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.
Way, 2
90904-12067
91621-B0816
Bolt, w/ Washer
a) Temporarily install the NEW front brake tube and NEW
2 way.
b) Reinstall the front brake tube and 2 way with the NEW
bolt and torque to spec.
Torque Spec: 28 N·m (286 kgf∙cm, 21 ft·lbf)
c) Reconnect the front brake tube and torque to spec.
Torque Spec: 15 N·m (153 kgf∙cm, 11 ft·lbf)
d) Repeat the procedure on the opposite side.
22. REINSTALL THE REAR AXLE HOUSING W/ LINK ASSY
a) Place rear axle on floor jack and position under the
frame.
b) Temporarily reinstall the 2 bolts, 2 nuts and 2 washers
on the frame side of the lower control arms to the frame.
c) Set the rear coil springs and hollow springs on the rear
axle housing.
NOTE:
• After stabilizing the suspension, torque the bolts
and nuts.
• Be sure to raise one side of the rear axle
housing at a time.
• Install the rear lateral control rod after
positioning the body on it.
51
d) Raise the jack, and temporarily install the 2 bolts, 2 nuts
and 2 washers on the frame side of the No.1 rear
suspension arm to the frame.
NOTE:
• After stabilizing the suspension, torque the bolt and
nuts.
• Be sure to raise one side of the rear axle housing at
a time.
• Install the rear lateral control rod after positioning
the body on it.
e) Reconnect the rear shock absorbers with the 2 nuts
and 2 retainers, then torque to spec.
Torque Spec: 58 N∙m (591 kgf∙cm, 43 ft∙lbf)
23. REINSTALL THE FOLLOWING PARTS
NEW Replacement Parts
Height Control Sensor
Purt Number
Purt Name
82711-2C250
82711-35280 Clamp, Wiring Harness
82711-3F440
90080-11180
Bolt, w/ Washer
90179-06292
Nut
90179-08025
Nut
*Individual part(s)
Kit #
6
6
6
NA*
6
6
Qty
1
1
1
1
1
2
•
•
Height Control Sensor (w/ Air Suspension)
° Torque Spec: 29 N∙m (296 kgf∙cm, 21 ft∙lbf)
° NOTE:
If the harness clamp is damaged, replace the
NEW parts.
Rear Pneumatic Cylinder Assy (w/ Air Suspension)
Rear Pneumatic Cylinder Assy
Purt Number
48932-30010
48934-30010
48958-35020
90301-04011
Purt Name
Plate, Height
Control Tube
Connector, Height
Control Tube, No.2
Clip, Pneumatic Cylinder
Ring, O
Kit #
Qty
6
2
6
2
5
5
2
4
24. RECONNECT THE REAR STABILIZER BAR
a) Reconnect the 2 rear stabilizer links with the 2 nuts and
torque to spec.
NEW Replacement Parts
Rear Stabilizer Bar
Part Number
Part Name
Kit #
Qty
90080-11482
4
4
Torque Spec: 69 N∙m (704 kgf∙cm, 51 ft∙lbf)
b) Install the 4 NEW bolts and 2 brackets, then torque to
spec.
Torque Spec: 37 N∙m (377 kgf∙cm, 27 ft∙lbf)
NEW Replacement Parts
25. RECONNECT THE REAR BRAKE FLEXIBLE HOSES
Rear Brake Flexible Hose
Part Number
Kit #
Qty
2
1
90468-08035
Part Name
Bracket, Flexible Hose,
No 5
Clip
2
2
91621-B0816
Bolt, w/ Washer
2
1
47351-34040
a) Install the No.5 flexible hose bracket with the NEW bolt
and torque to spec.
Torque Spec: 28 N∙m (286 kgf∙cm, 21 ft∙lbf)
b) Reconnect the rear brake tubes and torque to spec.
Torque Spec: 15 N·m (153 kgf∙cm, 11 ft·lbf)
26. REINSTALL THE NO.2 PARKING BRAKE CABLE
a) Reconnect the No.2 parking brake cable to
the 3 clamps.
b) Reinstall the 2 bolts and torque to spec.
c) Reinstall the clip.
Torque Spec: 26 N·m (265 kgf∙cm, 19 ft∙lbf)
27. RECONNECT THE NO.3 PARKING BRAKE CABLE
a) Reconnect the No.3 parking brake cable with the bolt
and torque to spec.
Torque Spec: 26 N∙m (265 kgf∙cm, 19 ft∙lbf)
53
NEW Replacement Parts
28. CONNECT THE NEW REAR SPEED SENSOR
CONNECTORS
Rear Wheel Speed Sensors
Part Number
Part Name
Kit #
Qty
89545-0C020
Sensor, Speed, Rear RH
Sensor, Speed, Rear LH
4
1
4
1
89546-0C020
a) Install the new rear speed sensor
b) Route the rear speed sensor connector and wire with
the 2 clamps.
c) Repeat the procedure on the opposite side.
29. REINSTALL THE 4 WHEELS
30. 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.
• DO NOT use 1 engine hoist or mini crane to lower
the engine and transmission assy, as the
unbalanced weight may lead to an accident/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
so that the engine and transmission assy is
properly balanced.
b) Attach the engine mounts with the 4 bolts and 4 NEW nuts and torque to spec.
Torque Spec: 38 N∙m (387 kgf∙cm, 28 ft∙lbf)
NEW Replacement Parts
Engine Mounts
Part Number
Part Name
Kit #
Qty
90179-10071
Nut
2
4
NEW Replacement Parts
c) Attach the transmission mount with 4 NEW bolts and
torque to spec.
Transmission Mount
Part Number
Part Name
Kit #
Qty
90080-11387
Bolt, w/ Washer
4
4
Torque Spec: 18 N∙m (184 kgf∙cm, 13 ft∙lbf)
d) Reinstall the items/parts that were removed during the
engine and transmission assy removal.
31. RECONNECT THE A.D.D. ACTUATOR CONNECTOR
(4WD ONLY)
32. REINSTALL THE POWER STEERING VANE PUMP
ONTO ENGINE ASSEMBLY ASSY
a) Reinstall the power steering vane pump assy to the
mounting bracket with the 2 bolts and nut, then torque
to spec.
Torque Spec: 28 N∙m (286 kgf∙cm, 21 ft∙lbf)
55
33. REINSTALL THE DRIVE BELT
34. RECONNECT THE FUEL PIPES AND HOSE
a) Reconnect the 2 fuel pipes.
b) Reinstall the No.1 fuel pipe clamp.
NOTE:
• Align the axis of the connector with the axis of the
pipe, and push into the connector until the
connector makes a "click" sound. If the connection
is tight, apply a little amount of fresh engine oil on
the tip of the pipe.
• After finishing the connection, check whether the
pipe and the connector are securely connected by
pulling them.
35. REINSTALL THE FUEL TANK STRAPS
a) Reinstall the fuel tank straps with the 2 pins and 2
clips.
36. REINSTALL THE FUEL TANK
NEW Replacement Parts
a) Reinstall the fuel tank with the 2 NEW bolts and torque
to spec.
Fuel Tank Straps
Purt Number
90119-A0077
Purt Name
Bolt, w/ Washer
Kit #
4
Qty
2
Torque Spec: 62 N∙m (632 kgf∙cm, 46 ft∙lbf)
b) Reinstall the fuel tubes.
c) Connect the clamp and connector(s).
37. REINSTALL THE NO.1 FUEL TANK PROTECTOR
a) Reinstall the No.1 fuel tank protector with the NEW
bolts and NEW nuts, then torque to spec.
Torque Specs: Bolt -20 N∙m (204 kgf∙cm, 15 ft∙lbf)
NOTE:
• The number of fuel connectors will differ
depending on the vehicle specs.
No.1 Fuel Tank Protector
Part Number
Part Name
Kit #
Qty
90080-11373
Bolt, w/ Washer
4
5
38. REINSTALL THE EXHAUST SYSTEM
a) Install the 3 NEW exhaust pipe gaskets.
b) Reinstall the center exhaust pipe with the 4 exhaust pipe supports, 2 NEW flange retainers and 4 bolts,
then torque to spec.
Torque Spec: 48 N∙m (489 kgf∙cm, 35 ft∙lbf)
c) Reinstall the tail exhaust pipe with the 2 tail pipe brackets.
d) Face the clamp in the direction indicated in the illustration, and torque to spec.
Torque Spec: 32 N∙m (326 kgf∙cm, 24 ft∙lbf)
NEW Replacement Parts
Exhaust System
Part Number
90080-46263
90917-06083
90917-06085
Part Name
Clamp
Gasket, Exhaust
System**
Gasket Exhaust System
*Individual Part(s)
Kit #
4
Qty
1
2
2
2
1
**Only 1 part # is used. The part # varies depending on vehicle model year.
57
39. REINSTALL THE FRONT PROPELLER SHAFT (4WD ONLY)
a) Aligning the matchmarks, install the front propeller shaft to the transfer case and the front differential with
the 8 bolts, 8 washers and 8 nuts, then torque to spec.
Torque Spec:
Fr Diff Side - 74 N∙m (755 kgf∙cm, 55 ft∙lbf)
Rr T/F Side - 88 N∙m (897 kgf∙cm, 65 ft∙lbf)
40. REINSTALL THE RECEIVER HITCH BRACKET
SUB-ASSY (IF EQUIPPED)
NEW Replacement Parts
Receiver Hitch
Part Number
90080-11491
Part Name
Bolt, w/ Washer
Kit #
4
Qty
6
a) Reinstall the receiver hitch bracket sub-assy with the 4
bolts and 6 NEW bolts and torque to spec.
Torque Spec: Bolt A - - 177 N∙m (1805 kgf∙cm, 131 ft∙lbf)
Torque Spec: Bolt B - 105 N∙m (1071 kgf∙cm, 78 ft∙lbf)
NEW Replacement Parts
41. INSTALL THE SPARE TIRE CARRIER
Spare Tire Carrier
Part Number
90080-11180
Part Name
Bolt, w/ Washer
*Individual Part(s)
Kit #
4
Qty
4
a) Install the spare tire carrier with the 4 NEW bolts and
torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
NOTE:
Install the spare wheel after tightening the rear
suspension arms.
42. REMOVE THE FRAME FROM THE LIFT
a) Remove the ratcheting tie down strap from the frame.
b) Lower the frame to the ground.
H. REINSTALL THE CAB BODY ASSY
1. INSTALL THE NEW ENGINE COMPARTMENT BRAKE
LINE
NEW Replacement Parts
Purt Number
47313-0C012
47316-0C040
47322-0C070
47325-0C060
Purt Name
Tube, FR Brake, No.3
Tube, FR Brake, No.6
Tube, RR Brake, No.2
Tube, RR Brake, No.5
*Individual part(s)
Kit #
4
NA*
NA*
NA*
Qty
1
1
1
1
a) Install the NEW No.3 and NEW No.6 front brake tubes.
b) Install the NEW No.2 and NEW No.5 rear brake tubes.
c) Torque all brake tubes to spec.
Torque Spec: 15 N·m (153 kgf∙cm, 11 ft·lbf)
NOTE:
The number of clamps will differ depending on the
vehicle spec.
2. 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.
Note: Line up the wheels with the alignment marks previously made to help align the frame with
the cab.
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 the 8 bolts, 8 nuts and 8 washers
and torque to spec.
Torque Specs: No.1 and No.4 Nut - 47 N∙m (479 kgf∙cm, 35 ft∙lbf)
Torque Specs: No.2 Nut - 54 N∙m (551 kgf∙cm, 40 ft∙lbf)
Torque Specs: No.3 Nut - 67 N∙m (683 kgf∙cm, 50 ft∙lbf)
NOTE:
• DO NOT work directly underneath the vehicle when pushing the frame under the cab assy.
• Slowly lower the cab body assy while making sure that the wire harness, steering shaft and
hoses do not interfere with it.
• With 2 to 3 people checking for interference, slowly lower the cab body assy to the frame.
• Center the vehicle’s weight on the lift arms so that it does not slant/tilt to one side.
59
3. READJUST LIFT ARMS AND LIFT VEHICLE
4. REMOVE THE FRONT WHEELS
LH Side
5. RECONNECT THE FRONT SPEED SENSOR
CONNECTORS
a) Reconnect the front speed sensor connector.
b) Reinstall the clamp.
c) Repeat the procedure on the opposite side.
RH Side
LH Side
6. RECONNECT THE FRONT BRAKE TUBES
a) Reconnect the front brake tube and torque to spec.
b) Repeat the procedure on the opposite side.
Torque Spec: 15 N·m (153 kgf∙cm, 11 ft·lbf)
RH Side
7. REINSTALL THE FRONT FENDER APRON SEALS
LH Side
a) Reinstall the 4 front fender apron seals with the 21
clips.
RH Side
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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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