TSB007019

T-SB-0070-19
Rev2
June 20, 2019
TRD Pro Bumper/Fender Interference
Service
Category
Suspension
Section
Tire/Wheel
Market USA
Applicability
YEAR(S)
MODEL(S)
2015 - 2023
4Runner
ADDITIONAL INFORMATION
REVISION NOTICE
November 08, 2023 Rev2:
 The Repair Procedure section has been updated.
October 16, 2023 Rev1:
 Applicability has been updated to include 2021 – 2023 model year 4Runner vehicles.
Any previous printed versions of this bulletin should be discarded.
SUPERSESSION NOTICE
The information contained in this bulletin supersedes Service Bulletin No. T-SB-0009-15.
 Applicability has been updated to include 2019 and 2020 model year 4Runner vehicles.
Service Bulletin No. T-SB-0009-15 is obsolete, and any printed versions should be discarded.
Introduction
Some 2015 – 2023 model year TRD Pro Edition 4Runner vehicles may exhibit an abnormal noise
when in Reverse with the wheels at or near full lock due to interference between the tire and
bumper and/or fender liner. Follow the Repair Procedure in this bulletin to address this condition.
© 2023 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
BD1505
Fender/Bumper Trim Modification
1.0
52119-#####*
91
57
*Warranty claim MUST be submitted with the correct 10-digit OFP. Choose the correct OFP for the vehicle being repaired
by searching for the parts in the Electronic Parts Catalog using the VIN filter.
APPLICABLE WARRANTY
 This repair is covered under the Toyota Basic Warranty. This warranty is in effect for
36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.
 Warranty application is limited to occurrence of the specified condition described in
this bulletin.
Parts Information
PART NUMBER
PREVIOUS
PART NAME
QTY
4Runner TRD Pro Trim Kit*
1
NEW
PTR25-89150
*CONTENTS OF 4RUNNER TRD PRO TRIM KIT
QTY
LH and RH Bumper Cover Marking Templates
1 Each
3M™ Foam Sanding Block
1
Clamp
1
Modified Channellock Cutting Plier
1
LH and RH Metal Fender Liner Templates
1 Each
Double-sided Foam Tape
1
© 2023 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Plastic Pry Tool Kit*
00002-06020-01
1
*Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
REQUIRED TOOLS & MATERIAL
QUANTITY
Electric Drill
1
Step Drill Bit
1
Wax Pencil
1
Center Punch
1
Cutters
1
Lint-free Cloth
1
Masking Tape
As Needed
© 2023 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Repair Procedure
Fender Liner Modification
1. Confirm the abnormal noise condition described in the Introduction.
2. Remove the front wheels.
3. Beginning with the driver side, remove the two fasteners on the lower side of the fender liner.
Figure 1.
4. Unclip the fender liner and carefully pull it
toward the rear of the vehicle.
Figure 2.
© 2023 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Repair Procedure (continued)
Fender Liner Modification (continued)
5. Install the driver-side metal fender liner template (from the TRD Pro trim kit) on the front side
of the fender liner.
NOTE
Make sure to place the alignment pins into the two existing holes.
Figure 3.
Figure 4.
© 2023 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Repair Procedure (continued)
Fender Liner Modification (continued)
6. Use a wax pencil to outline two NEW holes and the area to be removed.
Figure 5.
7. Use a center punch to mark the center of the two holes and remove the template.
© 2023 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Repair Procedure (continued)
Fender Liner Modification (continued)
8. Using cutters, remove the marked plastic area as shown.
Figure 6.
Figure 7.
1
Before Cut
2
After Cut
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TRD Pro Bumper/Fender Interference
Repair Procedure (continued)
Fender Liner Modification (continued)
9. Using the step drill bit, drill two holes in the fender liner at the identifying marks.
NOTE
Set the drill stop to 5/16 in. – 3/8 in. (8 mm – 9 mm) and drill both sides to remove the flash from the
fender liner.
Figure 8.
10. Repeat the same procedure for the passenger side.
NOTE
Make sure to use the passenger side template.
© 2023 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Repair Procedure (continued)
Front Bumper Cover Modification
PRECAUTIONS AND PROPER USE OF CUTTING PLIERS
BEFORE proceeding, it is important to understand the proper use of the cutting pliers. Read this section
thoroughly to ensure proper use BEFORE front bumper cover modification.
 One side of the pliers is marked red.
THE RED SIDE OF THE PLIERS IS
TO BE USED AGAINST THE PAINTED
SURFACE ONLY (paint against paint).
Figure 9. Red Side
 When holding the cutting pliers in place, it is important to keep the pliers at a 90-degree angle
as shown.
Figure 10.
1
Bumper Cover
4
Red Jaw
2
Paint
5
90-Degree Edge to Surface
3
Tape
© 2023 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Repair Procedure (continued)
Front Bumper Cover Modification (continued)
PRECAUTIONS AND PROPER USE OF CUTTING PLIERS (continued)
 Do NOT make full cuts across the face
of the bumper cover.
 ONLY MAKE HALF CUTS BEFORE
MOVING TO MAKE THE NEXT CUT.
Figure 11. Top to Bottom
NOTICE
Failure to make ONLY half cuts
may result in uneven cuts,
a wavy appearance, or
bumper replacement.
Figure 12. Half Cuts Along Same Line
1
Cut 1
2
© 2023 Toyota Motor Sales, USA
Cut 2
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TRD Pro Bumper/Fender Interference
Repair Procedure (continued)
Front Bumper Cover Modification (continued)
PRECAUTIONS AND PROPER USE OF CUTTING PLIERS (continued)
Figure 13. Examples of Half Cuts
1
Cut 1
3
Cut 3
2
Cut 2
4
Cut 4
 The depth of the cutting pliers is less than the maximum depth of the area to be removed.
 It is necessary to first make a preliminary cut to remove approximately half of the area (between
the arrows).
Figure 14.
1
Depth of Cutting Pliers
2
© 2023 Toyota Motor Sales, USA
Area of Removal (Between Rows)
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TRD Pro Bumper/Fender Interference
Repair Procedure (continued)
Front Bumper Cover Modification (continued)
PRECAUTIONS AND PROPER USE OF CUTTING PLIERS (continued)
Figure 15. Good Example
Figure 16. Bad Example
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TRD Pro Bumper/Fender Interference
Repair Procedure (continued)
Front Bumper Cover Modification (continued)
1. Carefully pull the fender liner back and secure it to the lower control arm.
Figure 17.
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TRD Pro Bumper/Fender Interference
Repair Procedure (continued)
Front Bumper Cover Modification (continued)
2. Using warm water and a lint-free cloth, clean the work area, ensuring ALL debris is removed.
Figure 18.
3. Locate the left-hand bumper template and
secure it to the bumper cover with a clamp.
Figure 19.
© 2023 Toyota Motor Sales, USA
T-SB-0070-19
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TRD Pro Bumper/Fender Interference
Repair Procedure (continued)
Front Bumper Cover Modification (continued)
4. Cut an 8-in. (203 mm) strip of
double-sided foam tape and apply it to
the edge of the marking template.
Figure 20.
Ensure the tape is straight and flush
against the template.
NOTE
 Do NOT remove the backing from the tape.
 A NEW piece of tape MUST be used when
repeating this step for the opposite side.
5. Remove the marking template and clamp.
Figure 21.
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TRD Pro Bumper/Fender Interference
Repair Procedure (continued)
Front Bumper Cover Modification (continued)
6. Make the preliminary cut, removing
approximately half of the area (between
the arrows).
Figure 22.
7. Starting at the outer edge, trim along the
tape working toward the inside with
overlapping cuts.
Figure 23.
NOTICE
BEFORE each cut, ensure the cutting
pliers are held at a 90-degree angle and
rest against the tape. Failure to do so may
result in uneven cuts and bumper
cover replacement.
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TRD Pro Bumper/Fender Interference
Repair Procedure (continued)
Front Bumper Cover Modification (continued)
8. Once the cutting is complete, remove the tape.
9. Apply masking tape to the painted edge of the bumper cover just above and below the top of
the cut.
Figure 24.
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TRD Pro Bumper/Fender Interference
Repair Procedure (continued)
Front Bumper Cover Modification (continued)
10. Use the foam sanding block to lightly sand the cut edges to remove any sharp edges or burrs.
When sanding, use light pressure and keep the block square with the edge. Only a few strokes
should be required to ensure the edges are smooth.
Figure 25.
11. Remove the tape and clean the bumper surface as performed in step 2.
12. Return the fender liner back to its original position and reinstall the two fender liner fasteners.
NOTE
 The fasteners MUST be inserted into the two NEW holes drilled in step 9 of the Fender Liner
Modification section.
 The silver fastener MUST be in the front location and the black fastener in the rear location.
© 2023 Toyota Motor Sales, USA
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TRD Pro Bumper/Fender Interference
Repair Procedure (continued)
Front Bumper Cover Modification (continued)
13. Using your hands, verify the fender liner
and bumper are flush.
Figure 26.
14. Repeat both procedures (Fender Liner Modification and Front Bumper Cover Modification) on
the passenger side of the vehicle.
15. Install the front wheels.
Refer to TIS:
Accessory – Accessories Installation – “2015-2024 4Runner, 2007-2014 FJ Cruiser TRD
Alloy Wheel (PTR20-35110-BK (Matte Black), PTR20-35110-GR (Graphite Gray), PTR2035110-G4 (Gunmetal Gray), PTR20-35110-F5 (Flat Bronze)) Rev. P”
© 2023 Toyota Motor Sales, USA