T CP ZTH

SUPPLEMENTAL TECHNICAL INSTRUCTIONS
FOR
CUSTOMER SUPPORT PROGRAM (CSP)
2001 THROUGH 2004 MODEL YEAR TACOMA

FRAME REPLACEMENT
I. PREPARATION
A. TOOLS & EQUIPMENT
• Standard hand tools
• Torque Wrench
• Techstream
• A/C Service Equipment
• Brake Bleeder
• Protective Gloves
• Protective Eyewear
• Alignment Rack
• Engine Hoist (Qty: 2) or Hydraulic Mini Crane (Qty 2)
• Engine Sling
• Ratcheting Tie Down Strap (2 in X 27 ft, Minimum Work Load Capacity: 3,000 lbs)
• Special Service Tools (SST)
° 07110-58060 - Air Conditioner Service Tool Set or
Commercially Available Air Conditioning Manifold Gauge Set
° 09325-20010 - Transmission Oil Plug
° 09325-40010 - Transmission Oil Plug
° 09610-20012 - Pit Man Arm Puller
° 09709-29018 - LSPV Gauge Set
° 09727-22011-ST - Coil Spring Compressor
° 09950-40011 - Universal Puller B Set
° 09960-10010 - Variable Pin Wrench Set
• 12282-62050 - VZ Engine: Engine hanger (Qty: 1)
• 12282-75020 - RZ Engine: Engine hanger (Qty: 2)
• 91512-61020 - Bolt (Qty: 1 per Engine Hanger)
B. SUPPLEMENTAL TOOLS & EQUIPMENT (FOR INGROUND LIFTS ONLY)

NOTE:
The following tools & equipment listed below will ONLY be needed if your dealer is NOT equipped
with an above ground 2-post lift.
Special Service Tools (SST)

• 00002-09077 – Weights (Qty: 6)
Beam Kit – P/N TOYTACCSP01 *

• Single Post Under Hoist Stand (Qty: 1)
• Ratcheting Tie Down Strap (Qty 2)
• Tripod Under Hoist Stands (Qty 4)
• Steel Support Beams (Qty: 2)
• Bubble Level (Qty: 1)
* If you have any question regarding the equipment in the beam kit, please contact the Toyota
Approved Dealer Equipment customer service representative at 1-800-368-6787.
C. SUPPLIES
• Hypoid Gear Oil API GL-5 SAE 75W-90 (Qty 1.3 Quarts)
• R134a Refrigerant (As needed)
• Toyota DOT 3 Brake Fluid (Qty 3 pints)
• Toyota Long Life Coolant (Qty 2 gallons)
2
D. PARTS
To assist dealers in determining the correct part number(s) to order, a website has been set up to look up part
numbers by VIN. Please go to http://www15.inno-tech.com/toyota_zth (also linked through TIS), enter the
VIN, and the correct part numbers to order will be displayed. The website is for part(s) application
reference only and will not order the part, nor will it confirm campaign completion status.
• The parts will need to be ordered through the Dealer Daily Parts system.
• ETAs for the parts will be available via the normal system.
• Frame ETAs will be made available on the Dealer Daily website, in the MAC reference area.
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 Part Description Quantity Illustration Name Page

04008-30104 Frame Assy 1 Frame & Misc Parts 9
04008-30A04 Frame Assy 1 Frame & Misc Parts 9
04008-30B04 Frame Assy 1 Frame & Misc Parts 9
04008-30C04 Frame Assy 1 Frame & Misc Parts 9
46420-35532 No. 2 Parking Brake Cable Assy 1 Parking Brake 12
47318-04030 No. 8 Front Brake Line 1 Brake Lines 11
47323-04070 No. 3 Rear Brake Line 1 Brake Lines 11
48068-35120 Front Suspension Lower Arm RH 1 Front Suspension 13
48069-35120 Front Suspension Lower Arm LH 1 Front Suspension 13
48210-04210 Rear Leaf Spring RH 1 Rear Suspension 9
3
Individual Parts (Continued):
48210-AD040 Rear Leaf Spring RH 1 Rear Suspension 9
48220-04100 Rear Leaf Spring LH 1 Rear Suspension 9
48220-AD040 Rear Leaf Spring LH 1 Rear Suspension 9
48304-35150 Bump Stop No. 1 2 Front Suspension 13
48305-35040 Bump Stop No. 2 2 Front Suspension 13
89515-35010 Clip (Speed Sensor) 2 Not Available -
90468-08046 Clip 4 Brake Lines 10
90480-01621 Clip 1 Brake Lines 10-11
90480-01628 Clip 1 Brake Lines 10
90904-12030 Way 1 Brake Lines 10-11
90904-14004 No. 3 Way 1 Brake Lines 10-11
90904-15001 No. 3 Way 1 Brake Lines 11
Parts Kits:
Part Number Part Description Quantity
04008-27135 Common Replacement Kit 1 1
The kit listed above includes the following parts:
17572-75020 No.2 Exhaust Pipe Support Bracket 1 Exhaust System 14
47931-35100 Load Sensing Valve Bracket 1 LSPV 10
47937-60010 Load Sensing Valve Set Plate 1 LSPV 10
64189-35030 Rear Body Mounting Bolt 2 Bed Assy 17
82711-16820 Wiring Harness Clip 2 Wiring Harness Clips 12
82711-2C190 Wiring Harness Clip 1 Wiring Harness Clips 12
82711-3A640 Wiring Harness Clip 2 Wiring Harness Clips 12
82711-3F050 Wiring Harness Clip 4 Wiring Harness Clips 12
82711-3H470 Wiring Harness Clip 2 Wiring Harness Clips 12
90105-14025 Bolt 2 Rear Suspension 9
90119-08667 Bolt 2 Exhaust System 14
90119-08B75 Bolt 4 Engine Mounting & Radiator 14
90119-10175 Bolt 4 Engine Mounting & Radiator 14
90119-10560 Bolt 4 Front Bumper 16
90119-12254 Bolt 4 Bed Assy 17
90159-50339 Bolt 4 Fuel Tank 15
90179-08063 Nut 2 Front Bumper 16
90179-10071 Nut 4 Engine Mounting & Radiator 14
90179-14039 Nut 2 Rear Suspension 9
90201-12061 Washer 2 Bed Assy 17
90201-14005 Washer 2 Rear Suspension 9
90201-15012 Washer 8 Rear Suspension 9
90201-23360 Washer 4 LSPV 10
90467-31110 Clip 1 LSPV 10
90904-12029 No.2 Way 1 Brake Lines 11
90917-06057 Exhaust Pipe Gasket 1 Exhaust System 14
90949-01C06 Clip 6 Brake Lines 10-11
91131-50840 Bolt 2 LSPV 10
94184-61201 Nut 2 Bed Assy 17
94512-00800 Washer 4 LSPV 10
4
Parts Kits (Continued):

04008-27104 Common Replacement Kit 2 1
52145-AD010 Front Bumper Side Mounting Bracket LH 1 Front Bumper 16
52146-AD010 Front Bumper Side Mounting Bracket RH 1 Front Bumper 16
90069-08019 O-ring 1 Engine Mounting & Radiator 14
Frame & Misc Parts 9
LSPV 10
90080-11180 Bolt 32
Brake Lines 10
Fuel Tank 15
90080-11203 Bolt 3 Brake Lines 10-11
90080-11232 Bolt 4 Frame & Misc Parts 9
90080-11373 Bolt 9 Frame & Misc Parts 9
90080-11471 Bolt 2 Fuel Tank 15
90080-11555 Bolt 2 Steering Shaft 15
90080-17265 Nut 8 Rear Suspension 9
90099-14120 O-ring 1 Air Conditioning 15
90099-14121 O-ring 1 Air Conditioning 15
90119-A0028 Bolt 4 Frame & Misc Parts 9
90119-A0029 Bolt 2 Frame & Misc Parts 9
90170-A0001 Nut 4 LSPV 10
90177-A0003 Nut 2 Exhaust System 14
90177-A0004 Nut 2 Exhaust System 14
90468-A0007 Clip 4 Brake Lines 10-11

04008-27335 2WD Replacement Kit 3 1
47910-35330 Load Sensing Proportioning Valve Assy 1 LSPV 10
90117-14039 U-bolt 4 Rear Suspension 9
90119-08686 Bolt 4 Front Suspension 13
90171-14002 Castle Nut 2 Front Suspension 13
90179-12133 Nut 4 Front Suspension 13
90252-03008 Cotter Pin 2 Front Suspension 13
95381-03220 Cotter Pin 2 Power Steering Rack 13

04008-27304 2WD Replacement Kit 4 1
04483-04050 Rear Spring Shackle Kit 2 Rear Suspension 9
47324-04040 No.4 Rear Brake Tube (Line) 1 Brake Lines 11
90119-A0180 Bolt 4 Front Suspension 13
5

04008-27435 4WD & PreRunner Replacement Kit 5 1
12157-10010 Gasket 1 Front Differential 12
17576-75030 No.6 Exhaust Pipe Support Bracket 1 Exhaust System 14
43514-28010 Front Axle Hub Grease Cap 2 Front Driveshaft 13
46441-30030 No.1 Wire Adjustment Nut 2 Parking Brake 12
47910-35320 Load Sensing Proportioning Valve Assy 1 LSPV 10
48409-35050 Front Suspension Toe Adjust Cam Assy 4 Front Suspension 13
48452-35020 No.2 Front Suspension Toe Adjust Plate 4 Front Suspension 13
48824-35100 No.1 Front Stabilizer Bracket RH 1 Front Suspension 13
48829-35070 No.2 Front Stabilizer Bracket LH 1 Front Suspension 13
90117-14008 U-bolt 4 Rear Suspension 9
90159-60393 Screw 8 Bed Assy 17
90206-08016 Wave Washer 2 Parking Brake 12
90240-08040 Pin 1 Parking Brake 12
90240-08059 Pin 2 Parking Brake 12
90430-24003 Gasket 1 Front Differential 12
90468-14021 Clip 1 Parking Brake 12
90904-67036 Clip 2 Bed Assy 17
90904-67037 Clip 5 Bed Assy 17
90949-01982 Clip 1 Front Differential 12
90949-01C25 Clip 1 Front Differential 12
95381-03230 Cotter Pin 2 Front Suspension 13
95381-04030 Cotter Pin 2 Power Steering Rack 13
95381-04045 Cotter Pin 2 Front Driveshaft 13

04008-27404 4WD & PreRunner Replacement Kit 6 1
04483-04060 Rear Spring Shackle Kit 2 Rear Suspension 9
43425-04020 Drive Shaft Snap Ring 2 Front Driveshaft 13
90171-A0005 Castle Nut 2 Front Suspension 13
90468-A0001 Clip 2 Parking Brake 12

04008-27535 AT Replacement Kit 7 1
33572-22010 Control Shaft Bush Lower 1 AT Shifter 16
33723-22010 Connecting Rod Swivel 1 AT Shifter 16
90389-08005 Bush 1 AT Shifter 16
94612-10800 Washer 1 AT Shifter 16
94613-10800 Washer 2 AT Shifter 16
6

04008-27504 AT Replacement Kit 8 1
90080-11158 Bolt 8 AT Shifter 16
90080-18070 Nut 1 AT Shifter 16
90468-A0006 Clip 1 AT Shifter 16

04008-27604 Brake Tube (Line) Kit 9 1
47312-04080 No.2 Front Brake Tube (Line) 1 Brake Lines 11


7




47314-04080 No.4 Front Brake Tube (Line) No.2 1 Brake Lines 10
8
E. PARTS ILLUSTARTION
Frame & Misc Parts
Rear Suspension
9
LSPV
Brake Lines
- With VSC -
10
Brake Lines Continued
- With ABS -
- Without ABS/VSC -
11
Parking Brake
- 2WD -
- 4WD & PreRunner -
Wiring Harness Clips
Front Differential
12
Front Driveshaft
Power Steering Rack

- 2WD - - 4WD & PreRunner-
Front Suspension
- 2WD - - 4WD & PreRunner-
13
Engine Mounting & Radiator
Exhaust System
14
Fuel Tank
Steering Shaft
Air Conditioning
15
AT Shifter
Front Bumper
16
Bed Assy
17
II. VEHICLE INSPECTION
• Visually inspect both the vehicle interior and exterior. Note any damage found during the
visual inspection prior to beginning work.
• As you disassemble the vehicle you may encounter parts that are in need of replacement,
which are not covered by this repair procedure. If this is the case, please take the time to
inform the customer that these parts can be replaced with minimal labor cost.
III. FRAME REPLACEMENT WORK PROCEDURE

A. SAFETY CHECKLIST & PRECAUTIONS WHEN DRAINING THE FUEL SYSTEM
• Always remember “SAFETY FIRST”.

• Be extremely careful when handling fuel to prevent fires from occurring.
• Before beginning work on the fuel system, perform the following safety check list.
• Before removing any fuel system part, drain all fuel to prevent spilling.
1. AIR VENTILATION
Perform work in a well ventilated area.
DO NOT work underground or in an area where fuel vapors may fill the room due to poor ventilation.
Quickly clean up any spilled fuel with a dry cloth and dissipate the fuel vapors.
Dry all cloths that have come in contact with fuel in a well ventilated area and dispose of them properly
(according to applicable local regulations).
2. FIRES AND IGNITION SOURCES ARE STRICTLY PROHIBITED

Fires and ignition sources are prohibited while working on the fuel system.
Clearly display the sign found on the next page stating “WORKING WITH GASOLINE, NO FIRES OR
IGNITION SOURCES”.
Smoking is prohibited near the work area.
DO NOT work in areas where there are welders, grinders, drills, electric motors, heaters, etc.
DO NOT use work lamps or any other electrical appliance due to the risk of sparks flying from the power
switch or a rise in temperature.
DO NOT use metal hammers while working, due to the risk of flying sparks.
DO NOT start any engines or perform any of the above in neighboring work bays.
3. FIRE EXTINGUISHER
Have a fire extinguisher ready and available before beginning work.
4. PREVENT STATIC ELECTRICITY

To help prevent static electricity, lightly wet the floor with water, but not to the point where it creates a
hazardous working condition.
Place appropriate warning cones or stand signs around the area as a caution.
5. PRECAUTIONS WHEN USING A LIFT

For bays equipped with auto lifts, cover all access cover joints with duct tape.
In the event that fuel has leaked inside the auto lift, remove the access cover and clean up any spilled fuel.
Dissipate fuel vapors until the smell is gone.
6. PREVENT THE FUEL FROM SPRAYING

When disconnecting any fuel lines, pipes, hoses or connectors there may still be some pressure remaining,
even after discharging the system. To prevent the fuel from spraying, cover the lines, pipes or connectors with
a shop rag before disconnecting.
Remember to always wear protective goggles especially when disconnecting fuel lines, 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.
18
19
20
B. 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 specs and parts for the model you are working on.
• For additional repair information, please reference to the appropriate repair manual for the
vehicle you are working on.
1. CENTER THE VEHICLE BETWEEN THE LIFT ARMS
a) Verify the vehicle is aligned with the center point of the lift to prevent interference and damage to the frame
and/or lift.
2. REMOVE THE FOLLOWING PARTS
• Front And Rear Wheels

• Rear Bumper Assy
• Rear Tail/Combination Lights
• Rear Mudguards
• Side Step Assemblies (If Equipped)
• Left Rear Fender Flare Molding (If Equipped)
• Left Rear Wheel Well Liner
• Fuel Tank Filler Pipe Shield
NOTE:
Be careful not to damage the rear tail/combination lights when removing them.
3. REMOVE THE WIRE HARNESS
a) Disconnect the 9 wire harness clips from the bed assy.
NOTE:
Be careful not to damage the wire harness clips when removing
them.
4. REMOVE THE BED ASSY
a) Remove the 2 nuts, 2 washers and 2 bolts.

b) Remove the 4 bolts and 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 or hit the fuel inlet pipe when
removing the bed assy as shown.
21
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 lines,
pipe, hoses and connectors as you separate them to reduce the risk of fuel spraying on
yourself, in the engine compartment and onto other parts.
1. CHECK FOR DTCs
2. DISCHARGE THE FUEL SYSTEM PRESSURE
a) Disconnect the fuel pump connector.

b) Start the engine.
c) After the engine has stopped, turn the ignition switch OFF.
d) Crank the engine again to check that it does not start.
e) Disconnect the fuel tank main lines.
NOTE:
Please make sure to follow the procedure listed above. This will
prevent a large amount of gasoline from spilling out when high
pressure fuel line is disconnected.
3. RECORD THE RADIO STATION PRESETS & REMOVE THE BATTERY
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.).
22
D. REMOVE THE CAB BODY ASSY
• If the frame is perforated, ONLY raise the vehicle high enough to remove the tires.
• For added safety and support place jack stands under the front and rear portions of the
frame.
• DO NOT work directly underneath the vehicle when performing cab body assy removal,
unless noted.
• The actual vehicle specs, equipment and parts required may differ than what is shown.
Please use the correct specs and parts for the model you are working on.
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
• Clutch Fluid (Manual Transmission Vehicles Only)
• Brake Fluid
NOTE:
DO NOT remove the radiator cap while the radiator and engine are hot, doing so may cause the coolant to
spray out causing potential injuries.
• Front Parking/Clearance Lights

• Radiator Grille
• Front Bumper Assy
• Front Bumper Reinforcement
5. DISCONNECT THE OXYGEN SENSOR
a) Remove the 4 screws and the right front door scuff plate.
b) Remove the right cowl side trim board.
c) Disconnect the oxygen sensor connector.
d) Remove the oxygen sensor wire harness grommet from the cab
assy.
e) Pull out the oxygen wire harness from the cab assy.
6. DISCONNECT THE NO. 1 PARKING BRAKE

CABLE ASSY
2WD 4WD & PreRunner NOTE:

Use precaution when performing this step, as
you will need to work underneath the vehicle.
For 2WD:
a) Remove the clip.
b) Disconnect the No.1 parking brake cable
assy.
For 4WD & PreRunner:

a) Remove the clip and pin.
b) Remove the clip.
c) Disconnect the No.1 parking brake cable
assy.
23
7. DISCONNECT THE NO. 1 GEAR SHIFT ROD
(AUTOMATIC TRANSMISSION VEHICLES ONLY)
NOTE:
Use precaution when performing this step, as you will need to work
underneath the vehicle.
a) Remove the nut and washer, and disconnect the No.1 gear shift rod.
8. REMOVE THE AIR CLEANER CASE ASSY AND HOSE
9. DISCONNECT THE ACCELERATOR/THROTTLE CABLE (ENGINE SIDE)
10. DISCONNECT THE ENGINE WIRE HARNESS (ONLY FOR VEHICLES

PRODUCED ON OR BEFORE SEPTEMBER 2001)
a) Disconnect the 3 connectors.

b) Disconnect the 4 wire harness clips.
11. DISCONNECT THE HOSES (ONLY FOR

VEHICLES PRODUCED ON OR BEFORE
SEPTEMBER 2001)
RZ Engine VZ Engine For RZ Engine:

a) Disconnect the brake booster hose from the
intake manifold.
b) Disconnect the vacuum hose from the VSV
and the clip.
c) Disconnect the hose from the EVAP.
d) Disconnect the air drain hose from the clip.
For VZ Engine:
a) Disconnect the brake booster hose from the
intake manifold.
b) Disconnect the VSV vacuum hose.
c) Disconnect the hose from the EVAP and the
clip.
12. DISCONNECT THE ENGINE WIRE HARNESS

(ONLY FOR VEHICLES PRODUCED AFTER SEPTEMBER 2001)
a) Disconnect the 2 connectors.

b) Disconnect the 5 wire harness clips.
13. DISCONNECT THE HOSES

(ONLY FOR VEHICLES PRODUCED AFTER SEPTEMBER 2001)
a) Disconnect the brake booster hose from the intake manifold (ONLY
for vehicles without VSC).
b) Disconnect the 2 hoses.
24
14. DISCONNECT THE BREATHER HOSE
a) Disconnect the 2 vacuum hoses.

b) Disconnect the breather hose(s).
NOTE:
There may be 2 different breather hoses depending on the vehicle
model.
15. DISCONNECT THE FUEL PIPES
a) Disconnect the fuel return hose.

b) Disconnect the main fuel pipe.
16. DISCONNECT THE NO.2 ENGINE WIRE HARNESS
a) Remove the bolt and ground wire.

b) Remove the nut and the 2 (+) positive battery cables.
c) Disconnect the No. 2 engine wire harness from the clip.
d) Disconnect the connector.

e) Remove the nut and clip to disconnect the fusebox wire harness.
17. REMOVE THE RADIATOR

NOTE:
After disconnecting the automatic transmission oil cooler hoses, plug them and cap the fittings to
prevent the ATF from spilling out (Automatic Transmission Vehicles Only).
18. DISCONNECT THE WATER/HEATER HOSES (ENGINE SIDE)
19. DISCONNECT THE AIR CONDITIONING DISCHARGE AND SUCTION HOSES FROM THE COMPRESSOR
a) Remove the bolt and the wire harness bracket.

b) Remove the 2 nuts and the engine wire harness from the cowl panel.
c) Remove the bolt and disconnect the ground wire.
21. REMOVE THE GLOVE BOX & THE LOWER FINISH PANEL
a) Remove the glove box.

b) Disconnect the wire harness clip.
c) Remove the 3 bolts and the lower finish panel.
25
a) Disconnect the 4 connectors and the engine wire harness.
b) Disconnect the 2 or 3 connectors from the ECM and remove the

engine wire harness.
NOTE:
The number of connectors may differ depending on the model.
23. DISCONNECT THE FRAME WIRE HARNESS
a) Remove the 4 screws and the driver’s door scuff plate.

b) Remove the left cowl side trim board.
c) Disconnect the connector(s).
NOTE:
d) Remove the frame wire harness grommet from the cab assy.
e) Pull out the frame wire harness from the vehicle cab assy.
• Rear Console Box (If Equipped)

• Front Console Box (If Equipped)
• Transfer Case Shift Lever (4WD Only)
• Manual Transmission Shift Lever (Manual Transmission Vehicles Only)
• Automatic Transmission Shift Lever Assy (Automatic Transmission Vehicles Only)
25. REMOVE THE FRONT FENDER APRON TO

2WD
FRAME SEALS
For 2WD:
a) Remove the 9 clips and front fender apron to
frame seal.
b) Repeat the procedure on the opposite side.
4WD & PreRunner For 4WD & PreRunner:

a) Remove the 12 clips and the left front fender
apron to frame seal.
b) Remove the 11 clips and the 2 right front
fender apron to frame seals.
26
26. DISCONNECT THE BRAKE LINES
With ABS/VSC Without ABS/VSC
For Vehicles with ABS/VSC:
a) Disconnect the 3 left front brake lines.
For Vehicles without ABS/VSC:

a) Disconnect the 2 left front brake lines.
27. DISCONNECT THE NO. 2 FRONT BRAKE LINE
a) Disconnect the No. 2 right front brake line.
28. DISCONNECT THE CLUTCH HOSE

(MANUAL TRANSMISSION VEHICLES ONLY)
a) Disconnect the clutch line from the hose.

b) Remove the clip and disconnect the clutch hose from the bracket.
29. DISCONNECT THE NO. 2 STEERING INTERMEDIATE SHAFT
a) Make sure the front wheels are in a straight-ahead position and the
steering wheel is centered.
b) Using the seat belt, hold the steering wheel in the centered position
to prevent damage to the spiral cable.
c) Place matchmarks on the No. 2 steering intermediate shaft and
control valve shaft.
d) Loosen bolt “A” and remove bolt “B”.
e) Disconnect the No. 2 intermediate shaft from the control valve shaft.
NOTE:
If the No. 2 intermediate shaft is stuck, tap it from below with a
brass hammer to disconnect it.
30. DISCONNECT THE FRONT SPEED SENSOR CONNECTOR

(ONLY FOR ABS/VSC EQUIPPED VEHICLES)
a) Disconnect the front speed sensor connector.

b) Repeat the procedure on the other side.
31. REINSTALL THE WHEELS
27
Double Cab - Center & Rear Cab Mounts Extra Cab - Center & Rear Cab Mounts
Regular Cab - Center & Rear Cab Mounts
Front Cab Mounts
If your dealer is NOT equipped with an above ground 2-post lift, please go to section “E.
REMOVE THE CAB BODY ASSY USING AN INGROUND LIFT” on page 29.
32. REMOVE THE CAB BODY ASSY USING AN ABOVE GROUND LIFT
a) Remove the 6 nuts and 6 washers.

b) Set the lift arms under the cab body assy so they DO NOT interfere with the frame or cab mounts.
c) Check that all wire harnesses, hoses, cables and the steering shaft are disconnected.
d) Lift the cab assy up slowly, making sure it does not interfere with anything while being raised.
e) Raise the cab assy high enough so that the top of the engine clears the lowest point of the cab assy.
f) Pull the frame assy out from under the vehicle.
g) Lower the cab assy all the way down and leave it on the lift.
h) Proceed to section “F. DISASSEMBLE THE FRAME” on page 34.
NOTE:
• Center the cab assy weight on the lift arms so that it does not slant/tilt to one side.
• Raise the cab assy slightly off the frame and verify that it is held securely by the lift arms.
• DO NOT work directly underneath the vehicle when pulling the frame assy out from under.
• DO NOT remove the cab mount bolts, as they will be used as guides during cab assy reinstallation
process.
28
E. REMOVE THE CAB BODY ASSY USING AN INGROUND LIFT
PROCEDURE & EQUIPMENT REQUIREMENTS

• When using an inground lift it will not be possible to pull the frame out from under the cab
assy after it has been raised. This is due to the inadequate spacing between the posts of
the inground lift, so the following alternate method will need to be required.
• Additional tools & equipment will be required when removing the cab assy using an
inground lift. Please reference the “SUPPLEMENTAL TOOLS & EQUIPMENT (FOR
INGROUND LIFTS ONLY)” on page 17.
INGROUND LIFT REQUIREMENTS & PRECAUTIONS

(REGULAR CAB ONLY)
When performing cab assy removal on a regular cab vehicle
with an inground lift, make sure the lift meets the
dimensions shown in the illustration to the right. If these
dimensions are not met please use another inground lift, as
you may not be able to raise the cab body off the frame.
1. CENTER THE VEHICLE BETWEEN THE LIFT ARMS

For Reference Purposes, Only The
Frame Is Shown. a) Verify the vehicle’s frame is aligned with the center point of the lift.
This will prevent interference and damage to the frame and/or lift.
2. CAB ASSY REMOVAL PREPARATION (REGULAR CAB ONLY)

Illustration A
a) Position the lift arms as shown (Illustrations A & B).
b) Slide the driver and passenger seats forward.
Illustration B
29
The center gravity for the regular cab body assy is located towards the front. This may cause
the cab body assy to tilt forward when lifted. To help prevent this, either place weights in
between the seats and the rear of the cab OR secure the rear of the cab assy to the lift arms
using a ratcheting tie down strap(s).
If Using Weights:
c) Slide the bench seat or driver and passenger seats forward.
d) Using six 22 lbs (10 kg) weights (SST 00002-09077) place three of
them in between the driver’s seating position and the cab, and the
remaining three in between the passenger seating position and the
cab.
If Using Ratcheting Tie Down Strap:

c) Slide the bench seat or driver and passenger seats forward.
d) Attach the hook of the tie down strap to the right rear seat rail.
e) Wrap the tie down around the lift arm 1 to 2 times.
f) Route the tie down strap through the cab and outside the opposite
door.
g) Wrap the tie down strap around the lift arm 1 to 2 times.
h) Attach the hook with the ratcheting mechanism to the left rear seat
rail.
i) Pull the tie down strap through the ratcheting mechanism and
tighten.
30
Front Cab Mounts
3. REMOVE THE CAB MOUNT BOLTS
a) Remove the 6 nuts and 6 washers.

b) Set the lift arms under the cab body assy so they DO NOT interfere with the frame or cab mounts.
c) Check that all wire harnesses, hoses, cables and the steering shaft are disconnected.
d) Lift the cab assy up slowly, making sure it does not interfere with anything while being raised.
e) Raise the cab assy high enough so that the top of the engine clears the lowest point of the cab assy.
NOTE:
• Center the vehicle’s weight on the lift arms so that it does not slant/tilt to one side.
• Raise the cab assy slightly off the frame and verify that it is held securely by the lift arms.
• DO NOT remove the cab mount bolts, as they will be used as guides during the cab assy
reinstallation process.
31
Regular Cab Shown Regular Cab Shown
(Illustration A) (Illustration B) (Illustration C)
4. SUPPORT THE CAB ASSY
a) Position the tripod under hoist stands so that they will not interfere with the lift arms when retracted
(Illustrations A & B).
b) Slide the steel support beams underneath the cab body and on top of the tripod under hoist stands
(Illustrations C & D).
c) Using the bubble level, adjust the tripod under hoist stands so that the steel support beams are level. This
will ensure the cab assy is balanced.
d) Slowly lower the cab assy onto the steel support beams (Illustration D).
NOTE:
Make sure to provide adequate room for the lift arms to retract, as this will to allow the frame to be pulled
out from underneath the cab assy.
Regular Cab Shown Extra Cab Shown Double Cab Shown
(Illustration D) (Illustration D) (Illustration D)
5. SUPPORT THE FRONT OF THE CAB ASSY (REGULAR CAB ONLY)
a) Pull the frame back slightly, and place a single post under hoist
stand at the front core support.
NOTE:
Make sure to install the single post under hoist stand, as this will
prevent the cab body assy from tilting forward.
32
6. REMOVE THE FRAME
Extra Cab Shown
a) Remove the ratcheting tie down strap if used (Regular Cab Only)
b) Lower the lift arms all the way down.
c) Pull the frame out from under the cab assy.
NOTE:
DO NOT work directly underneath the vehicle when pulling the
frame out from under the cab assy.
Extra Cab Shown d) Raise the lift arms back up to the cab body assy
e) Lift the cab body assy off of the steel support beams.
f) Remove the bubble level.
g) Remove the 2 steel support beams.
h) Move the 4 tripod under hoist stands.
i) Remove the single post under hoist stand (Regular Cab Only).
Extra Cab Shown j) Lower the cab assy all the way down and leave it on the lift.
k) Reinstall the ratcheting tie down strap, if used, as outlined on page
30. (Regular Cab Only)
33
F. DISASSEMBLE THE FRAME
1. PLACE THE FRAME ON A LIFT
a) Place the frame on the lift, and secure it with a ratcheting tie down strap. This will prevent the frame from
tilting or falling off as parts are removed.
• Ratcheting Tie Downs: Qty 1

° Length: 2 in X 27 ft
° Minimum Work Load Capacity: 3,000 lbs
• Wheels
• Spare Tire
• Front Propeller Shaft (4WD Only)
• Rear Propeller Shaft
° Insert the SST into the transmission after the rear propeller shaft is removed to prevent oil leakage (2WD
Only, Except PreRunner)
° SST:
09325-20010 (For 2-Joint Type Propeller Shafts)
09325-40010 (For 3-Joint Type Propeller Shafts)
NOTE:
Make sure to place matchmarks on the front (if equipped) and rear propeller shafts before removal.
3. REMOVE THE EXHAUST SYSTEM
a) Disconnect the 2 oxygen sensor wire harness clips from the frame.
b) Remove the 2 nuts and 2 bolts.

c) Remove the exhaust system as an assy.
• Fuel Tank Protector

• Fuel Tank Assy (All Vehicles) & The Charcoal Canister Assy (Only For Vehicles Produced On Or Before
September 2001)
5. REMOVE AND SET ASIDE THE POWER STEERING PUMP ASSY
a) Remove the power steering belt.

b) Remove the 2 bolts (RZ Engine Only) or the bolt and the nut (VZ Engine Only) and power steering pump
assy from the mounting bracket.
c) Remove the 3 bolts and the power steering lines from the frame.
NOTE:
• DO NOT disconnect the power steering pump hoses or lines.
• Make sure to keep the power steering pump reservoir in an upright position to prevent the fluid from
leaking out.
34
6. REMOVE THE ENGINE AND TRANSMISSION ASSY
a) Disconnect and remove the necessary items/parts to prepare the

engine and transmission assy for removal.
b) Install the engine hanger(s).
For RZ Engine:
12282-75020 = Engine Hanger, Qty:2
91512-61020 = Bolt, Qty: 2
For VZ Engine:
12282-62050 = Engine Hanger, Qty: 1
91512-61020 = Bolt, Qty: 1
c) Remove the engine and transmission assy.
NOTE:
• When removing the engine and transmission assy, ALWAYS
use 2 engine hoists or mini cranes to lift it.
• DO NOT use 1 engine hoist or mini crane to lift the engine and
transmission assy, as the unbalanced weight may lead to an
accident or injury.
• ONLY use engine hoists or mini cranes that can properly
support the weight of the engine and transmission assy.
• Carefully adjust the 2 engine hoists or mini cranes used so that
the engine and transmission assy is properly balanced.
7. DISCONNECT THE FRONT BRAKE HOSE

2WD (Left Side) 2WD (Right Side)
a) Disconnect the front brake hose from the
brake line.
b) Remove the clip and disconnect the brake
hose.
c) Repeat the procedure on the opposite side.
4WD (Left Side) 4WD (Right Side)
8. DISCONNECT THE FRONT SPEED SENSOR WIRE HARNESS
For 4WD with ABS/VSC:

a) Disconnect the 3 front speed sensor wire harness clips from the suspension support.
For 2WD with ABS:

a) Disconnect the front speed sensor wire harness.
9. REMOVE THE FRONT STABILIZER BAR

35
Illustration A Illustration B Illustration C
Illustration D Illustration E
10. REMOVE THE FRONT SUSPENSION (2WD ONLY, EXCEPT PRERUNNER)
a) Remove the cotter pin, nut and disconnect the tie rod end.
b) Remove the 2 bolts, and disconnect the brake hose from the lower suspension arm and strut bar assy
(illustration A).
c) Remove the 3 bolts, and the front shock absorber.
d) Using the SST 09727-22011-ST, compress the coil spring until it separates from the lower suspension
arm(Illustration B). DO NOT remove the SST until instructed.
NOTE:
When setting the fork on the SST, insert into the center of the coil spring and lower it by turning it with
the coil spring.
e) Remove the cotter pin and nut from the lower ball joint.
f) Using SST 09950-40011, disconnect the lower ball joint from the lower suspension arm.
g) Remove the 2 bolts, retainers, adjustment shims and the upper suspension arm with steering knuckle
attached (Illustration C).
NOTE:
Make sure to note the number, thickness and location of the adjustment shims.
h) Remove the 2 bolts, 2 nuts and the lower suspension arm and strut bar assy (Illustration D).
i) Decompress the coil spring and remove the SST and spring (Illustration E).
j) Repeat the procedure on the opposite side.
11. REMOVE THE FRONT SUSPENSION (4WD & PRERUNNER ONLY)
a) Remove the cotter pin, nut and disconnect the tie rod end using SST
09610-20012.
b) Remove the front axle nut (4WD Only).
c) Remove the cotter pin, nut and disconnect the lower ball joint using
SST: 09950-40011.
d) Remove the nut, bolt, 2 washers and front suspension upper arm
with steering knuckle attached.
e) Remove the 4 nuts, bolt, washer and the shock and spring assy.
f) Repeat the procedure on the opposite side.
36
12. REMOVE THE FRONT DIFFERENTIAL BREATHER TUBES (4WD
ONLY)
a) Remove the 2 bolts, 2 clips and front differential breather tubes.
13. DRAIN THE FRONT DIFFERENTIAL (4WD ONLY)
• Power Steering Rack With The Pump Assy Attached

• Front Drive Shafts (4WD Only)
• Front Differential Assy (4WD Only)
NOTE:
• When removing the power steering rack with the pump assy attached, have one person support the
power steering rack and the other support the pump assy.
• Make sure to keep the power steering pump reservoir in an upright position to prevent the fluid from
leaking out.
• If the drive shaft is difficult to remove tap it with a plastic hammer.
15. DISCONNECT THE PARKING BRAKE CABLES

Illustration A Illustration D
For 2WD:
a) Remove the 2 clips (Illustration A).
b) Disconnect the 2 No.2 parking brake cables
from parking brake equalizer (Illustration A).
c) Remove the parking brake lever/equalizer
(Illustration A).
d) Remove the 4 or 5 bolts and disconnect the 2
parking brake cables (Illustrations B & C).
NOTE:
The number of bolts used may differ
Illustration B Illustration E depending on the vehicle specs.

a) Remove the parking brake cable adjustment
nuts and disconnect the cable from the lever
(Illustration D).
b) Remove the intermediate parking brake lever
(Illustration D).
c) Remove the 2 bolts and disconnect the
parking brake cable (Illustration E).
d) Remove the clip, pin and disconnect the
parking brake cables (Illustration F).
Illustration F
Illustration C
(Left Side Shown) NOTE:
The parking brake cable is routed above the
rear leaf springs on vehicles produced on or
before September, 2002, and below the rear
leaf spring on vehicles produced after
September, 2002.
37
2WD 4WD & PreRunner Without VSC 4WD & PreRunner With VSC
.
16. DISCONNECT THE REAR BRAKE HOSE(S)
For 2WD Vehicles and 4WD & PreRunner Vehicles Without VSC:
a) Disconnect the brake hose from the brake line.
b) Remove the clip and the brake hose.
For 4WD & PreRunner Vehicles With VSC:

a) Disconnect the 2 brake hoses from the brake lines.
b) Remove the clip and the 2 brake hoses.
17. DISCONNECT THE LOAD SENSING PROPORTIONING VALVE

SPRING ASSY (LSPV EQUIPPED VEHICLES ONLY)
a) Remove the nut and bolt, and disconnect the LSPV spring and 2
washers.
18. REMOVE THE REAR SPRING BUMPER

(2WD ONLY, EXCEPT PRERUNNER)
a) Remove the 2 bolts and rear spring bumper.

• Rear Shock Absorbers

• Rear Differential Assy
• Spare Tire Carrier
• Spare Tire Carrier Stoppers (If Equipped)
• Fuel Tank Strap(s)
• No. 3 Exhaust Hanger
• Transportation/Toe Hooks (Qty: 2)
• Cab Mounts (Qty: 6)
NOTE:
Cut the rear differential “U” bolts off if the nuts cannot be removed.
38
20. REMOVE THE CHARCOAL CANISTER VENT HOSE (ONLY FOR
VEHICLES PRODUCED ON OR BEFORE SEPTEMBER 2001)
a) Remove the charcoal canister vent hose and plug.
21. REMOVE THE FRONT SUSPENSION BUMP STOPS

a) Remove the 2 front suspension bump stops.

22. REMOVE THE STUD BOLT (4WD & PRERUNNER ONLY)
a) Remove the stud bolt from the frame.
23. REMOVE THE ENGINE REAR MOUNTING BRAKET

a) Remove the 4 bolts and engine rear mounting bracket.
24. REMOVE THE REAR BRAKE HOSE BRACKET

With VSC With LSPV
For VSC Equipped Vehicles:
a) Remove the 2 bolts and brake hose bracket.
For LSPV Equipped Vehicles:

a) Remove the 4 bolts, the LSPV and the brake
hose bracket.
25. REMOVE THE FRAME WIRE HARNESS
a) Disconnect the clips and remove the frame wire harness.
NOTES:
• The number of wire harness clips will differ depending on the
vehicle spec.
• If possible, take care not to damage or break the wire harness
clips during removal.
26. REMOVE THE CLIPS THAT SECURE BRAKE LINES NO. 3 AND NO. 6 OR NO. 8 TO THE FRAME
27. REMOVE THE FRAME FROM THE LIFT
a) Remove the ratcheting tie down strap and the frame from the lift.
39
G. ASSEMBLE THE NEW FRAME
1. PLACE THE NEW FRAME ON THE LIFT
a) Place the NEW frame on the lift, and secure it with a ratcheting tie down strap. This will prevent the frame
from tilting or falling off as parts are installed.
• Ratcheting Tie Downs: Qty 1

° Length: 2 in X 27 ft
° Minimum Work Load Capacity: 3,000 lbs
2. INSTALL THE NEW REAR LEAF SPRING
a) Install the NEW rear leaf spring to the

NEW Replacement Parts
NEW frame with all NEW parts (shackle
Part Number Part Name Kit # Qty
Rear Leaf Spring pins, bushings, plates, bolts, washers
04883-04050 4 1
Shackle Kit (2WD) and nuts).
04883-04060
Rear Leaf Spring
6 1 b) Torque the shackle pin nuts and hanger
Shackle Kit (4WD)
90105-14025 Hanger Pin Bolt 1 2
pin nut to spec.
90179-14039 Nut 1 2 c) Repeat the procedure on the opposite
90201-14005 Washer 1 2 side.
Varies * Rear Leaf Spring (RH) NA 1
Varies * Rear Leaf Spring (LH) NA 1
• Shackle Pin Nut Torque Spec:
* Please reference the parts lookup website.
92 N·m (930 kgf·cm, 67 ft·lbf)
• Hanger Pin Nut Torque Spec:
157 N·m (1600 kgf·cm, 116 ft·lbf)
3. REINSTALL THE ENGINE REAR MOUNTING BRACKET

a) Reinstall the engine rear mounting bracket with 4 bolts and torque to
spec.
Torque Spec: 58 N·m (590 kgf·cm, 43 ft·lbf)
4. REINSTALL THE STUD BOLT (4WD & PRERUNNER ONLY)
a) Reinstall the stud bolt from the frame.
5. REINSTALL THE FRONT SUSPENSION BUMP STOPS

a) Reinstall the 2 front suspension bump stops.

6. REINSTALL THE CHARCOAL CANISTER VENT HOSE (ONLY FOR

VEHICLES PRODUCED ON OR BEFORE SEPTEMBER 2001)
a) Reinstall the charcoal canister vent hose and plug.
40
7. REINSTALL THE CAB MOUNTS
a) Reinstall cab mounts “A”.

b) Reinstall cab mounts “B” & “C” with 2 bolts
each and torque to spec.
8. REINSTALL THE FOLLOWING PARTS
NEW Replacement Parts • Transportation/Toe Hooks

° Reinstall with 4 NEW bolts and torque to spec.
Transportation/Toe Hooks
° Torque Spec: 95 N·m (969 kgf·cm, 70 ft·lbf)
Bolt
90119-A0028
Regular Cab
2 4 ° Reinstall with 4 NEW nuts and torque to spec.
Bolt (Left Side) Extra & ° Torque Spec: 26 N·m (265 kgf·cm, 19 ft·lbf)
90119-A0028 2 2
Double Cab • Fuel Tank Strap(s)
Bolt (Right Side) Extra
90119-A0029
& Double Cab
2 2 ° Reuse all components
• Spare Tire Carrier Stoppers (If Equipped)
Front Bumper Reinforcement ° Reinstall with 4 NEW bolts and torque to spec.
Part Number Part Name Kit # Qty ° Torque Spec: 20 N·m (204 kgf·cm, 15 ft·lbf)
90179-08241 Nut 1 4 • Spare Tire Carrier
° Reinstall with 4 NEW bolts and torque to spec.
Spare Tire Carrier Stoppers ° Torque Spec: 20 N·m (204 kgf·cm, 15 ft·lbf)
Part Number Part Name Kit # Qty • Rear Differential Assy
90080-11232 Bolt 2 4
° Reinstall with 4 NEW “U” bolts, 8 NEW washers and 8 NEW
nuts, then torque to spec.
Spare Tire Carrier
° Reuse all other components.
° Torque Spec For 2WD:
90080-11180 Bolt 2 4
123 N·m (1254 kgf·cm, 91 ft·lbf)
° Torque Spec For 4WD & PreRunner:
Rear Axle Housing
120 N·m (1224 kgf·cm, 89 ft·lbf)
• Rear Shock Absorbers
90080-17265 Nut 2 8
° Reinstall the rear shock absorbers with 4 retainers, 4 bushings
90117-14039 "U" Bolt (2WD) 3 4
"U" Bolt (4WD & and 2 bolts, then torque to spec.
90117-14008 5 4
PreRunner) ° Torque Spec For 2WD:
90201-15012 Washer 1 8 26 N·m (260 kgf·cm, 19 ft·lbf)
° Torque Spec For 4WD & PreRunner:
9. REINSTALL THE REAR SPRING BUMPER

a) Reinstall the rear spring bumper with 2 bolts and torque to spec.
10. REINSTALL THE REAR BRAKE HOSE

BRACKET (VSC VEHICLES ONLY)
NEW Replacement Parts a) Reinstall the brake hose bracket with 2

Part Number Part Name Kit # Qty NEW bolts and torque to spec.
90080-11180 Bolt 2 2
Torque Spec:
41
11. INSTALL THE NEW LSPV & REINSTALL
2WD THE SPRING ASSY (LSPV EQUIPPED
VEHICLES ONLY)
a) Install the NEW LSPV with the following

parts and torque to spec:
LSPV
47931-35100 LSPV Bracket 1 1 • NEW LSPV Bracket
47910-35320
LSPV (4WD &
5 1 • NEW Set Plate
PreRunner)
47910-35330 LSPV (2WD) 3 1
• 3 NEW Bolts (2WD)
47937-60010 Set Plate 1 1 4WD & PreRunner • 4 NEW Bolts (4WD & PreRunner)
90080-11180 Bolt (2WD) 2 3 • 2 NEW Washers
Bolt (4WD &
90080-11180
PreRunner)
2 4 • 2 NEW Nuts
90170-A0001 Nut 2 2 • Brake Hose Bracket
94512-00800 Washer 1 2
No. 4 Brake Line

Torque Spec:
Part Number Part Name Kit # Qty Bolt A - 29 N·m (300 kgf·cm, 22 ft·lbf)
47324-04040
No. 4 Rear Brake Line
4 1
Bolt B - 29 N·m (300 kgf·cm, 22 ft·lbf)
(2WD)
No. 6 Brake Line
47324-04060
(4WD & PreRunner)
6 1 b) Temporarily install the NEW No. 4 or the
NEW No. 6 rear brake line to the LSPV.
LSPV Spring Assy LSPV Spring Assy c) Reinstall the LSPV spring assy with the
Part Number Part Name Kit # Qty following parts and torque to spec.
90170-A0001 Nut 2 2
90201-23360 Washer 1 3
90467-31110 Clip 1 1 • 2 NEW Bolts
91131-50840 Bolt 1 2 • 5 NEW Washers
94512-00800 Washer 1 2
• 2 NEW Washers
• 1 NEW Clip
Torque Spec:
12. INSTALL THE NEW NO. 3 WAY

a) Install the NEW No. 3 Way with a NEW
90080-11180 Bolt 2 1
bolt and torque to spec.
No. 3 Way
90904-14004 NA 1
(With ABS/VSC) Torque Spec:
No. 3 Way 29 N·m (300 kgf·cm, 22 ft·lbf)
90904-15001 NA 1
(Without ABS)
13. INSTALL THE NEW (NO. 3 & NO. 6 OR NO.

NEW Replacement Parts 8) BRAKE LINES
Varies * No. 3 Brake Line NA 1 a) Temporarily install the NEW No. 3, NEW
47326-04120
No. 6 Brake Line
NA 1
No. 6 (With VSC) or NEW No. 8
(With VSC) (Without VSC) brake lines to the No. 3
No. 8 Brake Line way.
Varies * NA 1
(Without VSC)
* Please reference the parts lookup website.
42
b) Temporarily install the NEW No. 3 & NEW No.
2WD 4WD & PreRunner 6 or NEW No. 8 brake lines to the LSPV
(LSPV Equipped Vehicles Only).
c) Secure the brake lines to the frame with the
NEW clip, 2 or 3 NEW bolts and reuse all
other components, then torque to spec.
Torque Spec:
NOTE:
The number of clips securing the brake lines
to the frame will differ by model.
90080-11180 Bolt (With ABS/VSC) 2 4
90080-11180
Bolt (Without
2 5 d) Tighten all the brake lines to spec.
ABS/VSC)
90949-01C06 Clip (With ABS) 1 6
90949-01C06 Clip (Without ABS) 1 5 Torque Spec:
Illustration A Illustration D 14. INSTALL THE NEW PARKING BRAKE CABLE

ASSY (2WD ONLY, EXCEPT PRERUNNER)
For 2WD:
a) Install the 2 NEW parking brake cables with
the 4 or 5 bolts and torque to spec
(Illustrations A & B).
b) Reinstall the parking brake lever/equalizer
(Illustration C)
c) Connect the 2 parking brake cables to the
Illustration E equalizer (Illustration C).
Illustration B
(Left Side Shown) d) Reinstall the 2 clips (Illustration C).
Torque Spec:
NOTE:
The number of bolts used may differ
depending on the vehicle specs.
Illustration C Illustration F For 4WD & PreRunner:

a) Install the NEW parking brake cables with the
2 bolts and torque to spec (Illustrations D).
b) Connect the parking brake cables to the bell
cranks with the 2 NEW pin, 2 NEW washers
and reuse all other components (Illustration
E).
c) Reinstall the intermediate parking brake lever
(Illustration F).
d) Connect the parking brake cable to
NEW Replacement Parts intermediate lever with 2 NEW adjustment
Application Part Number Part Name Kit # Qty nuts (Illustration F).
Parking Brake
Varies * NA 1
2WD
Cable Assy (LH) Torque Spec:
Parking Brake
Varies * NA 1 26 N·m (265 kgf·cm, 19 ft·lbf)
Cable Assy (RH)
Parking Brake
Varies * NA 1
Cable Assy NOTE:
4WD & 46441-30030 Nut 5 2 The parking brake cable is routed above the
PreRunner 90206-08016 Wave Washer 5 2
90240-08059 Pin 5 2
rear leaf springs on vehicles produced on or
90468-A0001 Clip 6 1 before September, 2002, and below the rear
* Please reference the parts lookup website. leaf spring on vehicles produced after
September, 2002.
43
15. REINSTALL THE FRAME WIRE HARNESS
NOTE:
If the wire harness clips are damaged, repair them by following the steps on this page.
Clip Repair Application

82711-16820 Clip 1 2
82711-16830 Clip 1 3
82711-2C190 Clip 1 1
82711-3A640 Clip 1 2
82711-3F050 Clip 1 4
82711-3H470 Clip 1 2
82711-89159 Clip 1 4
REPAIR PROCEDURE FOR CLIPS A & B
a) Install the replacement zip tie clip to the

frame in the direction shown in the
illustration.
b) Cut the damaged clip as shown in the
illustration. The length of the section “A”
should be between 1.4 and 1.6 inches.
c) Route the zip tie through the cutout area
of the damaged clip and fasten securely.
REPAIR PROCEDURE FOR CLIPS C & D
a) Cut off the damaged section of the clip.

b) Install the NEW clip to the frame wire
harness with vinyl tape as shown in the
illustration.
REPAIR PROCEDURE FOR CLIPS E
a) Remove the damaged clip.

b) Install the NEW clip to the frame wire
harness with vinyl tape as shown in the
illustration.
44
4WD & PreRunner 4WD & PreRunner
2WD Without VSC With VSC

90468-08046 Clip (With VSC) NA 2
90468-A0007 Clip (Without VSC) 2 1
16. REINSTALL THE REAR BRAKE HOSE(S)
For 2WD Vehicles and 4WD & PreRunner Vehicles Without VSC:
a) Reinstall the brake hose to the bracket with the NEW clip.
b) Reinstall the brake line to the brake hose and torque to spec.
c) Torque the No. 4 or the No. 6 rear brake line connected to the LSPV to spec (LSPV Equipped Vehicles
Only).
For 4WD & PreRunner Vehicles With VSC:

a) Reinstall the 2 brake hoses to the bracket with the 2 NEW clips.
b) Reinstall the 2 brake lines to the 2 brake hoses and torque to spec.

90080-11180 Bolt 2 1
90904-12029 No. 2 Way 1 1
47315-04050
No. 5 Brake Line * 9-15 1
47315-04060
* Only 1 part is used. Part number varies
depending on Parts Kit #.
17. INSTALL THE NEW RIGHT FRONT BRAKE LINE & WAY
a) Install the NEW No. 2 way with a NEW bolt and torque to spec.
b) Temporally install the NEW No. 5 front brake line to the No. 2 way.

Without ABS With ABS
47314-04040 No. 4 Front Brake Line
9-10 1
47314-04060 (w/o ABS) *
90080-11180 Bolt 2 1
90904-12030 Way NA 1
47317-04010 No. 7 Brake Line
11-15 1
47317-04020 (with ABS) *
18. INSTALL THE NEW LEFT FRONT BRAKE LINE & WAY (2WD ONLY, EXCEPT PRERUNNER)
Without ABS:
a) Temporally install the NEW No. 4 front brake line to the No. 3 way.
With ABS:
a) Install the NEW way with the NEW bolt and torque to spec.
b) Temporally install the NEW No. 7 front brake line to the way.

45
Without ABS/VSC With ABS/VSC
47314-04040 No. 4 Front Brake Line
9-10 1
47314-04060 (w/o ABS) *
90080-11180 Bolt 2 1
90904-12030 Way NA 1
47317-04010 No. 7 Brake Line
11-15 1
47317-04020 (with ABS) *
19. INSTALL THE NEW LEFT FRONT BRAKE LINE & WAY (4WD & PRERUNNER ONLY)
Without ABS/VSC:
a) Temporally install the NEW No. 4 front brake line to the No.3 way.
With ABS/VSC:
a) Install the NEW way with the NEW bolt and torque to spec.
b) Temporally install the NEW No. 7 front brake line to the way.
20. INSTALL THE NEW NO. 2 & NO. 3
EXHAUST HANGERS
a) Reinstall the No. 3 engine hanger with 2
17572-75020 No. 2 Exhaust Hanger 1 1 NEW bolts and torque to spec.
Bolt (No. 2 Exhaust b) Install the NEW No. 2 engine hanger
90119-08667 1 2
Hanger) with 2 NEW bolts and torque to spec.
Bolt (No. 3 Exhaust
90119-08667 5 2
Hanger) Torque Spec:
21. INSTALL THE NEW NO. 6 EXHAUST

HANGERS (4WD & PRERUNNER ONLY)
Part Number Part Name Kit # Qty a) Install the NEW No. 6 engine hanger
17576-75030 No. 6 Exhaust Hanger 5 1 with 2 NEW bolts and torque to spec.
90119-08667 Bolt 5 2
Torque Spec:
22. REINSTALL THE FRONT DIFFERENTIAL ASSY (4WD ONLY)

a) Reinstall the front differential assy with 2 bolts and 3 nuts, then
torque to spec.
Torque Spec:
Bolt - 137 N·m (1400 kgf·cm, 101 ft·lbf)
Nut - 87 N·m (887 kgf·cm, 64 ft·lbf)
2WD 23. REINSTALL THE POWER STEERING RACK ASSY
For 2WD:
a) Reinstall the power steering rack assy with 2 bolts, 2 washers and 2
nuts, then torque to spec.
4WD & PreRunner For 4WD & PreRunner:

a) Reinstall the power steering rack assy with the bracket, 3 bolts, a
washer and 2 nuts, then torque to spec.
Torque Spec:
Bolt A & Nut C - 167 N·m (1700 kgf·cm, 123 ft·lbf)
Bolt B - 190 N·m (1937 kgf·cm, 140 ft·lbf)
Bolt C - 165 N·m (1683 kgf·cm, 122 ft·lbf)
46
24. REINSTALL THE FRONT DIFFERENTIAL
BREATHER TUBES (4WD ONLY)
Part Number Part Name Kit # Qty a) Install the front differential breather tubes
90949-01982 Clip 5 1
90949-01C25 Clip 5 1
with the 2 bolts and 2 NEW clips.
25. INSTALL THE NEW FRONT SUSPENSION

LOWER ARM (4WD & PRERUNNER
ONLY)
a) Install the NEW front suspension lower

arm with 2 NEW Bolts, 2 NEW Toe
Adjustment Plates and 2 NEW Toe
Front Suspension Adjustment Cam, then torque to spec
48068-35120 NA 1
Lower Arm (RH)
48069-35120
Front Suspension
NA 1
Torque Spec:
Lower Arm (LH) 130 N·m (1325 kgf·cm, 96 ft·lbf)
48304-35150 Bump Stop No. 1 NA 2
48305-35040 Bump Stop No. 2 NA 2
Toe Adjustment b) Install the 2 NEW bump stops to the front
48409-35030 5 4 suspension lower arms with SST 09922-
Cam
48452-35020
Toe Adjusment
5 4 10010 and torque to spec.
Plate
90080-11283 Bolt 6 4
Torque Spec:
w/o SST - 31 N·m (316 kgf·cm, 23 ft·lbf)
with SST - 23 N·m (235 kgf·cm, 17 ft·lbf)
c) Repeat the procedure on the opposite

side.
NEW Replacement Parts Illustration A Illustration B

43425-04020 Snap Ring 6 2
90080-17206 Nut 6 6
90171-A0005 Castle Nut 6 2
Cotter Pin
95381-03230 5 2
(Ball Joint)
95381-04030 Cotter Pin (Tie Rod) 5 2
26. REINSTALL THE FRONT SUSPENSION (4WD & PRERUNNER ONLY)
a) Reinstall the front drive shaft with a NEW snap ring (4WD Only).
b) Reinstall the shock and spring assy with the bolt, washer, nut (B) and 3 NEW nuts (A), then torque to spec
(Illustration A).
Nut A Torque Spec: 64 N·m (650 kgf·cm, 47 ft·lbf)

Nut B Torque Spec: 135 N·m (1400 kgf·cm, 101 ft·lbf)
c) Reinstall the front suspension upper arm with steering knuckle attached using the bolt, 2 washers and the
nut, then torque to spec (Illustration B).
d) Reinstall the lower ball joint with the NEW nut and torque to spec, then install the NEW cotter pin.
e) Reinstall the tie rod end with the nut and torque to spec, then install the NEW cotter pin.
f) Temporarily reinstall the front axle nut. This nut will be tightened when the vehicle is completed (4WD Only).
g) Repeat the procedure on the opposite side.
47
NEW Replacement Parts Illustration A Illustration B
90080-10122 Bolt 4 4
90080-10128 Bolt 4 2
90171-14002 Castle Nut 3 2
90179-12133 Nut 3 4
90179-16028 Nut 3 2
Cotter Pin
90252-03008 3 2
(Ball Joint)
95381-03220 Cotter Pin (Tie Rod) 3 2
Illustration C Illustration D Illustration E
Illustration F Illustration G Illustration H
27. REINSTALL THE FRONT SUSPENSION (2WD ONLY, EXCEPT PRERUNNER)
a) Reinstall the front coil spring using SST 09727-22011 (Illustration A)

b) Make sure the front coil spring and SST are installed in the proper position (Illustration B).
c) Compress the spring until it is approximately 250 mm (Illustration C).
d) Temporarily reinstall the lower suspension arm with the bolt and nut, and the strut bar with the NEW bolt and
NEW nut. These bolts will be tightened after the tire has been installed (Illustartion D).
e) Reinstall the upper suspension arm with steering knuckle attached and the adjustment shims with 2 NEW
bolts, then torque to spec (Illustartion E).
f) Reinstall the lower ball joint with the NEW nut and torque to spec, then install the NEW cotter pin.
g) Reinstall the tie rod end with the nut and torque to spec, then install the NEW cotter pin.
h) Reinstall the brake hose with the 2 bolts and torque to spec (Illustration F).
i) Remove the SST (Illustration G).

j) Reinstall the shock absorber with the NEW nut and 2 NEW bolts, then torque to spec (Illustration H).
Torque Spec:
Nut - 25 N·m (250 kgf·cm, 18 ft·lbf)
k) Repeat the procedure on the opposite side.
48
28. REINSTALL THE FRONT STABILIZER BAR
NEW Replacement Parts a) Reinstall the front stabilizer bar and 2 brackets, with 4 NEW bolts
Part Number Part Name Kit # Qty (2WD Only).
90119-08686 Bolt (2WD) * 3 4 b) Reinstall stabilizer bar and 2 NEW brackets, with 4 NEW bolts
90119-08782 Bolt (4WD) 5 4
90119-A0180 Bolt (2WD) ** 4 4 (4WD & PreRunner Only).
48824-35100 Bracket RH (4WD) 5 1
48829-35070 Bracket LH (4WD) 5 1 Torque Spec: 22 N·m (224 kgf·cm, 16 ft·lbf)
* For vehicles produce between
September 2000 & March 2002
** For vehicles produce between c) Reinstall the stabilizer bar links to the lower suspension arm with
March 2002 & September 2004 the 2 nuts, then torque to spec.
29. REINSTALL THE FRONT SPEED SENSOR WIRE HARNESS
For 4WD with ABS/VSC:

NEW Replacement Parts a) Reinstall the front speed sensor wire harness to the suspension
Part Number Part Name Kit # Qty support with 2 clips and 1 NEW clip.
89515-35010
Clip - Speed Sensor
NA 2
(4WD)
For 2WD with ABS:
a) Reinstall the front speed sensor wire harness.
2WD (Left Side) 2WD (Right Side) NEW Replacement Parts

90468-A0007 Clip 2 2
30. REINSTALL THE FRONT BRAKE HOSES
a) Reinstall the front brake hose to the bracket

with the NEW clips.
4WD (Left Side) 4WD (Right Side) b) Reinstall the brake line to the front brake hose
and torque to spec.
Torque Spec:
c) Repeat the procedure on the opposite side.
31. REINSTALL THE ENGINE AND TRANSMISSION ASSY
a) Reinstall the engine and transmission assy.
NOTE:
• When reinstalling the engine and transmission assy, ALWAYS
use 2 engine hoists or mini cranes to lower it.
• DO NOT use 1 engine hoist or 1 mini crane to lower the engine
and transmission assy, as the unbalanced weight may lead to
an accident or injury.
• ONLY use engine hoists or mini cranes that can properly
support the weight of the engine and transmission assy.
• Carefully adjust the 2 engine hoists or mini cranes used so that
the engine and transmission assy is properly balanced.
49
Illustration A (Right Side Shown) Illustration B
90119-08B75 Bolt 1 4
90179-10071 Nut 1 4
90119-10175 Bolt 1 4
b) Attach the engine mounts with 2 NEW bolts and 2 NEW nuts each, then torque to spec (Illustration A).
c) Attach the transmission mount with 4 NEW bolts, then torque to spec (Illustration B).
d) Remove the engine hanger(s).
e) Reinstall the items/parts that were removed during the engine and transmission assy removal.
32. REINSTALL THE POWER STEERING PUMP ASSY
a) Reinstall the power steering pump assy to the mounting bracket with 2 bolts (RZ Engine Only) or with the
bolt and nut (VZ Engine Only), then torque to spec.
Torque Spec:
RZ Engine - 39 N·m (398 kgf·cm, 29 ft·lbf)
VZ Engine - 43 N·m (440 kgf·cm, 34 ft·lbf)
b) Reinstall the power steering belt and check the belt tension.
c) Reinstall the power steering lines to the frame with 3 bolts, then torque to spec.
Extra Cab & Fuel Tank Strap Fuel Filler Pipe Charcoal Canister
Double Cab Only (Regular Cab Shown)
33. REINSTALL THE FUEL TANK ASSY (ALL VEHICLES) & CHARCOAL CANISTER ASSY (FOR VEHICLES
PRODUCED AFTER SEPTEMBER 2001
a) Reinstall the fuel tank assy with the bolt and torque to spec (Extra Cab & Double Cab Only).
b) Reinstall the fuel tank strap(s) with the bolt(s), then torque to spec.
c) Reinstall any connector(s), hose(s) and line(s) that were removed during the fuel tank assy removal.
d) Reinstall the fuel filler pipe with 2 bolts (2WD Only) or 3 bolts (4WD & PreRunner Only), then torque to spec.
Torque Spec:
Bolt A (All Models) - 62 N·m (632 kgf·cm, 46 ft·lbf)
Bolt B (4WD & PreRunner Only) - 26 N·m (265 kgf·cm, 19 ft·lbf)
Bolt C (All Models) - 29 N·m (300 kgf·cm, 22 ft·lbf)
For Vehicle Produced After September 2001 Only:
e) Reinstall the charcoal canister assy with 4 bolts, then torque to spec.
f) Reinstall any connector(s) and hose(s) that were removed during the charcoal canister assy removal.
50
34. REINSTALL THE FUEL TANK PROTECTOR
Part Number Part Name Kit # Qty a) Reinstall the fuel tank protector with 4 NEW bolts and torque to
90080-11180 Bolt 2 2 spec.
90080-11471 Bolt 2 2

82711-48060 Clip 1 2
90080-10064 Bolt 2 2
90177-A0004 Nut 2 2
90917-06057 Exhaust Gasket 1 1
35. REINSTALL THE EXHAUST SYSTEM
a) Reinstall the exhaust system assy with the NEW gasket, 2 NEW bolts and 2 NEW nuts, then torque to spec.
b) Reinstall the 2 oxygen sensor wire harness clips to the frame.
NOTE:
If the wire harness clips are damaged, replace them with NEW clips included in the parts kit.
36. REINSTALL THE REAR PROPELLER SHAFT
a) Remove the SST (2WD Only, Except PreRunner).

b) Referencing the matchmarks, reinstall the propeller shaft to the the
transmission (2WD Only, Except PreRunner).
c) Referencing the matchmarks, reinstall the propeller shaft to the the
transmission/ transfer case (4WD & PreRunner Only).
d) Reinstall the center support bearing to the frame as shown in the

illustration with 2 bolts and torque to spec (3-Joint Type Only).
e) Referencing the matchmarks, reinstall the propeller shaft to the rear

differential with 4 bolts, 4 washers and 4 nuts, then torque to spec.
• Front Propeller Shaft (4WD Only)

° Referencing the matchmarks, reinstall the front propeller shaft to the transfer case and the front
differential with 8 bolts, 8 washers and 8 nuts, then torque to spec.
• Spare Tire
• Wheels
° Reinstall and torque to spec.
38. REMOVE THE FRAME FROM THE LIFT
a) Remove the ratcheting tie down strap from the frame.

b) Lower the frame to the ground.
51
• If using an above ground 2-post lift, please proceed to section “I. REINSTALL THE CAB
BODY ASSY” on page 55.
• If using an inground lift continue with the next step below.
H. REINSTALL THE CAB BODY ASSY USING AN INGROUND LIFT
PROCEDURE & EQUIPMENT REQUIREMENTS

• When using an inground lift it will not be possible to push the frame under the cab assy
after it has been raised. This is due to the inadequate spacing between the posts of the
inground lift, so the following alternate method will need to be required.
• Additional tools & equipment will be required when removing the cab assy using an
inground lift. Please reference the “SUPPLEMENTAL TOOLS & EQUIPMENT (FOR
INGROUND LIFTS ONLY)” on page 17.
INGROUND LIFT REQUIREMENTS & PRECAUTIONS

(REGULAR CAB ONLY)
When performing cab assy reinstallation on a regular cab

vehicle with an inground lft, make sure the lift meets the
dimensions shown in the illustration to the right. If these
dimensions are not met please use another inground lift, as
you may not be able to raise the cab body off the frame.
1. INSTALL THE NEW ENGINE COMPARTMENT BRAKE LINES

Part Number Part Name Kit # Qty Right Side Without ABS/VSC:
No. 2 RH Brake Line
47312-04080
(Without ABS/VSC)
9-10 1 a) Install the NEW No. 2 brake line with 3 NEW bolts.
No. 3 LH Brake Line b) Install the NEW No. 4 brake line with 1 or 3 NEW bolts.
47313-04080 11-14 1
(With ABS) c) Torque all brake lines to spec.
No. 3 LH Brake Line
47313-04120 9-10 1
(Without ABS/VSC)
47314-04050 Right Side With VSC:
No. 4 RH Brake Line
47314-04110
(With ABS/VSC) *
11-15 1 a) Install the NEW No. 4 brake line with the NEW clip, then torque to
47314-04130
spec.
No. 4 RH Brake Line
47314-04080 15 1
(With VSC)
47316-04031 Left Side With ABS/VSC:
47316-04051 a) Install the NEW No. 2, the NEW No. 3, the NEW No. 5 and the NEW
No. 6 LH Brake Line
47316-04060 11-15 1
47316-04100
(With ABS/VSC) ** No. 6 brake lines with 1 to 3 NEW clips, then torque to spec.
47316-04130
No. 6 LH Brake Line NOTE:
47316-04120 15 1
(With VSC)
No. 1 LH Brake Line
The number of clips used varies from 1 to 3.
47321-04070 9-10 1
(Without ABS/VSC)
47322-04141
No. 2 LH Brake Line Left Side Without ABS/VSC:
47322-04240 11-15 1
47322-04260
(With ABS/VSC) * a) Install the NEW No. 1 and NEW No. 3 brake lines then torque to
No. 5 LH Brake Line spec.
47325-04150 15 1
(With VSC)
90080-11203 Bolt 2 3
Torque Spec For All Brake Lines:
90468-A0007 Clip 2 2
90480-01621 Clip (With ABS/VSC) NA 1 15 N·m (155 kgf·cm, 11 ft·lbf)
90480-01628 Clip (With VSC) NA 1
** 1 or 2 parts may be used. Part number varies
52
Extra Cab Shown Regular Cab Shown
(Illustration C)
(Illustration A) (Illustration A)
2. SUPPORT THE CAB ASSY
a) Raise the cab assy and position the tripod under hoist stands so that they will not interfere with the lift arms
when retracted (Illustrations A, B & C).
b) Slide the steel support beams underneath the cab body and on top of the tripod under hoist stands
(Illustrations A & D).
c) Using the bubble level, adjust the tripod under hoist stands so the steel support beams are level. This will
ensure the cab assy is balanced.
d) Slowly lower the cab assy onto the steel support beams (Illustration D).
e) Remove the ratcheting tie down strap, if used. (Regular Cab Only)
f) Lower the lift arms to the floor.
g) Place a single post under hoist stand at the front core support (Regular Cab Only).
NOTE:
• Make sure to provide adequate room for the lift arms to retract, as this will to allow the frame to be
pushed underneath the cab assy.
• Make sure to install the single post under hoist stand, as this will prevent the cab body assy from
tilting forward.
Regular Cab Shown Extra Cab Shown Double Cab Shown
(Illustration D) (Illustration D) (Illustration D)
For Reference Purposes, Only The 3. REINSTALL THE FRAME

Frame Is Shown
a) Push the frame under the cab assy.
b) Verify the vehicle’s frame is aligned with the center point of the lift as
shown. This will prevent interference and damage to the frame
and/or lift.
c) Adjust the vehicle’s frame as needed to align the cab mounts with
the cab assy bolts as best as possible.
NOTE:
DO NOT work directly underneath the vehicle when pushing the
frame under the cab assy.
53
d) Raise the lift arms back up to the cab body assy.
Extra Cab Shown e) Reinstall the ratcheting tie down strap, if used, as outlined on page
30. (Regular Cab Only)
f) Lift the cab assy off the steel support beams.
g) Remove the bubble level.
h) Remove the 2 steel support beams.
i) Move the 4 tripod under hoist stands.
j) Remove the single under hoist stand (Regular Cab Only).
Front Cab Mounts
k) Lower the cab assy slowly, making sure it does not interfere with anything.
l) Adjust the vehicle’s frame as needed to align the cab mounts with the cab assy bolts.
m) Once the cab assy is set on the mounts, secure it to the frame with 6 washers and 6 bolts and torque to spec.
n) Remove the ratcheting tie down strap, if used. (Regular Cab Only)
o) Remove the six 22 lbs (10 kg) weights (SST: 00002-09077) from the vehicle, if used (Regular Cab Only).
p) Proceed to section “2. RECONNECT THE FRONT SPEED SENSOR CONNECTOR (ONLY FOR ABS/VSC
EQUIPPED VEHICLES)” on page 56.
54
I. REINSTALL THE CAB BODY ASSY
Front Cab Mounts
1. REINSTALL THE CAB BODY ASSY
a) Raise the cab assy high enough so that the top of the engine clears the lowest point of the cab.
b) Push the frame under the cab assy.
c) Lower the cab assy slowly, making sure it does not interfere with anything.
d) Adjust the vehicle’s frame as needed to align the cab mounts with the cab assy bolts.
e) Once the cab assy is set on the mounts, secure it to the frame with 6 washers and 6 bolts and torque to spec.
NOTE:
DO NOT work directly underneath the vehicle when pushing the frame under the cab assy.
55
2. RECONNECT THE FRONT SPEED SENSOR CONNECTOR (ONLY
FOR ABS/VSC EQUIPPED VEHICLES)
a) Reconnect the front speed sensor connector.

3. RECONNECT THE NO. 2 STEERING INTERMEDIATE SHAFT

Part Number Part Name Kit # Qty a) Make sure the front wheels are in a straight-ahead position and the
90080-11555 Bolt 2 2 steering wheel is centered.
b) Referencing the matchmarks, reconnect the No. 2 intermediate shaft
to the control valve shaft with the NEW bolt (B).
c) Remove bolt (A) and install the NEW bolt.
d) Torque all bolts to spec.
Torque Spec:
e) Disconnect the seat belt that is holding the steering wheel.
4. RECONNECT THE CLUTCH HOSE

(MANUAL TRANSMISSION VEHICLES ONLY)
a) Reconnect the clutch hose to the bracket with a NEW clip.

b) Reconnect the clutch line to the hose and torque to spec.
5. RECONNECT THE NO. 2 FRONT BRAKE LINE
a) Reconnect the No. 2 right front brake line and torque to spec.
6. RECONNECT THE BRAKE LINES
With ABS/VSC Without ABS/VSC For Vehicles with ABS/VSC:

a) Reconnect the 3 left front brake lines and
torque to spec.
For Vehicles without ABS/VSC:

a) Reconnect the 2 left front brake lines and
torque to spec,
Torque Spec For All Brake Lines:

56
2WD 7. REINSTALL THE FRONT FENDER APRON TO
FRAME SEALS
For 2WD:
a) Reinstall the fender to apron seal with the 9
clips.

4WD & PreRunner a) Reinstall the 2 right front fender apron to
frame seals with the 11 clips.
b) Reinstall the left front fender apron to frame
seal with the 12 clips.
8. REINSTALL AUTOMATIC TRANSMISSION

SHIFT LEVER ASSY (AUTOMATIC
TRANSMISSION VEHICLES ONLY)
a) Reinstall the automatic transmission shift
lever assy with the 8 NEW bolts, and
90080-11158 Bolt 8 8
torque to spec.
Torque Spec:
6.0 N·m (61 kgf·cm, 53 in·lbf
• Manual Transmission Shift Lever (Manual Transmission Vehicles Only)

• Transfer Case Shift Lever (4WD Only)
• Front Console Box (If Equipped)
• Rear Console Box (If Equipped)
10. RECONNECT THE FRAME WIRE HARNESS
a) Insert the frame wire harness into the vehicle cab.

b) Reinstall the frame wire harness grommet to the vehicle body.
c) Reconnect the connector.

d) Reinstall the left cowl side trim board.
e) Reinstall the left front door scuff plate with the 4 screws.
NOTE:
There may be 2 connectors depending on the model.
11. RECONNECT THE ENGINE WIRE HARNESS
a) Reinstall the engine wire harness and reconnect the 2 or 3

connectors to the ECM.
NOTE:
57
b) Reconnect engine wire harness and the 4 connectors.
12. REINSTALL THE LOWER FINISH PANEL & THE GLOVE BOX
a) Reinstall the lower finish panel and the 3 bolts.

b) Reconnect the wire harness clip.
c) Reinstall the glove box.
13. RECONNECT THE ENGINE WIRE HARNESS
a) Reinstall the ground wire with the bolt.

b) Reinstall engine wire harness container to the cowl panel with 2
nuts.
c) Reinstall the wire harness connector bracket with the bolt..
14. RECONNECT THE FOLLOWING PARTS
• Air Conditioning Discharge And Suction Hoses To The Compressor

NEW Replacement Parts ° Install the NEW o-ring to the A/C discharge and suction hoses.
A/C Discharge & Suction Hoses ° Torque the A/C discharge and suction hoses to spec.
Part Number Part Name Kit # Qty ° Torque Spec: 10 N·m (100 kgf·cm, 7 ft·lbf)
90099-14120 O-ring (Discharge) 2 1 • Water/Heater Hoses (Engine Side)
90099-14121 O-ring (Suction) 2 1
• Radiator
Radiator
° Install the NEW o-ring to the drain plug.
° Tighten the radiator drain plug.
90069-08019 O-ring 2 1 ° Reinstall the radiator with 4 bolts and torque to spec.
° Torque Spec: 12.5 N·m (129 kgf·cm, 9 ft·lbf)
° Reinstall the automatic transmission cooler lines (Automatic
Transmission Vehicles Only).
15. RECONNECT THE NO.2 ENGINE WIRE HARNESS
a) Reinstall fusebox wire harness with the nut and torque to spec.
b) Reinstall the wire harness clip.

c) Reconnect the connector.
d) Reconnect the No. 2 engine wire harness to the clip.

e) Reinstall the 2 (+) positive battery cables with the nut and torque to
spec.
f) Reinstall the ground wire with the bolt and torque to spec.

58
16. RECONNECT THE FUEL PIPES
a) Reconnect the main fuel pipe and torque to spec.
b) Reconnect the fuel return hose.
17. RECONNECT THE BREATHER HOSE(S)
a) Reconnect the breather hose(s).

b) Reconnect the 2 vacuum hoses.
NOTE:
There may be 2 different breather hoses depending on the vehicle
spec.
18. RECONNECT THE HOSES (ONLY FOR VEHICLES PRODUCED

AFTER SEPTEMBER 2001)
a) Reconnect the 2 hoses.

b) Reconnect the brake booster hose to the intake manifold. (ONLY for
vehicles without VSC).
19. RECONNECT THE ENGINE WIRE HARNESS (ONLY FOR VEHICLES

PRODUCED AFTER SEPTEMBER 2001)
a) Reconnect the wire harness clips.

b) Reconnect the 2 connectors.
20. RECONNECT THE HOSES (ONLY FOR

VEHICLES PRODUCED ON OR BEFORE
SEPTEMBER 2001)
RZ Engine VZ Engine For RZ Engine:
a) Reconnect the air drain hose to the clip.
b) Reconnect the hose to the EVAP.
c) Reconnect the vacuum hose to the VSV and
the clip.
d) Reconnect the brake booster hose to the
intake manifold.
For VZ Engine:
a) Reconnect the hose to the clip and the EVAP.
b) Reconnect the VSV vacuum hose.
c) Reconnect the brake booster hose to the
intake manifold.
21. RECONNECT THE ENGINE WIRE HARNESS (ONLY FOR VEHICLES

PRODUCED ON OR BEFORE SEPTEMBER 2001)
a) Reconnect the 4 wire harness clips.

b) Reconnect the 3 connectors.
22. RECONNECT THE ACCELERATOR/THROTTLE CABLE (ENGINE SIDE)
23. REINSTALL THE AIR CLEANER CASE ASSY AND HOSE
59
24. RECONNECT THE NO. 1 GEAR SHIFT
NEW Replacement Parts ROD (AUTOMATIC TRANSMISSION
Part Number Part Name Kit # Qty VEHICLES ONLY)
33572-22010 Control Shaft Bushing 7 1
a) Reinstall the No.1 gear shift rod with the
Connecting Rod NEW connecting rod swivel, NEW
33723-22010 7 1
Swivel
control shaft bushing, NEW bushing, 2
90080-18070 Nut 8 1
90389-08005 Bushing 7 1 NEW washers, NEW nut and NEW clip,
90468-A0006 Clip 8 1 then torque to spec.
94612-10800 Washer 7 1
94613-10800 Washer 7 2 Torque Spec:
NEW Replacement Parts 25. RECONNECT THE NO. 1 PARKING

Part Number Part Name Kit # Qty BRAKE CABLE ASSY
90240-08040 Pin 5 1
90468-14021 Clip 5 1 For 2WD:
90468-A0001 Clip 6 1 a) Reconnect the No. 1 parking brake cable
2WD 4WD & PreRunner assy.
b) Reinstall the clip.
a) Reconnect the No.1 parking brake cable
assy.
b) Install the NEW clip.
c) Install the NEW pin and the NEW clip.
26. RECONNECT THE OXYGEN SENSOR

a) Insert the oxygen sensor wire harness into the vehicle cab.
b) Reinstall the oxygen sensor wire harness grommet to the vehicle
body.
c) Reconnect the oxygen sensor connector.
d) Reinstall the right cowl side trim board.
e) Reinstall the right front scuff plate with 4 screws.
27. REINSTALL THE FRONT BUMPER ASSY

NEW Replacement Parts a) Reinstall the front bumper reinforcement
Front Bumper Reinforcement with 4 NEW nuts and torque to spec.
90179-08241 Nut 1 4
Torque Spec:
Front Bumper Assy
b) Reinstall the front bumper assy with the
Front Bumper Side
2 NEW bumper side mounting brackets,
52145-AD010 2 1 4 NEW nuts and 4 NEW bolts, then
Mounting Bracket RH
52146-AD010
Front Bumper Side
2 1 torque to spec.
Mounting Bracket LH
90080-18065 Nut 2 2 Torque Spec:
90119-10560 Bolt 1 4
90179-08063 Nut 1 2
Nut A - 20 N·m (204 kgf·cm, 15 ft·lbf)
Nut B - 5.5 N·m (56 kgf·cm, 49 in·lbf)

• Radiator Grille
• Front Parking/Clearance Lights
29. RECONNECT THE FUEL TANK MAIN LINES
a) Reconnect the fuel tank main lines.
60
J. REINSTALL THE BED ASSY
1. REINSTALL THE BED ASSY
Part Number Part Name Kit # Qty a) Reinstall the bed assy with 4 NEW bolts and torque to spec.
64189-35030 Bolt 1 2
90119-12254 Bolt 1 4
90201-12061 Washer 1 2 Torque Spec: 105 N·m (1071 kgf·cm, 77 ft·lbf)
94184-61201 Nut 1 2
b) Install 2 NEW bolts, 2 NEW washers and 2 NEW nuts, then torque
to spec.
NOTE:
• Use 4 or more people to reinstall the bed assy to the frame.
• Evenly support the bed assy when reinstalling it.
• Be careful not to damage or hit the fuel inlet pipe when
reinstalling the bed assy, as shown in the illustration.
2. REINSTALL THE WIRE HARNESS
a) Reconnect the 9 wire harness clips to the rear body (bed) assy.
• Fuel Tank Filler Pipe Shield

° Install with 4 NEW screws.
• Left Rear Wheel Well Liner
NEW Replacement Parts • Left Rear Fender Flare Molding (If Equipped)
Part Number Part Name Kit # Qty ° Install with 7 NEW clips and 8 NEW screws.
90159-50339 Screw 1 4 • Side Step Assemblies (If Equipped)
90159-60393 Screw 5 6
90904-67036 Clip 5 2 ° Reinstall with 5 bolts and torque to spec.
90904-67037 Clip 5 5 ° Torque Spec: 18 N·m (184 kgf·cm, 13 ft·lbf)
• Rear Mudguards
• Rear Tail/Combination Lights
• Rear Bumper Assy
° Reinstall with 4 bolts and 2 nuts, then torque to spec.
61
K. FINAL ASSEMBLY
1. REINSTALL THE BATTERY
2. REFILL THE FOLLOWING FLUIDS
• Brake Fluid
° Refill with Toyota Dot 3 Brake Fluid.
° Remove the brake lines from the master cylinder.
° Bleed the master cylinder (VSC Equipped Vehicles Only).
° Reinstall the brake lines to the master cylinder and torque to
spec.
° Bleed the brake system at each wheel and torque the bleeder
NEW Replacement Parts screws to spec.
Front Differential ° Torque Spec: 11 N·m (110 kgf·cm, 8 ft·lbf)
Part Number Part Name Kit # Qty • Clutch Fluid (Manual Transmission Vehicles Only)
12157-10010 Washer 5 1
90430-24003 Washer 5 1
° Bleed the clutch system and torque the bleeder screws to spec.
• Coolant
° Refill with Toyota Long Life Coolant.
° Bleed the cooling system.
• Front Differential
° Install the NEW drain plug washer and torque to spec.
° Refill with Hypoid Gear Oil API GL-5 75W-90.
° Install the NEW filler plug washer and torque to spec.
3. START THE VEHICLE AND INSPECT THE FOLLOWING FOR LEAKS
• Fuel System
° Start the engine and let it run for 5 seconds, then stop the engine and inspect for leaks.
° If there are no leaks, restart the engine and re-inspect.
• Cooling System
• Brake System
• Front Differential System
4. RECHARGE AND CONFIRM THE OPERATION OF THE AIR CONDITIONING SYSTEM
5. CHECK THE OPERATION OF THE FOLLOWING SYSTEMS AND ADJUST AS NEEDED
• Parking Brake Lever Travel

• Shift Control Lever (Automatic Transmission Vehicles Only)
• LSPV (If Equipped)
6. CHECK ALL FLUID LEVELS AND ADJUST AS NEEDED
7. TORQUE THE LOWER SUSPENSION ARM BOLTS TO SPEC

(2WD ONLY)
Torque Spec:
Nut A - 300 N·m (3050 kgf·cm, 221 ft·lbf)
Nut B - 200 N·m (2050 kgf·cm, 148 ft·lbf)
62
8. TORQUE THE FRONT AXLE NUT TO SPEC (4WD ONLY)
a) Remove the front wheel.

NEW Replacement Parts b) Torque the front axle nut to spec.
43514-28010 Grease Cap 5 2 Torque Spec:
95381-04045 Cotter Pin 5 2 235 N·m (2400 kgf·cm, 174 ft·lb)
c) Reinstall the lock cap with the NEW cotter pin.

d) Install the NEW grease cap.
e) Reinstall the front wheel and torque to spec.
Torque Spec:
110 N·m (1150 kgf·cm, 83 ft·lbf)
f) Repeat the procedure on the opposite side.
NOTE:
If the holes for the cotter pin are not aligned, tighten the axle nut
further, up to 60°.
9. PERFORM A WHEEL ALIGNMENT
10. CHECK THE HEADLIGHT AIM AND ADJUST AS NEEDED
11. REINSTALL THE ENGINE UNDER COVERS

Part Number Part Name Kit # Qty a) Remove the engine under covers with 9 NEW bolts and torque to
90080-11373 Bolt 2 9 spec.
Torque Spec: 29 N·m (300 kgf·cm, 22 ft·lb)
12. CHECK FOR DTC’S AND REPAIR AS NEEDED
13. FINAL INSPECTION
a) Check the operation of the following systems:
• 4WD system (If Equipped)

• Interior Lights
• Exterior Lights
• HVAC System
• Audio System
• Power Windows
• Power Door Locks
• All Gauges, Indicators and Warning Lights
• Cooling Fans
• Etc.
14. TEST DRIVE THE VEHICLE
L. 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.
63

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SUPPLEMENTAL TECHNICAL INSTRUCTIONS

CUSTOMER SUPPORT PROGRAM (CSP)

2001 THROUGH 2004 MODEL YEAR TACOMA

B. SUPPLEMENTAL TOOLS & EQUIPMENT (FOR INGROUND LIFTS ONLY)

Special Service Tools (SST)

Beam Kit – P/N TOYTACCSP01 *

Part Number Part Description Quantity Illustration Name Page

Part Number Part Description Quantity

Part Number Part Description Quantity

Part Number Part Description Quantity

Part Number Part Description Quantity

Part Number Part Description Quantity

Part Number Part Description Quantity

Part Number Part Description Quantity

Part Number Part Description Quantity

Part Number Part Description Quantity

Part Number Part Description Quantity

Part Number Part Description Quantity

Part Number Part Description Quantity

Part Number Part Description Quantity

Part Number Part Description Quantity

- 4WD & PreRunner -

Wiring Harness Clips

Power Steering Rack

III. FRAME REPLACEMENT WORK PROCEDURE

• Always remember “SAFETY FIRST”.

2. FIRES AND IGNITION SOURCES ARE STRICTLY PROHIBITED

4. PREVENT STATIC ELECTRICITY

5. PRECAUTIONS WHEN USING A LIFT

6. PREVENT THE FUEL FROM SPRAYING

7. PREVENT THE FUEL FROM CONTACTING OTHER PARTS

8. ASSIGN A SAFETY SUPERVISOR

1. CENTER THE VEHICLE BETWEEN THE LIFT ARMS

2. REMOVE THE FOLLOWING PARTS

• Front And Rear Wheels

3. REMOVE THE WIRE HARNESS

a) Disconnect the 9 wire harness clips from the bed assy.

4. REMOVE THE BED ASSY

a) Remove the 2 nuts, 2 washers and 2 bolts.

1. CHECK FOR DTCs

2. DISCHARGE THE FUEL SYSTEM PRESSURE

a) Disconnect the fuel pump connector.

3. RECORD THE RADIO STATION PRESETS & REMOVE THE BATTERY

1. REMOVE THE ENGINE UNDER COVERS

2. EVACUATE THE REFRIGERANT FROM THE AIR CONDITIONING SYSTEM

3. DRAIN THE FOLLOWING FLUIDS

4. REMOVE THE FOLLOWING PARTS

• Front Parking/Clearance Lights

5. DISCONNECT THE OXYGEN SENSOR

6. DISCONNECT THE NO. 1 PARKING BRAKE

2WD 4WD & PreRunner NOTE:

For 4WD & PreRunner:

8. REMOVE THE AIR CLEANER CASE ASSY AND HOSE

9. DISCONNECT THE ACCELERATOR/THROTTLE CABLE (ENGINE SIDE)

10. DISCONNECT THE ENGINE WIRE HARNESS (ONLY FOR VEHICLES

a) Disconnect the 3 connectors.

11. DISCONNECT THE HOSES (ONLY FOR

RZ Engine VZ Engine For RZ Engine:

12. DISCONNECT THE ENGINE WIRE HARNESS

a) Disconnect the 2 connectors.

13. DISCONNECT THE HOSES

a) Disconnect the 2 vacuum hoses.

15. DISCONNECT THE FUEL PIPES