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.
•
Engine Coolant (including the engine block
)
Brake Fluid
Front Differential Oil (4WD ONLY)
Note: DO NOT remove the radiator cap while the radiator and engine are hot, as doing so may cause
the coolant to spray out causing potential injuries.
27
13. DISCONNECT THE AUTOMATIC TRANSMISSION NO.2
OIL COOLER OUTLET TUBE
a) Disconnect the hose.
b) Remove the bolt and disconnect the No.2 oil cooler
outlet tube.
a) Remove the pin and washer.
b) Remove the 2 bolts and disconnect the transmission
control cable.
NOTE: If the pin is difficult to remove, remove the nut
and then the cable.
14. REMOVE THE NO. 2 STEERING INTERMEDIATE SHAFT
NOTE:
Use precaution when performing this step, as you will
need to work underneath the vehicle.
a) Place match marks on the steering sliding yoke and
No.2 steering intermediate shaft.
b) Loosen the bolt (A) and remove the bolt (B).
c) Disconnect the steering sliding yoke from the No.2
steering intermediate shaft.
NOTE: If the No. 2 intermediate shaft assy. is stuck, tap
it from below with a brass hammer to disconnect it.
15. DISCONNECT THE REAR BRAKE TUBES
a) Using a flare nut wrench, disconnect the 2 rear brake
tubes.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
16. DISCONNECT THE PARKING BRAKE CABLES
a) Disconnect the No.1 parking brake cable from the No.3
parking brake cable.
b) Remove the clip and pin and disconnect the No.2
parking brake cable.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
c) Remove the bolt and cable support bracket from LH side
frame rail.
d) Remove the bolt and disconnect the No.1 parking brake
cable from LH side frame rail.
17. DISCONNECT THE FUEL TANK VENT HOSE
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
18. DISCONNECT THE FUEL TANK TO FILLER PIPE HOSE
AND FUEL TANK BREATHER HOSE
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
29
19. DISCONNECT THE FRAME WIRE
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
a) Disconnect the connector for charcoal canister and
clamp(s).
Receiver Hitch Equipped Vehicle
b) Disconnect the connector(s) and clamp(s) for the
receiver hitch.
(Receiver Hitch Equipped Vehicle Only)
NOTE: The number of fastening connectors and clamps
for the frame wire will differ depending on the vehicle
options. Please verify the current vehicle options and
continue.
20. REMOVE THE FOLLOWING FRONT END COMPONENTS
•
•
•
Front Fender Mudguard LH/RH
Front Bumper Assy
Front Bumper Energy Absorber
21. DISCONNECT THE FRONT FENDER LINERS
a) Remove the 2 screws and disconnect the front fender
liners from the front bumper reinforcement.
LH Side
22. REMOVE THE FRONT FENDER APRON SEALS
a) Remove the 21 clips and 4 front fender apron seals.
RH Side
31
LH Side
23. DISCONNECT THE FRONT BRAKE TUBES
a) Disconnect the front brake tube.
Note: Seal off the front brake lines to ensure no rust
and debris enters the brake system.
b) Repeat the procedure on the opposite side.
RH Side
LH Side
24. DISCONNECT THE FRONT SPEED SENSOR
CONNECTORS
a) Disconnect the clamp and front speed sensor
connector.
b) Repeat the procedure on the opposite side.
RH Side
25. REMOVE THE FOLLOWING PARTS
•
•
Rear Quarter Panel Mudguard LH/RH
Rear Bumper Assy.
26. REMOVE THE REAR BUMPER EXTENSION MOUNTING
BRACKET W/ BACK STEP REINFORCEMENT
a) Loosen the 4 bolts.
b) Remove the 4 nuts and the rear bumper extension
mounting bracket w/ back step reinforcement.
27. REMOVE/DISCONNECT THE FOLLOWING PARTS FROM ENGINE COMPARTMENT AREA
•
•
•
•
•
•
•
•
Throttle Body Cover
Air Cleaner
Radiator Inlet Hose (disconnect from engine)
Radiator Outlet Hose (disconnect from engine)
Disconnect Heater Coolant Hose
Fan Shroud
External Trans Cooler (If Equipped)
Radiator Assy
NOTE: After disconnecting the automatic transmission oil cooler hoses, plug them and cap the
fittings to prevent the ATF from spilling out.
28. DISCONNECT THE FOLLOWING ENGINE
COMPARTMENT HOSES
a) Disconnect the brake booster hose.
b) Disconnect the No.2 fuel vapor feed hose.
29. DISCONNECT THE REAR HEATER WATER HOSES
(IF EQUIPPED)
a) Disconnect the 2 rear heater water hoses from the
water pipe.
33
30. DISCONNECT THE ENGINE WIRE HARNESS
a) Remove the bolt and disconnect the ground wire from
cowl panel.
b) Remove the bolt and the 2 nuts holding the engine wire
harness connector from the cowl panel.
c) Gently pull the engine wire harness out from body
assembly.
Note: Ensure all connectors have been previously
disconnected from the glove compartment to ensure
you do not damage the wire harness
31. DISCONNECT THE NO.2 ENGINE WIRE HARNESS
a) Disconnect the connector and clamp from inner LH
front fender.
b) Remove the bolt and disconnect the ground wire.
c) Remove the nut and disconnect the positive (+) battery
cable.
d) Remove the nut and 2 clamps and disconnect the No.2
engine wire harness from the junction block.
32. DISCONNECT THE A/C DISCHARGE HOSE AND SUCTION HOSE
33. DISCONNECT THE POWER STEERING PUMP OIL
RESERVOIR
a) Remove the 2 nuts and place the power steering
reservoir on the engine assembly.
D. REMOVAL OF THE BODY ASSY
34. REMOVE THE CAB BODY ASSY USING AN ABOVE GROUND LIFT
Note: Before rolling chassis out, mark the location of the tires on the floor, this will help align the
chassis when the cab is reinstalled.
a)
b)
c)
d)
e)
f)
g)
Remove the 8 nuts and 8 washers.
Set the lift arms under the cab body assy. so they DO NOT interfere with the frame or cab mounts.
Check that all wire harnesses, hoses, cables and the steering shaft are disconnected.
Lift the cab assy. up slowly, making sure it does not interfere with anything while being raised.
Raise the cab assy high enough so that the top of the engine clears the lowest point of the cab assy.
Pull the frame assy out from under the cab assembly.
Lower the cab assy all the way down and leave it on the lift.
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 it.
• DO NOT remove the cab mount bolts, as they will be used as guides during the cab assy.
reinstallation process.
35
E. DISASSEMBLE THE FRAME
1. PLACE THE FRAME ON A 2nd LIFT
a) Place the frame on the 2nd 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 Down: Qty: 1
° Demensions: 2 in X 27 ft
° Minimum Work Load Capacity: 3,000 lbs
2. REMOVE THE FOLLOWING PARTS
•
•
•
•
•
•
•
Spare Tire Carrier
Receiver Hitch Bracket Assy (If Equipped)
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)
° SST: 09325-40010
No.1 Fuel Tank Protector
Fuel Tank Straps
Fuel Tank
NOTE:
Make sure to place matchmarks on the front (if equipped) and rear propeller shafts before removal.
3. REMOVE THE EXHAUST SYSTEM
a) Remove the clamp, 2 rear tail pipe brackets and rear
tail pipe.
b) Remove the 4 bolts, 4 exhaust pipe supports and
center exhaust pipe.
c) Remove the 3 exhaust pipe gaskets.
4. DISCONNECT THE FUEL PIPE AND HOSE
a) Remove the No.1 fuel pipe clamp.
b) Disconnect the 2 fuel pipes.
NOTE:
• Put a shop towel under the delivery pipe.
• Slowly loosen the pulsation damper.
5. REMOVE THE DRIVE BELT
6. REMOVE AND SET A SIDE THE POWER STEERING PUMP ASSY
a) Remove the 2 bolts and nut and power steering vane pump assy.
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.
7. DISCONNECT THE A.D.D. ACTUATOR CONNECTOR
(4WD ONLY)
8. REMOVE THE ENGINE AND TRANSMISSION ASSY.
a) Disconnect and remove the necessary items/parts to
prepare the engine and transmission assy for removal.
b) 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.
9. REMOVE THE 4 WHEELS
37
10. DISCONNECT THE REAR SPEED SENSOR
CONNECTOR
a) Remove the 2 clamps and disconnect the rear speed
sensor connector.
b) Repeat the procedure on the opposite side.
11. DISCONNECT THE NO.3 PARKING BRAKE CABLE
a) Remove the bolt and disconnect the No.3 parking brake
cable.
12. REMOVE THE NO.2 PARKING BRAKE CABLE
a) Remove the clip.
b) Remove the 2 bolts.
c) Disconnect the No.2 parking brake cable from the 3
clamps.
13. DISCONNECT THE REAR BRAKE FLEXIBLE HOSES
a) Using a flare nut wrench, disconnect the 2 rear brake
tubes.
b) Remove the bolt and disconnect the No.5 flexible hose
bracket.
14. DISCONNECT THE REAR STABILIZER BAR
a) Remove the 2 nuts and disconnect the 2 rear stabilizer
links from the frame.
b) Remove the 4 bolts, 2 brackets and rear stabilizer bar.
15. LOOSEN THE REAR SUSPENSION ARMS
a) Loosen the bolts and nuts of the rear suspension arms,
at the rear axle housing.
b) Loosen the bolts and nuts of the rear suspension arms
at the frame.
16. DISCONNECT THE REAR SHOCK ABSORBERS
a) Using a floor jack raise the rear axle housing.
b) Remove the 2 nuts and 2 retainers and disconnect the
rear shock absorbers.
17. REMOVE THE REAR AXLE HOUSING W/ LINK ASSY
a) Position the floor jack underneath the center section of the rear axle to support during the disassembly
process.
b) Remove the 2 bolts, washer, nut and the rear lateral control rod (Illustration A).
c) Remove the 2 bolts, 2 washers and 2 nuts and disconnect the No.1 rear suspension arms from the
frame (Illustration B).
d) Slowly lower the jack, and remove the rear coil springs and hollow springs (Illustration C).
e) Remove the 2 bolts, 2 washers and 2 nuts and disconnect the lower control arms from the frame
(Illustration C).
f) Roll the rear axle assembly away from frame.
Illustration A
Illustration B
Illustration C
18. DISCONNECT THE NO.1 FRONT BRAKE FLEXIBLE
HOSES
a) Disconnect the front brake tube.
b) Remove the clip and disconnect the No.1 flexible hose.
c) Plug the hose to ensure not rust or debris enter the
brake hose
d) Repeat the procedure on the opposite side.
39
19. DISCONNECT THE FRONT SPEED SENSOR
CONNECTORS
a) Remove the 2 bolts and 2 clamps and disconnect the
front speed sensor connector.
b) Repeat the procedure on the opposite side.
20. REMOVE THE FOLLOWING FRONT END COMPONENTS
•
•
•
•
•
Front Bumper Reinforcement
Front Stabilizer Bar
Front Axle Shaft Nuts (4WD Only)
Tie Rod Ends
° Remove the cotter pins and nuts.
° Using the SST, disconnect the tie rod ends.
° SST: 09610-20012
Front Lower Ball Joints
° Remove the cotter pins and nuts.
° Using the SST, disconnect the lower ball joint.
° SST: 09628-62011
21. REMOVE THE FRONT SUSPENSION UPPER ARMS W/
STEERING KNUCKLE AND STRUT ASSY
a) Remove the bolt, nut, 2 washers and front suspension
upper arm w/ steering knuckle.
b) Repeat the procedure on the opposite side.
NOTE:
If the drive shaft is difficult to disconnect, tap it loose
with a plastic hammer.
22. REMOVE FRONT STRUT ASSY AND LOWER CONTROL
ARMS
a) Remove Front Strut Assy by removing the three nuts
and bolt.
b) Repeat procedure on opposite side.
c) Remove Front Suspension Lower Control Arm
23. REMOVE THE FOLLOWING POWERTRAIN COMPONENTS
•
•
•
Power Steering Gear Assy w/ Power Steering Vane Pump
Front Drive Shafts (4WD Only)
° Using the SST, remove the drive shafts.
° SST: 09520-01010, 09520-32040
Front Differential Carrier (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.
• Keep the power steering pump reservoir in an upright position to prevent fluid from leaking out.
• If the drive shaft is difficult to remove tap it with a plastic hammer.
• Be careful not to damage the dust cover and oil seal.
24. REMOVE THE FOLLOWING PARTS
•
•
•
Height Control Compressor Cover (w/ Air Suspension)
Height Control Compressor Assy (w/ Air Suspension)
No.2 Height Control Valve Sub-Assy (w/ Air Suspension)
Height Control Tubes and Way (w/ Air Suspension)
25. REMOVE THE FUEL TUBES
a) Remove the bolts and clamps and the fuel tubes.
NOTE:
• The number of fastening clips and clamps for the
fuel tubes will differ depending on the vehicle
model. Please verify the current vehicle and
continue.
26. REMOVE THE STUD BOLT
27. REMOVE THE FRONT PARKING BRAKE CABLE
RETAINER BRACKET AND CLAMPS
a) Remove the bolt and the front cable retainer bracket
from crossmember.
b) Remove the 2 bolts and the clamps from crossmember
and LH frame rail.
c) Remove the clamp from RH side frame rail.
28. REMOVE THE REMAINING COMPONENTS
•
•
•
Front Spring Bumpers
Rear Spring Bumpers
Cab Mounting Cushions (Qty: 8)
29. REMOVE THE FRAME FROM THE LIFT
41
30. REMOVE THE FRAME FROM THE LIFT
a) Remove the ratcheting tie down strap and the frame from the lift.
F. INSTALL FRAME PLUGS (You may not use every plug provided in the kit)
1. INSTALL THE FRAME PLUGS AS SHOWN IN THE DIAGRAMS BELOW
PLUG DIAGRAM/ID
P/N
INSTALLATION INSTRUCTIONS
TOTAL QTY
Plug ‘19’
90950-01A09
Push to seat install.
22
90950-01984
Push to seat install.
2
90950-01987
Push to seat install.
39
90950-01983
Push to seat install.
7
90950-01539
Push to seat install.
2
Plug ‘1’
Plug ‘4’
Plug ‘0’
Plug ‘18’
Push to seat install.
90480-18492
It must be installed with the channel opening facing the
outer portion of the frame to ensure road spray does
not enter the frame.
4
90950-01A24
Push to seat install
4
PLUG INSTALLATION 1/6
PLUG INSTALLATION 2/6
43
PLUG INSTALLATION 3/6
PLUG INSTALLATION 4/6
PLUG INSTALLATION 5/6
PLUG INSTALLATION 6/6
45
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 Down: Qty: 1
° Demension: 2 in X 27 ft
° Minimum Work Load Capacity: 3,000 lbs
NEW Replacement Parts
2. REINSTALL THE REAR SPRING BUMPER
Rear Spring Bumper
Part Number
Part Name
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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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