCEMENT (IF EQUIPPED)
Remove the 2 bolts and No.1 receiver hitch attachment
reinforcement.
33. REMOVE THE CAB MOUNTS
34. REMOVE THE FRAME FROM THE LIFT
Remove the ratcheting tie down strap and the frame from the lift.
51
G. PLUG HOLES IN REPLACEMENT FRAME (see Appendix)
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)
Install all plugs. Use the picture found in appendix to reference the plug installation.
NOTE:
• You may have to remove certain stickers to install optional equipment.
• You may not install all the plugs in plug kit.
• Make sure all the plugs are flush with the frame.
• Make sure the surface of the frame is clean before you apply stickers.
52
H. ASSEMBLE THE FRAME
Part #
51719-04010
NEW Replacement Parts
Part Name
Kit #
Holder, Body Support Bracket
2
Qty
2
1.
INSTALL THE NEW CLIPS
2.
REINSTALL THE NO.1 RECEIVER HITCH ATTACHMENT
REINFORCEMENT (IF EQUIPPED)
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)
Repeat the procedure on the opposite side.
3.
REINSTALL THE NO.1 REAR SPRING BUMPER
(2WD ONLY)
Reinstall the rear spring bumper with the 2 nuts and torque
to spec.
Torque Spec: 15 N∙m (153 kgf∙cm, 11 ft∙lbf)
Repeat the procedure on the opposite side.
4.
REINSTALL THE PARKING BRAKE CABLE HEAT
INSULATOR (IF EQUIPPED)
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)
Part #
82715-04290
82715-04200
90119-A0169
NEW Replacement Parts
Part Name
Bracket
Bracket
Bolt
*Individual Part(s)
Kit #
NA*
NA*
NA*
Qty
1
1
2
5.
INSTALL THE NEW OXYGEN SENSOR BRACKETS
(2TR-FE ONLY)
Install the 2 NEW brackets with the 2 NEW bolts and
torque to spec.
Torque Spec: 29 N∙m (296 kgf∙cm, 21 ft∙lbf)
53
6.
REINSTALL THE REAR ENGINE MOUNTING
REINFORCES (1GR-FE ONLY)
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)
Part #
90119-A0192
90119-A0193
NEW Replacement Parts
Part Name
Kit #
Bolt
8
Bolt
NA*
*Individual Part(s)
7.
Qty
2
2
REINSTALL THE HOOK
Reinstall the hook with the 2 NEW bolts and torque to
spec.
Torque Spec: 70 N∙m (714 kgf∙cm, 52 ft∙lbf)
8.
REINSTALL THE FRAME AUXILIARY CROSSMEMBER
EXTENSION (IF EQUIPPED)
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)
9.
REINSTALL THE CAB MOUNTS
Reinstall cab mounts No.1
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)
10. INSTALL THE NEW FRONT SUSPENSION LOWER ARM (2WD ONLY)
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.
Torque Spec: 210 N∙m (2141 kgf∙cm, 155 ft∙lbf)
Repeat the procedure on the opposite side.
54
2WD Only
Part #
48069-04030
48068-04030
48190-25010
48198-25010
90178-A0013
NEW Replacement Parts
Part Name
Arm Sub-Assy, Front
Suspension, Lower No.1, LH
Arm Sub-Assy, Front
Suspension, Lower No.1, RH
Cam, Front Suspension
Camber Adjust, No.1 LH/RH
Cam, Front Suspension
Camber Adjust, No.2 LH/RH
Nut
*Individual Part(s)
Kit #
Qty
NA*
1
NA*
1
4
4
4
4
NA*
4
11. INSTALL THE NEW FRONT SUSPENSION LOWER ARM (4WD, PRE-RUNNER ONLY)
Install the NEW front suspension lower arm with the NEW bolt, NEW 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)
Repeat the procedure on the opposite side.
Part #
48069-04040
48068-04040
48190-60020
48198-60011
48409-60020
48452-35020
90119-A0166
90178-A0001
NEW Replacement Parts
Part Name
Arm Sub-Assy, Front
Suspension, Lower No.1, LH
Arm Sub-Assy, Front
Suspension, Lower No.1, RH
Cam, Front Suspension
Camber Adjust, No.1 LH/RH
Cam, Front Suspension
Camber Adjust, No.2 LH/RH
Cam, Sub-Assy, Front
Suspension Toe Adjust
Plate, Front Suspension Toe
Adjust, No.2
Bolt
Nut
*Individual Part(s)
Kit #
Qty
NA*
1
NA*
1
5
2
5
2
5
2
5
2
8
NA*
2
2
NEW Replacement Parts (2WD Only)
Part Name
Kit # Qty
NA*
2
Bumper, Front Spring,
LH/RH**
NA*
2
*Individual Part(s)
**Only 1 part used, part number varies by vehicle type.
Part #
48304-AD010
48304-04090
4WD, Pre-Runner Only
12. INSTALL THE NEW FRONT SPRING BUMPER
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)
Repeat the procedure on the opposite side.
Part #
48304-04100
NEW Replacement Parts
(4WD, Pre-Runner Only)
Part Name
Kit #
Bumper, Front Spring, LH/RH
8
Qty
2
13. INSTALL THE NEW REAR BRAKE TUBES
Install the NEW rear brake tubes with the NEW clamp(s).
55
Part #
47325-*****
47326-*****
NEW Replacement Parts
Part Name
Kit #
Tube, Rear Brake, No.5
NA*
Tube, Rear Brake, No.6
NA*
NA*
90469-A0004
Clamp, Brake Tube, No.11**
NA*
NA*
90949-A1006
Qty
1
1
2
or
3
or
4
3
Clamp, Brake Tube, No.10
2
*Individual Part(s)
** Only 1 part used, part number varies by vehicle type.
14. REINSTALL THE NO. 2 CHARCOAL CANISTER PIPE
Reinstall the fuel return and main tube support.
Reinstall the No.2 charcoal canister pipe.
NEW Replacement Parts
Part Name
Kit # Qty
Bolt
2
4
NA*
1
Carrier Assy, Spare Wheel**
NA*
1
*Individual Part(s)
** Only 1 part used, part number varies by vehicle type.
Part #
90119-A0169
51900-35410
51900-35420
15. INSTALL THE NEW SPARE TIRE CARRIER ASSY
(2011MY ONLY)
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)
16. REINSTALL THE SPARE TIRE CARRIER ASSY
(2012-2015MY ONLY)
Reinstall the spare tire carrier assy with the 4 NEW bolts
and torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
Part #
82715-04250
82715-04260
82711-16830
90105-A0066
NEW Replacement Parts
Part Name
Bracket
Bracket
Clamp
Bolt
*Individual Part(s)
Kit #
NA*
NA*
NA*
NA*
Qty
1
1
1
1
17. INSTALL THE NEW SKID CONTROL SENSOR WIRE
BRACKET (W/ REAR DIFFERENTIAL LOCK ONLY)
Install the NEW clamp (A).
Install the 2 NEW brackets with the 2 clamps and 2
connectors.
Install the NEW bolt.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
Part #
90177-A0010
NEW Replacement Parts
Part Name
Kit #
Nut
2
*Individual Part(s)
Qty
2
18. REINSTALL THE LEAF SPRINGS AND SHOCK
ABSORBER ASSY
Reinstall the leaf springs with the 4 bolts, 4 washers and 4
nuts, then torque to spec.
Torque Spec: 120 N∙m (1224 kgf∙cm, 89 ft∙lbf)
Reinstall the shock absorber assy with the 2 NEW nuts, 2
retainers and 2 cushions, then torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
56
19. REINSTALL THE REAR STABILIZER BAR (IF EQUIPPED)
Part #
90119-08A91
Part #
90468-A0007
90119-A0169
NEW Replacement Parts
Part Name
Kit #
Bolt
NA*
*Individual Part(s)
NEW Replacement Parts
Part Name
Clip
Bolt
Qty
4
20. REINSTALL THE NO.2 FLEXIBLE HOSE BRACKET
Kit #
2
14 or
15
or
NA*
Qty
2
2
*Individual Part(s)
Part #
82715-04200
82715-04290
82715-04240
82715-04350
90119-A0169
Reinstall the rear stabilizer bar with the 2 brackets and 4
NEW bolts, then torque to spec.
Torque Spec: 30 N∙m (306 kgf∙cm, 22 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)
NEW Replacement Parts
Part Name
Bracket
Bracket
Bracket
Bracket
Bolt
*Individual Part(s)
Kit #
NA*
NA*
NA*
NA*
NA*
Qty
1
1
1
1
4
Reinstall the No.2 flexible hose bracket with the 2 NEW
bolts.
Reconnect the 2 brake hoses with the 2 NEW clips.
Connect the No.5 and No.6 rear brake tubes, then 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)
21. INSTALL THE NEW NO.2 FRAME WIRE HARNESS
BRACKETS (IF EQUIPPED)
Install the NEW bracket (A) with the NEW bolt and torque
to spec. (Except 2TR-FE)
Torque Spec: 29 N∙m (296 kgf∙cm, 21 ft∙lbf)
Install the NEW bracket (B) with the NEW bolt and torque
to spec. (Except 2TR-FE)
Torque Spec: 29 N∙m (296 kgf∙cm, 21 ft∙lbf)
For Floor Connecting Type:
Rear Side
(Floor Connecting Type)
Rear Side
(Frame Connecting Type)
Install the NEW bracket with the NEW bolt and torque to
spec.
Torque Spec: 29 N∙m (296 kgf∙cm, 21 ft∙lbf)
For Frame Connecting Type:
Install the NEW bracket with the 2 NEW bolts and torque to
spec.
Torque Spec: 29 N∙m (296 kgf∙cm, 21 ft∙lbf)
22. REINSTALL THE NO.2 FRAME WIRE HARNESS
(IF EQUIPPED)
Reconnect the clamps to install the No.2 frame wire
harness.
NOTE: The number of wire harness clamps will differ
depending on the vehicle spec.
Part #
82715-04220
NEW Replacement Parts
Part Name
Kit #
Bracket
NA*
Qty
1
23. INSTALL THE NEW HARNESS BRACKETS
57
82715-04230
90119-A0169
Front Side
Bracket
Bolt
*Individual Part(s)
NA*
NA*
1
2
Rear Side
Install the 2 NEW brackets with the 2 NEW bolts and
torque to spec.
Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft∙lbf)
24. REINSTALL THE FRAME WIRE HARNESS
Reconnect the clamps to install the frame wire harness.
Reconnect the ground wire with the bolt and torque to spec
(If Equipped).
Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft∙lbf)
NOTE: The number of wire harness clamps will differ
depending on the vehicle spec.
25. RECONNECT THE PARKING BRAKE CABLES
Reinstall the 2 parking brake cables with the 6 bolts, then
torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
Access Cab Parking Brake Cable Routing
58
NEW Replacement Parts
Part Name
Kit # Qty
NA*
1
Bracket**
NA*
1
Bolt
NA*
1
*Individual Part(s)
** Only 1 part used, part number varies by vehicle type.
Part #
82715-04160
82715-3D680
90119-A0141
2TR-FE
1GR-FE
26. REINSTALL THE FRONT DIFFERENTIAL CARRIER
(4WD ONLY)
Apply adhesive to the serration bolt.
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)
Disconnect the connector from the bracket.
Remove the bolt and bracket.
Install the NEW bracket with the NEW bolt and torque to
spec.
Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft.∙lbf)
27. REINSTALL THE POWER STEERING LINK ASSY W/
POWER STEERING VANE PUMP
Reinstall the power steering link assy w/ power steering
vane pump with the bolts and nuts, then torque to spec.
Torque Spec: 2TR-FE 4WD
Bolt A - 95 N∙m (969 kgf∙cm, 70 ft∙lbf)
Bolt B - 28 N∙m (286 kgf∙cm, 21 ft∙lbf)
Torque Spec: Except 2TR-FE 4WD
Bolt A - 92 N∙m (938 kgf∙cm, 68 ft∙lbf)
Bolt B - 28 N∙m (286 kgf∙cm, 21 ft∙lbf)
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.
28. RECONNECT THE FRONT DIFFERENTIAL BREATHER
TUBE (4WD ONLY)
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)
59
Part #
90080-17215
NEW Replacement Parts
Part Name
Kit #
Nut
2
Qty
6
29. REINSTALL THE FRONT SHOCK ABSORBER ASSY
Install the 3 NEW nuts (A) and torque to spec.
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)
Repeat the procedure on the opposite side.
Part #
90119-A0161
NEW Replacement Parts (2WD Only)
Part Name
Kit # Qty
Bolt
NA*
4
*Individual Part(s)
30. REINSTALL THE FRONT STABILIZER BAR
Reinstall the stabilizer bar with 2 brackets and 4 NEW
bolts, then torque to spec. (2WD Only)
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)
31. REINSTALL THE FRONT SUSPENSION MEMBER BRACE
SUB-ASSY
2WD Only
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
Part #
90311-47026
90311-47027
43425-04040
NEW Replacement Parts
Part Name
Kit #
3
Seal, Oil (For Differential Side
Gear Shaft)
3
Ring, Shaft Snap (For Front
NA*
Drive Inner Shaft Outer)
*Individual Part(s)
Qty
1
1
2
32. REINSTALL THE FRONT DRIVE SHAFT ASSY (4WD ONLY)
Remove the type T oil seal.
Install the NEW type T oil seal.
Install a NEW snap ring.
Reinstall the front drive shaft assy.
Repeat the procedure on the opposite side.
NOTE:
Be careful not to damage the dust cover and oil seal.
60
33. REINSTALL THE FRONT SUSPENSION UPPER ARM AND
STEERING KNUCKLE ASSY (2WD ONLY)
Reinstall the front suspension upper arm w/ steering
knuckle with the 2 bolts, 2 nuts and 2 washers, then torque
to spec.
Torque Spec: Bolt - 82 N∙m (836 kgf∙cm, 60 ft∙lbf)
Repeat the procedure on the opposite side.
34. REINSTALL THE FRONT SUSPENSION UPPER ARM AND
STEERING KNUCKLE ASSY (4WD, PRE-RUNNER ONLY)
Reinstall the front suspension upper arm w/ steering
knuckle with the bolt, nut and 2 washers, then torque to
spec.
Torque Spec: Nut - 115 N∙m (1173 kgf∙cm, 85 ft∙lbf)
Repeat the procedure on the opposite side.
NEW Replacement Parts
Part #
90171-A0005
95381-03230
Lower Ball Joint Attachment
Part Name
Kit #
Nut, Castle (For Front Lower
2
Ball Joint LH/RH)
4
Cotter Pin
or
5
Qty
2
2
Tie Rod End
Part #
Part Name
Kit # Qty
95381-03025
4
2
Cotter Pin**
95381-03225
5
2
** Only 1 part used, part number varies by vehicle type.
35. REINSTALL THE FOLLOWING PARTS
• Lower Ball Joint Attachment

Reinstall the lower ball joint attachment with the
NEW nut and 2 bolts, then torque to spec.

Install the NEW cotter pin.

Repeat the procedure on the opposite side.

Torque Spec:
Nut - 140 N∙m (1428 kgf∙cm, 103 ft.∙lbf)
Bolt - 160 N∙m (1632 kgf∙cm, 118 ft∙lbf)
• Front Stabilizer Link Assy (2WD Only)

Reinstall the front stabilizer link assy 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 Assy (4WD, Pre-Runner Only)

Reinstall the front stabilizer link assy with the 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 the tie rod end with the 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 shaft nut.

Nut will be tightened when the vehicle is completed.

Repeat the procedure on the opposite side.
61
NEW Replacement Parts
Part Name
Kit # Qty
12
1
Tube, Front Brake, No.4**
13
1
12
1
Tube, Front Brake, No.6**
13
1
Way (For Front Brake Tube)
1
2
Bolt
NA*
2
*Individual Part(s)
** Only 1 part used, part number varies by vehicle type.
36. INSTALL THE NEW FRONT BRAKE TUBE AND
NEW WAY (2WD ONLY)
Temporarily install the NEW front brake tube and NEW
way.
Install the NEW bolt to the NEW way and torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
NEW Replacement Parts
Part Name
Kit # Qty
14
1
Tube, Front Brake, No.4**
15
1
14
1
Tube, Front Brake, No.6**
15
1
Way (For Front Brake Tube)
1
2
14
90119-A0169
Bolt
or
2
15
**Only 1 part used, part number varies by vehicle type.
37. INSTALL THE NEW FRONT BRAKE TUBE AND
NEW WAY (4WD, PRE-RUNNER ONLY)
Temporarily install the NEW front brake tube and NEW
way.
Install the NEW bolt to the NEW way and torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
Repeat the procedure on the opposite side.
Part #
47314-04140
47314-04141
47316-04140
47316-04141
90412-10289
90119-A0169
Part #
47314-04150
47314-04151
47316-04150
47316-04151
90412-10289
Part #
90119-A0169
90468-A0007
Part #
90119-A0169
90468-A0007
NEW Replacement Parts
Part Name
Kit #
Bolt
NA*
Clip
2
*Individual Part(s)
NEW Replacement Parts
Part Name
Kit #
14
Bolt
or
15
Clip
2
Qty
4
2
Qty
2
2
Repeat the procedure on the opposite side.
38. RECONNECT THE FRONT BRAKE HOSE (2WD ONLY)
Reinstall the flexible hose bracket with the NEW bolt and
torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
Reconnect the front brake hose with a NEW clip.
Reconnect the front brake tube and torque to spec.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
Reinstall the NEW bolt and torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
Repeat the procedure on the opposite side.
39. RECONNECT THE FRONT BRAKE HOSE
(4WD, PRE-RUNNER ONLY)
Reinstall the flexible hose bracket with the NEW bolt and
torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
Reconnect the front brake hose with a NEW clip.
Reconnect the front brake tube and torque to spec.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
Repeat the procedure on the opposite side.
62
Part #
90105-A0064
NEW Replacement Parts
Part Name
Kit #
Bolt
NA*
*Individual Part(s)
Qty
1
40. RECONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS (2WD ONLY)
2011MY RH Side:
Remove the clamp from the front skid control sensor wire
harness.
Install the NEW bolt (A) and torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
Reconnect 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)
Except 2011MY RH Side:
Reconnect the front skid control sensor wire harness with
the 2 bolts.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
Repeat the procedure on the opposite side.
41. RECONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS (4WD, PRE-RUNNER ONLY)
Reconnect 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)
Repeat the procedure on the opposite side.
42. REINSTALL THE WHEELS
43. REINSTALL THE FRONT PROPELLER SHAFT ASSY
(4WD ONLY)
Referencing the matchmarks, reinstall the propeller shaft
assy to the front differential.
Reinstall the 4 bolts, 4 washer and 4 nuts, them torque to
spec.
Torque Spec: 88.2 N∙m (899 kgf∙cm, 65 ft∙lbf)
44. REINSTALL THE ENGINE AND TRANSMISSION ASSY
Reinstall engine and transmission assy.
NOTE:
• Hang up the front exhaust pipe with string to avoid
applying pressure at the joint part. (2TR-FE only)
• 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.
63
Part #
90910-03001
94151-21001
NEW Replacement Parts
Part Name
Kit #
Bolt
1
Nut
1
LH Side
Qty
4
4
Attach the engine mounts with the 4 NEW bolts and 4 NEW
nuts, then torque to spec.
2011MY:
Torque Spec: 38 N∙m (387 kgf∙cm, 28 ft∙lbf)
2012-2015MY:
Torque Spec: 40 N∙m (408 kgf∙cm, 30 ft∙lbf)
RH Side
Part #
91671-80814
NEW Replacement Parts
Part Name
Kit #
Bolt
1
Qty
4
Attach the transmission mount with 4 NEW bolts and
torque to spec.
2011MY:
Torque Spec: 18.5 N∙m (189 kgf∙cm, 14 ft∙lbf)
2012-2015MY:
Torque Spec: 30 N∙m (306 kgf∙cm, 22 ft∙lbf)
Remove the bolt(s) and the engine hangers.
Reinstall the items/parts that were removed during the
engine and transmission assy removal.
LH Side
Reinstall the bolt and reconnect the ground wire. (LH Side)
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
Reconnect the connector and clamp. (4WD Only)
Reconnect the clamp. (2TR-FE Only)
RH Side (4WD Only)
RH Side (2TR-FE Only)
64
45. RECONNECT THE OIL COOLER TUBE (AUTO TRANS ONLY)
Reconnect the oil cooler tube with the 2 bolts and torque to
spec.
Torque Spec: 28 N∙m (286 kgf∙cm, 21 ft∙lbf)
46. REINSTALL THE INTAKE AIR SURGE TANK (1GR-FE ONLY)
Part #
17176-0P030
NEW Replacement Parts
Part Name
Kit #
Gasket, Air Surge Tank to
6
Intake Manifold
Qty
1
Install a NEW gasket onto the intake air surge tank.
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)
Reinstall the 2 intake air surge tank nuts and torque to
spec.
Torque Spec: 28 N∙m (286 kgf∙cm, 21 ft∙lbf)
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)
Reinstall oil baffle plate with the bolt and torque to spec.
Torque Spec: 9.0 N∙m (92 kgf∙cm, 80 in∙lbf)
Reinstall the throttle body bracket with the 2 bolts, then
torque to spec.
Torque Spec: 21 N∙m (214 kgf∙cm, 15 ft∙lbf)
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.
47. REINSTALL THE INTAKE AIR CONNECTOR (2TR-FE ONLY)
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)
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.
48. REINSTALL THE POWER STEERING VANE PUMP
Reinstall the bolt and reconnect the ground wire and torque to spec. (1GR-FE Only)
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
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)
Reconnect the connector.
Reconnect the clamp. (1GR-FE Only)
49. REINSTALL THE V-BELT
65
50. REINSTALL THE FUEL TANK STRAPS
Reinstall the fuel tank straps with the 2 pins and 2 clips.
Part #
90119-A0249
NEW Replacement Parts
Part Name
Kit #
Bolt
2
Qty
2
51. REINSTALL THE FUEL TANK
Reinstall the fuel tank with the 2 NEW bolts and torque to
spec.
Torque Spec: 62 N∙m (632 kgf∙cm, 46 ft∙lbf)
Reconnect the connector.
52. REINSTALL THE NO.2 FUEL TANK PROTECTOR (IF EQUIPPED)
53. REINSTALL THE NO.1 FUEL TANK PROTECTOR ASSY
(IF EQUIPPED)
Part #
90179-08241
NEW Replacement Parts
Part Name
Kit #
Nut
NA*
*Individual Part(s)
Qty
4
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)
Part #
77285-35760
90105-A0066
Part #
17451-0D020
NEW Replacement Parts
Part Name
Kit #
Clamp. Fuel Tube, No.1
1
Bolt
NA*
*Individual Part(s)
NEW Replacement Parts
Part Name
Kit #
Gasket, Exhaust Pipe
6
Qty
1
1
54. REINSTALL THE CHARCOAL CANISTER ASSY
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)
Reconnect the fuel tank vent hose.
Reconnect the fuel hose.
Reconnect the main tube support and reconnect the filter
hose.
Reconnect the connector.
w/ Rear Differential Lock:
Install the NEW bolt and connect the skid control sensor
wire bracket and torque to spec.
w/o Rear Differential Lock:
Install the bolt and reconnect the skid control sensor wire
bracket and torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
Install the NEW clamp.
55. REINSTALL THE EXHAUST SYSTEM (1GR-FE ONLY)
Qty
1
Reconnect the 2 exhaust pipe supports to the frame.
Install the NEW exhaust pipe gasket.
66
Part #
90080-10291
NEW Replacement Parts
Part Name
Kit #
Bolt
6
Reconnect the 4 exhaust pipe supports to the frame and
reinstall the center exhaust pipe assy.
Install the 2 NEW bolts and 2 springs, then torque to spec.
Qty
2
Torque Spec: 43 N∙m (438 kgf∙cm, 32 ft∙lbf)
56. REINSTALL THE EXHAUST SYSTEM (2TR-FE ONLY)
Part #
90080-43033
90080-10064
90177-A0004
NEW Replacement Parts
Part Name
Kit #
Gasket
7
Bolt
7
Nut
7
Qty
1
2
2
Reconnect the exhaust pipe support to the frame.
Reconnect the 2 oxygen sensor wire harness clamps.
Install the NEW exhaust pipe gasket.
Reconnect the 4 exhaust pipe supports to the frame and
reinstall the center exhaust pipe assy.
Install the 2 NEW bolts and 2 NEW nuts then torque to
spec.
Torque Spec: 48 N∙m (489 kgf∙cm, 35 ft∙lbf)
57. REINSTALL THE EXHAUST PIPE STOPPER BRACKET
(IF EQUIPPED)
Part #
90080-11180
Part #
90119-A0151
NEW Replacement Parts
Part Name
Kit #
Bolt
6
NEW Replacement Parts
Part Name
Kit #
Bolt
NA*
*Individual Part(s)
Qty
2
Reinstall the exhaust pipe stopper bracket with the 2 NEW
bolts and torque to spec.
Torque Spec: 19 N∙m (194 kgf∙cm, 14 ft∙lbf)
58. REINSTALL THE PROPELLER SHAFT HEAT INSULATOR
Qty
2
(IF EQUIPPED)
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)
67
59. REINSTALL THE REAR PROPELLER SHAFT ASSY
Remove the SST. (2WD Only)
Referencing the matchmarks, reinstall the rear propeller
shaft assy to the transmission / transfer case.
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)
Reinstall the center support bearing to the frame as shown
in the illustration with 2 washers and 2 bolts, then torque to
spec. (3-Joint Type Only)
Torque Spec: 36.2 N∙m (369 kgf∙cm, 27 ft∙lbf)
Referencing the matchmarks, reinstall the rear 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)
60. RECONNECT THE FRONT PROPELLER SHAFT ASSY (4WD ONLY)
Referencing the matchmarks, reconnect the front propeller shaft assy to the transfer case and the front
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)
61. REMOVE THE FRAME FROM THE LIFT
Remove the ratcheting tie down strap from the frame.
Lower the frame to the ground.
68
I.
REINSTALL THE CAB BODY ASSY
Before lowering the cab assembly ensure that you install the NEW brakelines onto the bulk
head.
NEW Replacement Parts
Part Name
Kit # Qty
10
1
11
1
Tube, Front Brake, No.3**
NA*
1
NA*
1
10
1
11
1
Tube, Front Brake, No.5**
NA*
1
NA*
1
10
1
11
1
Tube, Rear Brake, No.3**
NA*
1
NA*
1
10
1
11
1
Tube, Rear Brake, No.4**
NA*
1
NA*
1
*Individual Part(s)
**Only 1 part used, part number varies by vehicle type.
Part #
47313-04200
47313-04231
47313-04210
47313-04241
47315-04170
47315-04171
47315-04180
47315-04191
47323-04170
47323-04171
47323-04180
4732304191
47324-04130
47324-04131
47324-04140
47324-04151
2.
1.
INSTALL THE NEW ENGINE COMPARTMENT BRAKE
TUBES
Install the NEW No.3 and NEW No.5 front brake tubes.
Install the NEW No.3 and NEW No.4 rear brake tubes.
Torque all brake tubes to spec.
Torque Spec:
Flare Nut (M10) - 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
Flare Nut (M12) - 19.5 N∙m (199 kgf∙cm, 14 ft∙lbf)
REINSTALL THE CAB BODY ASSY
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 and line the tires up with the alignment marks.
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, 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)
Reinstall the 4 hole plugs.
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.
69
Part #
90412-10276
90119-A0169
NEW Replacement Parts
Part Name
Kit #
Way, 2 (For Rear Brake Tube)
2
14
or
Bolt
15
or
NA*
*Individual Part(s)
Qty
1
3.
RECONNECT THE PARKING BRAKE CABLE
4.
CONNECT THE REAR BRAKE TUBES
Temporarily install the NEW 2 way with the NEW bolt.
Temporarily install the 4 rear brake tubes.
Torque the bolt to spec.
1
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
Torque the 4 rear brake tubes to spec.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
5.
RECONNECT THE FUEL TANK TUBES
Reconnect the 2 fuel tank tubes.
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
Reconnect the No.2 fuel hose with the clip.
7.
RECONNECT THE SHIFT CABLE (AUTO TRANS ONLY)
Cable Type (Shown):
Reconnect the shift cable with the nut and torque to spec.
NEW Replacement Parts (Rod Type)
Part Name
Kit # Qty
Clip
NA*
1
Pin, W/ Hole (For Transmission
90240-08054
NA*
1
Control Rod)
*Individual Part(s)
Part #
90468-14033
Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft∙lbf)
Install the clip.
Rod Type:
Reconnect the shift cable with the NEW pin and NEW clip.
70
8.
RECONNECT THE CLUTCH RELEASE CYLINDER ASSY
(2TR-FE MANUAL TRANS ONLY)
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)
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)
Reconnect the No.1 clutch hose with the clip.
Reconnect the clutch release cylinder tube to the clutch
hose.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
Part #
90080-11555
NEW Replacement Parts
Part Name
Kit #
Bolt
2
LH Side
10. RECONNECT THE STEERING SLIDING YOKE
Qty
2
Make sure the front wheels are in a straight-ahead position
and the steering wheel is centered.
Referencing the match marks, reconnect the steering
sliding yoke to the No.2 intermediate shaft with the NEW
bolt (B).
Remove bolt (A) and install the NEW bolt (A).
Torque all bolts to spec.
Torque Spec: 35 N∙m (357 kgf∙cm, 26 ft∙lbf)
Disconnect the seat belt that is holding the steering wheel.
11. RECONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS
Reconnect the harness clamp and front skid control sensor
connector.
Repeat the procedure on the opposite side.
RH Side
RH Side
12. RECONNECT THE NO.2 FRAME WIRE HARNESS
(IF EQUIPPED)
Reconnect the harness clamp and connector.
71
LH Side
13. CONNECT THE FRONT BRAKE TUBES
Connect the front brake tube and torque to spec.
Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
Repeat the procedure on the opposite side.
RH Side
Part #
90210-A0002
90210-A0004
NEW Replacement Parts
Part Name
Kit #
O Ring
2
O Ring
2
Qty
1
1
14. RECONNECT THE AIR CONDITIONING DISCHARGE AND
SUCTION HOSES TO THE COMPRESSOR
Install a NEW o-ring to the A/C discharge and suction
hoses.
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)
15. RECONNECT THE SUCTION HOSE BRACKET
Reconnect the suction hose bracket with the bolt and
torque to spec.
Torque Spec: 7.5 N∙m (76 kgf∙cm, 66 in∙lbf)
LH Side
16. REINSTALL THE FRONT FENDER APRON SEALS
4WD, Pre-Runner Only (Shown):
Reinstall the 4 front fender apron seals with the 20 clips.
2WD Only:
Reinstall the 4 front fender apron seals with the 22 clips.
RH Side
17. RECONNECT THE WATER / HEATER HOSES, ENGINE SIDE
72
18. RECONNECT THE ENGINE WIRE HARNES
Reinstall the engine wire harness container to the cowl
panel.
Reconnect the clamp.
19. RECONNECT THE NO.1 HOSE
2TR-FE Only (Shown):
Reconnect the ground wire with the bolt.
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
Reconnect the No.1 hose to the air pump assy.
2012-2015MY (1GR-FE Only):
Reconnect the No.1 hose to the air pump assy.
20. RECONNECT THE POWER STEERING PUMP OIL
RESERVOIR ASSY (1GR-FE ONLY)
Reconnect the power steering pump oil reservoir assy.
21. RECONNECT THE GROUND WIRE (1GR-FE ONLY)
Reconnect the ground wire with the bolt.
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
Reconnect the clamp.
22. REINSTALL THE FAN SHROUD
Part #
90069-08019
NEW Replacement Parts
Part Name
Kit #
Packing (For Radiator Drain
2
Cock)
23. REINSTALL THE RADIATOR ASSY
Qty
1
Install the NEW o-ring to the drain plug.
Tighten the radiator drain plug.
Reinstall the radiator with 4 bolts and torque to spec.
Torque Spec: 18 N∙m (184 kgf∙cm, 13 ft∙lbf)
Reinstall the automatic transmission cooler lines (Auto Trans
Only).
Reinstall the fan shroud with the 2 bolts.
Torque Spec: 5.0 N∙m (51 kgf∙cm, 44 in∙lbf)
24. RECONNECT THE RADIATOR HOSES
25. REINSTALL THE RADIATOR SUPPORT TO FRAME SEAL
26. RECONNECT THE VACUUM HOSE
Reconnect the vacuum hose.
73
27. RECONNECT THE FUEL PIPES
Reconnect the No.1 and No.2 fuel pipe.
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.
Reinstall the 2 fuel pipe clamps.
28. RECONNECT THE FUEL VAPOR FEED HOSE
29. RECONNECT THE FRONT DIFFERENTIAL BREATHER
TUBES (4WD ONLY)
Reconnect the front differential breather tubes.
NOTE: There may be 2 different breather tubes
depending on the vehicle spec.
30. RECONNECT THE NO.2 ENGINE WIRE HARNESS
Remove the upper relay block cover.
Reconnect the 3 connectors.
Reconnect fuse box wire harness with the nut and torque
to spec.
Torque Spec: 11 N∙m (112 kgf∙cm, 8 ft∙lbf)
Reinstall the No.1 upper relay block cover.
Reconnect the No.2 engine wire harness with the 2
clamps.
Reconnect the (+) positive battery cable with the nut and
torque to spec.
Torque Spec: 7.6 N∙m (77 kgf∙cm, 67 in∙lbf)
Reconnect the ground wire with the bolt and torque to
spec.
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
31. REINSTALL THE FOLLOWING PARTS
• Air Cleaner Assy (1GR-FE Only)

Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙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)
32. REINSTALL THE FOLLOWING PARTS (ACCESS CAB ONLY)
• Rear Floor Side Service Hole Cover LH/RH
• Seat Floor Box
• Floor Board No.1/No.2
• No.1 w/ Box Speaker Assy (If Equipped)
• Rear Seat Cushion Assy
• Rear Lower Console Box
74
33. RECONNECT THE PARKING BRAKE CABLES
For Separate Seat Type:
Reconnect the 2 parking brake cables.
Reinstall the 2 clips.
For Bench Seat Type:
Reconnect the 2 parking brake cables.
Reinstall the 2 clips.
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)
Turn back the floor carpet.
34. REINSTALL THE FOLLOWING PARTS
• Manual Transmission Shift Lever (Manual Trans Only)
• Voltage Inverter Assy (If Equipped)
• Front Console Box(Manual Trans Only)
• Rear Console Box (for Separate Seat Type)
35. RECONNECT THE ENGINE WIRE HARNESS
Reconnect each connector and clamp to the ECM and
engine wire harness.
NOTE: The number of connectors may differ depending
on the model.
36. REINSTALL THE GLOVE BOX AND THE LOWER
INSTRUMENT PANEL FINISH PANEL
Reconnect the radio setting condenser connector
(If Equipped).
Reinstall the lower instrument panel finish panel with the
bolt.
Reinstall the glove box.
37. RECONNECT THE NO.2 FRAME WIRE HARNESS
(IF EQUIPPED)
For Frame Connecting Type:
Reconnect the 2 connectors and clamp.
Part #
90119-A0148
NEW Replacement Parts
Part Name
Bolt
*Individual Part(s)
Kit
#
NA*
Qty
2
Reinstall the wiring harness protector cover with the 2
NEW bolts and torque to spec.
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 in∙lbf)
75
For Floor Connecting Type:
Insert the No.2 frame wire harness into the cab assy.
Reinstall the No.2 frame wire harness grommet to the cab
assy.
Reconnect the 2 connectors.
Reinstall the wiring harness protector with the bolt and
torque to spec.
Torque Spec: 8.0 N∙m (82 kgf∙cm, 71 ft∙lbf)
Turn back the floor carpet.
Reinstall the passenger side seat with the 4 bolts and
torque to spec.
Torque Spec: 37 N∙m (377 kgf∙cm, 27 ft∙lbf)
38. RECONNECT THE FRAME WIRE HARNESS
Insert the frame wire harness into the cab assy.
Reinstall the frame wire harness grommet to the cab assy.
Reconnect the connector(s).
Reconnect the 5 clamps.
NOTE: The number of connectors may differ depending
on the model.
39. REINSTALL THE FOLLOWING INTERIOR COMPONENTS
• Instrument Panel Box
• Cowl Side Trim Board LH/RH
• Front Floor Footrest
• Front Door Scuff Plate LH/RH
76
40. REINSTALL THE FOLLOWING BODY COMPONENTS
• Front No.2 Bumper Extension Sub-assy LH/RH

Reinstall the front No.2 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 (2011MY):

Reinstall the front bumper assy with the 6 screws
and 9 clips.
• Front Bumper Assy (2012-2015MY):

Reinstall the front bumper assy with the 2 bolts, 6
screws and 5 clips.
• Front Fender Mudguard LH/RH
• Front Bumper Filler LH/RH (Except 2011MY)
• Radiator Grille
NEW Replacement Parts
Front No.2 Bumper Extension Sub-Assy LH/RH
Part #
Part Name
Kit # Qty
90178-A0044
Nut
2
6
J. REINSTALL THE BED ASSY
1.
REINSTALL THE BED ASSY
Using a Torx® T55H Socket, reinstall the bed assy Torx ®
bolts and torque to spec.
Torque Spec: 60 N∙m (612 kgf∙cm, 44 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.
• Protect the front side of the bed assy to not
damage the cab assy.
2.
REINSTALL THE FUEL INLET PIPE SUB-ASSY
Reinstall the fuel inlet pipe sub-assy with the bolt and
torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
3.
RECONNECT THE FRAME WIRE HARNESS
Reconnect the 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.
77
4.
NEW Replacement Parts
Left Rear Wheel Well Liner
Part #
Part Name
Kit # Qty
90189-A0002
8
8
Clip**
90189-A0002
9
6
**Only 1 part used, part number varies by vehicle type.
Quarter Panel Wheel Opening Moulding
Part #
Part Name
Kit # Qty
90189-A0002
Clip
8
2
75395-35070
Clip
8
3
75396-35020
Clip
8
7
Part #
75395-35070
75396-35020
90189-A0002
Body Rocker Panel Moulding Assy LH
Part Name
Kit #
Clip
9
Clip
9
Clip
9
Qty
2
1
1
Outside LH Back Door Moulding Sub-Assy
Part #
Part Name
Kit # Qty
75395-35070
Clip
9
2
75396-35020
Clip
9
1
90189-A0002
Clip
9
1
Part #
75395-04010
75396-04010
Part #
90119-A0192
Rocker Panel Moulding LH/RH
Part Name
Kit #
Clip
9
Clip
9
Rear Bumper Assy
Part Name
Bolt
Kit #
2
REINSTALL THE FOLLOWING PARTS
•
•
•
•
•
•
•
•
•
Power Outlet Socket Assy (If Equipped)
Left Rear Wheel Well Liner
Quarter Panel Wheel Opening Moulding LH (If Equipped)
Body Rocker Panel Moulding Assy LH (If Equipped)
Outside LH Back Door Moulding Sub-Assy (If Equipped)
Side Step Assy LH/RH (If Equipped)
Rocker Panel Moulding LH/RH (If Equipped)
Rear Mudguard LH/RH (If Equipped)
Rear Bumper Assy

Reinstall the rear bumper assy with the 10 NEW
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)
• Rear Tail/Combination Light LH/RH
Qty
4
14
Qty
6
78
K. FINAL ASSEMBLY
1.
RECONNECT THE NEGATIVE (-) BATTERY TERMINAL
2.
NEW Replacement Parts
art #
12157-10010
90430-24003
3.
Front Differential
Part Name
Gasket, Front Differential Filler
Plug
Gasket, Front Differential Drain
Plug
Kit #
Qty
3
1
3
1
REFILL THE FOLLOWING FLUIDS
• 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: 19.5 N*m (199 kgf*cm, 14 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-FE Manual Trans uses master cylinder
reservoir for clutch.
• Coolant

Refill with Toyota Long Life Coolant.

Bleed the cooling system.
• Front Differential Fluid (4WD Only)

Install the 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 the NEW filler plug washer and torque to
spec.

Torque Spec: 39.2 N·m (400 kgf·cm, 29 ft·lbf)
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 thoroughly to ensure
proper operation of these systems.
• Parking Brake Travel
• Shift Control Lever (Automatic Trans Only)
• Clutch Pedal (Manual Trans Only)
6.
CHECK ALL FLUID LEVELS AND ADJUST AS NEEDED
79
Part #
95381-04045
43514-28010
NEW Replacement Parts
Part Name
Kit #
Cotter Pin
3
Cap, front Axle Hub Grease,
3
LH/RH
Qty
2
2
7.
TORQUE THE FRONT AXLE NUT (4WD ONLY)
Remove the front wheels.
Torque the front axle nut to spec.
Torque Spec: 235 N∙m (2396 kgf∙cm, 173 ft∙lb)
Reinstall the lock cap with the NEW cotter pin.
NOTE: If the holes for the cotter pin are not aligned,
tighten the axle nut further, up to 60°.
Install 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)
8.
PERFORM A WHEEL ALIGNMENT
9.
CHECK THE HEADLIGHT AIM AND ADJUST AS NEEDED
10. REINSTALL THE ENGINE UNDER COVERS
Part #
90080-11373
90080-11373
NEW Replacement Parts
Part Name
Kit #
Bolt
8
Bolt
8
Qty
4
4
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
Check the operation of the following systems:
• 4WD System (4WD Only)
• Interior Lights
• Exterior Lights
• HVAC System
• Audio System
•
•
•
•
Power Windows
Power Door Locks
All Gauges, Indicators and Warning Lights
Etc.
14. TEST DRIVE THE VEHICLE AND DOCUMENT FINAL REPAIR STATUS
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.
80
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.
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