4
2
4
2
4
8
2

Illustration Name
Brake Tubes
Brake Tubes
Brake Tubes
Fuel Tubes
Fuel Tubes
ABS
ABS
ABS
ABS
Air Conditioning
Rear Spring & Shock Absorber
Spare Wheel Carrier
Fuel Tubes
Front Suspension & Front Driveshaft
Suspension Crossmember & Under Cover
Fuel Tank
Engine Mounting
Front Suspension & Front Driveshaft
Front Suspension & Front Driveshaft
Rear Spring & Shock Absorber
Frame & Misc Parts
Power Steering
Exhaust System
Rear Bumper
Rear Bumper
Rear Bumper
Fuel Tank
Frame & Misc Parts
Frame & Misc Parts
Fuel Tank

Page
13
13
13
14
14
17
17
17
17
20
10
9
14
12
9
19
17
12
12
10
9
16
18
21
21
21
19
9
9
19

Part Number

Part Description

Quantity

04001-7050C

Parts Kit No.5 – Height Control 1 (05-07MY)

1

The kit listed above includes the following parts:

Part Number

Part Name

90301-04011
48958-35020

RING,O 4 REAR SPRING & SHOCK ABSORBER
CLIP, PNEUMATIC CYLINDER 2 REAR SPRING & SHOCK ABSORBER

Qty
4
2

5

Parts Kits (Continued):
Part Number

Part Description

Quantity

04001-7060C

Parts Kit No.6 – Height Control 2 (05-07MY)

1

The kit listed above includes the following parts:
Part Number
48932-30010
48933-30010
48934-30010
82711-2C250
82711-35280
82711-3F440
82711-48060
90179-06292
90179-08025
90301-04006
90301-04011
90467-09093
90468-12012
90949-01883
90949-01B59

Part Number
04007-18334

Part Description
Plate, Height Control Tube
Holder, Air Connector Clip
Connector, Height Control Tube, No.2
Clamp, Wiring Harness
Clamp, Wiring Harness
Clamp, Wiring Harness
Clamp, Wiring Harness
Nut
Nut
Ring, O
Ring, O
Clip
Clip
Clamp
Clamp

Quantity
4
2
4
1
1
1
1
1
2
2
8
3
2
2
6

Illustration Name
Height Control (Auto-Leveler)
Height Control (Auto-Leveler)
Height Control (Auto-Leveler)
Electronic Modulated Suspension
Electronic Modulated Suspension
Electronic Modulated Suspension
Height Control (Auto-Leveler)
Height Control (Auto-Leveler)
Electronic Modulated Suspension
Height Control (Auto-Leveler)
Height Control (Auto-Leveler)
Height Control (Auto-Leveler)
Height Control (Auto-Leveler)
Height Control (Auto-Leveler)
Height Control (Auto-Leveler)

Part Description
PLUG, HOLE KIT (You may not use all plugs provided in kit)
The kit listed above includes the following parts:

Page
11
11
11
22
22
22
11
11
22
11
11
11
11
11
11

Quantity
1

D. PARTS ILLUSTARTION
Frame & Misc Parts

Suspension Crossmember &
Under Cover

Spare Tire Carrier

7

Rear Spring & Shock Absorber

Parts Kit No. 5

Front Suspension & Front Driveshaft

9

Brake Tubes

Fuel Tubes

Wire Harness Clamps

Front Differential

11

Power Steering

ABS

Engine Mounting

Exhaust System

13

Fuel Tank

Air Conditioning

Auto Trans Shift Cable

Radiator

Front Bumper

Rear Bumper

15

Front Floor Panel & Front Floor Member

III.

FRAME INSPECTION

1. PERFORM INITIAL PRE-HOIST INSPECTION
1. INSPECT THE FRAME FOR EXCESSIVE FRAME CORROSION THAT COULD AFFECT THE
STRUCTURAL INTEGRITY OF THE FRAME

2. FRAME INSPECTION
All frame inspection must be performed using the NEW frame inspection
application on TIS. Ensure you inspect the frame and properly document the
inspection. Failure to perform this will result in denial of the claim.
1. ACCESS INSPECTION APPLICATION
a. Run the VIN in TIS and click on the Warranty Tab
b. Click on the “Frame Inspection” link on TIS

2. LOG INTO THE INSPECTION APPLICATION
a. Reenter your TIS password

17

3. ENTER VEHICLE INFORMATION
a. Enter the vehicle mileage.
b. Select the state from the drop-down menu that the vehicle is registered.
Note: Do NOT select the state the dealership is located.
c.

Inspect the frame for CRC compound that could have been previously applied:
CRC was Previously Applied: Select the CRC Bottle Button
NO CRC Previously Applied: Select Frame Button

Note: CRC could only be previously applied to 2005 to 2008 Tacoma vehicles.

4. INSPECT THE FRAME SECTIONS
a. Inspect the frame in the colored areas below and use the application to document the results of the
inspection.
Note: Crossmember mounting locations should be inspected 6” into the crossmember.
Sequoia 05 to 07

b. Select Section A
Note: The frame inspection application must be completed in alphabetical order.

c.

Inspect the frame section and inspect all surfaces of the frame rail and crossmember. Select the photo
that best represents the frame condition. If perforation of 10mm or larger is identified select “Peroration
of the Frame”.
Note: You must click the bubble next to the image to select the condition.

d. If you selected Perforation of the Frame, the application will request more information about the
size of perforation(s) and location.
e. The section with perforation will split into 2 sub-sections to further identify the perforation location.
f. Select the size of the perforation in each sub-section.
g. Upload a photo for each area containing perforation and describe the location in the comments
section.
Note:
• Include the R.O. in the image of at least one of the perforation holes.
• If both sub-sections have perforation, it will require two pictures to be uploaded.
• If perforation was accidentally selected use the back button to reselect the correct frame
condition.
h. Select Next to move onto the next section.

19

i.

Once all sections have been completed, select the Submit button.

NO Perforation Found
j. If no perforation was not found, follow the directions as provided.

Perforation Found
k.

If perforation was found, this application will be submitted to your Regional Office for review. The
region office will review the inspection and provide feedback if the frame replacement is approved
for future repair.
DO NOT proceed with frame replacement or parts ordering until you are provided
with approval from the Regional Office. Approval will be sent to the TIS inbox for the
inspection, Service Manager and Parts Manager.

21

IV.

FRAME REPLACEMENT WORK PROCEDURE
A. PERFORM PRELIMINARY VEHICLE INSPECTION

1. Perform health check and record any preexisting DTCs
2. Test drive the vehicle and inspect the following vehicle functions/current operating conditions prior to
vehicle repair.
•
•
•
•
•

4WD System (4WD Only)
Interior Lights
Exterior Lights
HVAC System
Audio System

•
•
•
•
•

Power Windows
Power Door Locks
All Gauges, Indicators and Warning Lights
Cooling Fans
Etc.

3. Documents the current vehicle operating condition on the Frame Replacement Inspection Sheet.
B. SAFETY CHECKLIST & PRECAUTIONS WHEN DRAINING THE FUEL SYSTEM
•
•
•
•

Always remember “SAFETY FIRST”.
Be extremely careful when handling fuel to prevent fires from occurring.
Before beginning work on the fuel system, perform the following safety check list.
Before removing any fuel system part, drain all fuel to prevent spilling.

1. AIR VENTILATION
Perform work in a well-ventilated area.
DO NOT work underground or in an area where fuel vapors may fill the room due to poor ventilation.
Quickly clean up any spilled fuel with a dry cloth and dissipate the fuel vapors.
Dry all cloths that have come in contact with fuel in a well-ventilated area and dispose of them properly (according to applicable local
regulations).

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

3. FIRE EXTINGUISHER
Have a fire extinguisher ready and available before beginning work.

4. PREVENT STATIC ELECTRICITY
To help prevent static electricity, lightly wet the floor with water, but not to the point where it creates a hazardous working condition.
Place appropriate warning cones or stand signs around the area as a caution.

5. PRECAUTIONS WHEN USING A LIFT
For bays equipped with auto lifts, cover all access cover joints with duct tape.
In the event that fuel has leaked inside the auto lift, remove the access cover and clean up any spilled fuel. Dissipate fuel vapors
until the smell is gone.

6. PREVENT THE FUEL FROM SPRAYING
When disconnecting any fuel tubes, pipes, hoses or connectors there may still be some pressure remaining, even after discharging the
system. To prevent the fuel from spraying, cover the tubes, pipes or connectors with a shop rag before disconnecting.
Remember to always wear protective goggles especially when disconnecting fuel tubes, pipes, hoses or connectors.

7. PREVENT THE FUEL FROM CONTACTING OTHER PARTS
Do not allow the fuel to come in contact with any parts made of rubber or leather.

8. ASSIGN A SAFETY SUPERVISOR
Assign a safety supervisor to be in charge of all safety precautions and fire hazards around the work area.

23

• 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.
DO NOT disconnect any part of the fuel system until you have discharged the fuel
pressure.
Even after discharging the fuel 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.
Before commencing the operation, set the vehicle in the center of a lift, stop it in a
position where all the doors can be opened, and center the steering wheel so that the
front wheels are in a straight-ahead position.

1. CHECK FOR DTCs TO ENSURE VEHICLE ORIGINAL OPERATING CONDITION
2. REMOVE THE FUEL PUMP RELAY
a) Remove the junction block cover.
b) Remove the fuel pump relay.

3. DISCHARGE THE FUEL SYSTEM PRESSURE
a) Start the engine.
b) After the engine has stopped, turn the ignition switch OFF.
c) Crank the engine again to check that it does not start.
NOTE: Make sure to follow the procedure listed above, this prevents a large amount of gasoline from
leaking out of the high pressure fuel line when it is disconnected.
4. EVACUATE THE A/C REFRIGERANT

25

C. PREPERATION FOR REMOVAL OF THE BODY ASSY
1. RECORD THE RADIO STATION PRESETS
2. DISCONNECT THE NEGATIVE (-) BATTERY TERMINAL CABLE
Note: if the vehicle is equipped with power seats, you will need to access the front passenger seat
bolts prior to disconnecting the battery in order to remove the seat to access the chassis wire.
•

Wait at least 90 seconds after disconnecting the negative (-) battery terminal from the
battery to prevent the SRS System from deploying (i.e. airbag, seat belt pretensioner,
etc.).

3. REMOVE THE FOLLOWING INTERIOR PARTS TO ACCESS WIREHARNESS CONNECTORS & CAB
MOUNTING BOLTS
•
•
•
•
•
•

Front Door Scuff Plate LH/RH
Cowl Side Trim Board LH/RH
Passenger Front Seat
Glove Compartment Door
Lower No.2 Instrument Finish Panel
No.4 Heater To Register Duct
•
•

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.
4. DISCONNECT THE FRAME WIRE CONNECTORS
a) Fold back the floor carpet and disconnect the 2
connectors.
b) Disconnect the frame wire harness grommet.
c) Pull out the frame wire harness from the vehicle cab.

5. DISCONNECT THE ENGINE WIRE HARNESS
a) Disconnect the 6 connectors and clamp.
NOTE: The number of connectors will differ depending
on the vehicle specs.

6. REMOVE THE FOLLOWING PARTS FROM THE CENTER CONSOLE AREA (4WD Only)
•
•
•
•
•

Transfer Shift Lever Knob
Shifting Hole Cover
Upper Console Panel
No.1 Shift and Select Lever Boot
Transfer High and Low Shift Lever
7. SECURE THE STEERING WHEEL
a) Make sure the front wheels are in a straight-ahead
position and the steering wheel is centered.
b) Using the seat belt, hold the steering wheel in position
as shown in the illustration, in order to prevent damage
to the spiral cable.

8. FOLD UP THE 2nd ROW SEATS AND REMOVE REAR PASSENGER DOOR SCUFF PLATES
9. REMOVE THE FOLLOWING INTERIOR COMPONENTS TO ACCESS CAB MOUNTING BOLTS
•
•
•
•
•

2nd Row Seat Outer Belt Floor Anchor
3rd Row Seats (If Equipped)
3rd Row Seats Outer Belt Floor Anchors (If Equipped)
Rear Floor Mat Support Plate
Rear Quarter Trim Panel LH/RH
•
•
•
•

Place jack stands under the front and rear portions of the frame to support the frame.
DO NOT work directly underneath vehicle when preparing the vehicle for 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.
For additional repair information, please reference to the appropriate repair manual for
the vehicle you are working on.

10. LIFT VEHICLE ON LIFT
11. REMOVE THE FOLLOWING PARTS UNDER VEHICLE COMPONENTS
•
•

No.1 Engine Under Cover
Side Step Assy LH/RH (if applicable)

12. DRAIN THE FOLLOWING FLUIDS
•
•