NHTSA ID Number: 10129985
Manufacturer Communication Number: ZH8_Sequoia_Tech
TSB/Document Date: 2018-03-12
Summary
Technical Instructions: Technical Instructions for Warranty Enhancement Program ZH8. Certain 2005-2007 Model Year Sequoia. UPDATED 2-15-2018. Frame Replacement.
TECHNICAL INSTRUCTIONS
FOR
WARRANTY ENHANCEMENT PROGRAM ZH8
*****************************
CERTAIN 2005-2007 MODEL YEAR SEQUOIA
*****************************
FRAME REPLACEMENT
UPDATED 2-15-2018
Update 2-15-18
- Parts information updated
Update 12-21-17
- Update to the Frame Serial Tracker Information
The repair quality of covered vehicles is extremely important to Toyota
. All dealership
technicians performing this recall are required to successfully complete the most current
version of the E-Learning course “Safety Recall and Service Campaign Essentials”. To ensure
that all vehicles have the repair performed correctly; technicians performing this repair are
required to currently hold at least one of the following certification levels:
• Certified Technician (any specialty)
• Expert Technician (any specialty)
• Master Technician
• Master Diagnostic Technician
Final repair must be signed off and validated by a MDT, Shop Foreman or Service Manager
using the Frame Replacement Inspection Form.
It is the dealership’s responsibility to select technicians with the above certification level or
greater to perform this recall repair. Carefully review your resources, the technician skill level,
and ability before assigning technicians to this repair. It is important to consider technician
days off and vacation schedules to ensure there are properly trained technicians available to
perform this repair at all times.
I.
OPERATION FLOWCHART
Verify Vehicle Eligibility:
1. Check the VIN range
2. Check the TIS vehicle Inquiry system
Yes
Perform pre-hoist inspection.
No
No further action required.
No
Contact your regional
representative for assistance.
Perform Frame Inspection utilizing the Inspection application.
Was perforation 10mm or larger found in the locations identified in
green below (during the rust removal and/or cleaning process)?
Is the vehicle applicable to LSC
H0F?
No
If No, no further action required;
return vehicle to customer.
Yes
Yes
Is your dealership located in a
cold climate state?
Inspection application submits report for FTS approval.
Was approval received from the FTS?
If No, H0F cannot be performed
at your facility; return vehicle to
customer.
Yes
Yes
Order parts and complete frame replacement.
Perform LSC H0F
Yes
WEP Complete
1
II.
PREPARATION
A. TOOLS & EQUIPMENT
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
A/C service equipment
Alignment rack
Brake bleeder
Engine Hanger
° 1GR-FE Engine
- 12281-31060 – Engine hanger no. 1 (Qty: 1)
- 12282-31040 – Engine hanger no. 2 (Qty: 1)
- 90119-08A87 – Bolt (Qty: 4)
° 3UR-FE Engine
- 12281-38150 – Engine hanger no. 1 (Qty: 2)
- 90119-14120 – Bolt (Qty: 2) (Japan sourced parts)
- 90119-A0166 – Bolt (Qty: 2) (Local sourced parts)
Engine hoist (Qty: 2) or Hydraulic mini crane (Qty: 2)
Engine sling (Qty: 2)
Floor jack
Protective eyewear
Protective gloves
Ratcheting tie down strap (2 in X 27 ft, minimum work load capacity: 3,000 lbs)
Special Service Tools (SST)
° 09985-20010 – Air conditioner service tool set or Commercially available air conditioning
manifold gauge set
° 09325-40010 – Transmission oil plug (Transmission A750E)
° 09325-60010 – Transmission oil plug (Transmission AB60E)
° 09610-20012 – Pitman arm puller
° 09520-32040 – A component of SST 09520-24010, Differential side gear shaft puller
° 09520-01010 – Drive shaft remover attachment
° 09951-04010,09952-04010,09953-04020,09954-04010,09955-04031,09958-04011,
– A component of SST 09950-40011, Puller B set
° 09955-04090 – Craw no.9
° 09922-10010-01 – Variable open wrench
Standard hand tools
Techstream
Torque wrench
Torx® T55H tamper resistant socket
Socket wrench 39mm
Hexagon wrench 8, 10
Deep socket wrench 10, 12, 14, 17, 19, 24mm
Union Nut Wrench 10mm
Weights
B. SUPPLIES
•
•
•
•
•
•
•
Toyota Genuine ATF WS or DEXRON® lll (DEXRON® ll) – As needed
Hypoid gear oil API GL-5 SAE 75W-90 – 2.1 liter
R134a refrigerant – As needed
Toyota DOT 3 brake fluid – 3 pints
Toyota long life coolant – 2 gallons
Paint
MP Grease
C. PARTS
To assist dealers in determining the correct part number(s) to order, a website has been set up to look up part
numbers by VIN. Please go to http://toyota-frame-parts-lookup.imagespm.info, 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
04001-7550C
04001-7560C
Part Description (Model Year)
Frame, Sub-Assy
Frame, Sub-Assy (w/Towing Hitch)
Quantity
1
1
Illustration Name
Frame & Misc Parts
Frame & Misc Parts
Page
6
6
Individual Parts (Continued):
Part Number
12157-10010
43425-04020
47322-0C070
47323-0C060
47325-0C060
47326-0C030
82164-0C041
82164-0C120
90080-11180
90430-24003
95381-04045
47316-0C040
Part Description
Gasket, Drain Plug
Ring, Drive Shaft Snap
Tube, RR Brake, No.2
Tube, RR Brake, No.3
Tube, RR Brake, No.5
Tube, RR Brake, No.6
Wire, Frame (w/o air suspension)
Wire, Frame (w/ air suspension)
Bolt, w/ Washer
Gasket
Pin, Cotter
TUBE,FR BRAKE,No.6
Quantity
1
2
1
1
1
1
1
1
6
1
2
1
Illustration Name
Front Differential
Front Suspension & Front Driveshaft
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Wire Harness Clamps
Wire Harness Clamps
Height Control (Auto-Leveler)
Front Differential
Front Suspension & Front Driveshaft
BRAKE TUBE & CLAMP
Page
15
12
13
13
13
13
15
15
11
15
12
10
3
Parts Kits:
Part Number
04001-7020C
Part Description
Parts Kit No.2 – Common Replacement kit A-2 (05-07MY)
Quantity
1
The kit listed above includes the following parts:
Part Number
16492-21050
47351-34040
47353-35110
47354-35100
48409-34020
48409-34030
48452-35020
48824-34030
48829-34020
77285-34031
90099-14121
90119-08516
90178-08011
90178-10024
90179-08054
90179-08068
90179-10071
90179-14062
90182-10004
90252-03015
90460-37003
90460-40007
90468-08035
90904-12066
90904-12067
90904-12068
90917-06083
90917-06085
90949-01C06
91621-B0816
94130-01232
94622-31200
95381-03225
Part Description
Ring, O Radiator
Bracket, Flexible Hose, No.5
Bracket, Flexible Hose, No.3
Bracket, Flexible Hose, No.4
Cam Sub-Assy, Toe Adjust
Cam Sub-Assy, Toe Adjust
Plate, Toe Adjust, No.2
Bracket, Stabilizer, RH
Bracket, Stabilizer, LH
Clamp, Fuel Tube, No.1
RING, O
Bolt, w/ Washer
Nut, Flange
Nut, Flange
Nut
Nut
Nut
Nut
Nut, w/ Washer
Pin, Cotter
Clamp, Hose
Clamp, Hose
Clip
Way, 2
Way, 2
Way, 2
Gasket, Exhaust Pipe
Gasket, Exhaust Pipe
Clamp
Bolt, w/ Washer
Nut, Hexagon
Washer, Plate
Pin, Cotter
Quantity
1
1
1
1
2
2
4
1
1
4
1
10
4
4
1
6
4
1
2
2
1
1
4
1
1
1
2
1
7
6
6
6
2
Illustration Name
Radiator
Brake Tubes
Brake Tubes
Brake Tubes
Front Suspension & Front Driveshaft
Front Suspension & Front Driveshaft
Front Suspension & Front Driveshaft
Front Suspension & Front Driveshaft
Front Suspension & Front Driveshaft
Fuel Tubes
Air Conditioning
Front Floor Panel & Front Floor Member
Rear Bumper
Front Bumper
AT Shaft Cable
Front Floor Panel & Front Floor Member
Engine Mounting
Rear Spring & Shock Absorber
Front Suspension & Front Driveshaft
Front Suspension & Front Driveshaft
Fuel Tank
Fuel Tank
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Exhaust System
Exhaust System
Brake Tubes
Brake Tubes
Rear Bumper
Rear Bumper
Power Steering
Page
20
13
13
13
12
12
12
12
12
14
20
22
21
21
20
22
17
10
12
12
19
19
13
13
13
13
18
18
13
13
21
21
16
Parts Kits (Continued):
Part Number
04001-7040C
Part Description
Parts Kit No.4 – Common Replacement kit B-2 (05-07MY)
Quantity
1
The kit listed above includes the following parts:
Part Number
47313-0C012
47314-0C011
47317-0C020
77285-0C010
77285-0C020
89542-0C010
89543-0C010
89545-0C020
89546-0C020
90069-08007
90080-11180
90080-11180
90080-11180
90080-11275
90080-11373
90080-11373
90080-11387
90080-11410
90080-11482
90080-11482
90080-11491
90080-11555
90080-46263
90119-A0026
90119-A0027
90119-A0064
90119-A0077
90119-A0085
90119-A0169
90179-08241
Part Description
TUBE, FR BRAKE, No.3
TUBE, FR BRAKE, No.4
TUBE, FR BRAKE, No.7
SUPPORT, FUEL RETURN & MAIN TUBE
SUPPORT, FUEL RETURN & MAIN TUBE
Sensor, Speed, Front RH
Sensor, Speed, Front LH
Sensor, Speed, Rear RH
Sensor, Speed, Rear LH
RING, O
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Clamp
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Nut
Quantity
1
1
1
1
1
1
1
1
1
1
4
4
2
2
5
2
4
2
2
4
6
3
1
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TSB/Document ID: ZH8_Sequoia_Tech
Replacement Service Bulletin Number:
MFR Communication Date: 2018-02-15
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: STRUCTURE
MFR Component System:
MFR Component Subsystem:
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