NHTSA ID Number: 10129986
Manufacturer Communication Number: ZH6_Tacoma Frame
TSB/Document Date: 2018-03-12
Summary
Technical Instructions: Technical Instructions for Warranty Enhancement Program ZH6. Certain 2005 through 2010 Model Year Tacoma. UPDATED 2-15-2018. Frame Replacement.
TECHNICAL INSTRUCTIONS
FOR
WARRANTY ENHANCEMENT PROGRAM ZH6
*****************************
CERTAIN 2005 THROUGH 2010 MODEL YEAR TACOMA
*****************************
UPDATED 2-15-2018
Update 2-15-18
- Parts information updated
FRAME REPLACEMENT
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 ELearning 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)
° 2TR-FE Engine
- 12281-75040 – Engine hanger no. 1 (Qty: 1)
- 12281-75040 – Engine hanger no. 2 (Qty: 1)
- 91552-A1020 – Bolt (Qty: 2)
Engine hoist (Qty: 2) or Hydraulic mini crane (Qty 2)
Engine sling (Qty: 2)
Protective eyewear
Protective gloves
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
° 09325-40010 – Transmission oil plug (Transmission A340E)
° 09610-20012 – Pitman arm puller (2WD)
° 09628-62011 – Ball joint puller (4WD, Pre-Runner)
° 09520-32040 – A component of SST 09520-24010, Differential side gear shaft puller
° 09520-01010 – Drive shaft remover attachment
° 09628-00011 – Ball joint puller
° 09922-10010-01 – Variable open wrench
Standard hand tools
Techstream
Torque wrench
Torx® T55H socket
Socket wrench 36mm
Hexagon wrench 8, 10
Deep socket wrench 10, 12, 14, 17, 19mm
Union Nut Wrench 10mm
Weights
Drill
B. SUPPLIES
•
•
•
•
•
•
•
Toyota Genuine ATF WS or DEXRON® lll (DEXRON® ll) – As needed
Hypoid gear oil API GL-5 SAE 75W-90 – 1.5 liter (4wd Only)
R134a refrigerant – As needed
Toyota DOT 3 brake fluid – 3 pints
Toyota long life coolant – 2 gallons
Paint Marker
MP Grease
2
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 select the appropriate
campaign/vehicle, enter the VIN, and the correct part numbers to order will be displayed. The website is
for part(s) application reference only and won’t order the parts, confirm campaign completion status,
or confirm campaign applicability.
•
•
•
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.
Note: When first logging in; enter your dealer code and the default password; XXXXX. Upon logging
in the website will ask for you to reset the password and provide an email address.
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
04001-76104
04001-76204
04001-76304
04001-76404
04001-76504
04001-76604
04001-76704
04001-77604
04001-76904
04001-77104
04001-77204
04001-77304
04001-77404
04001-77504
04006-63104
04006-63204
04006-63304
04006-63404
04006-63504
04006-63604
04006-63704
04006-63804
04006-63904
04006-64104
04006-64204
04006-64304
04006-64404
04006-64504
Part Description
(RCB 2WD 2TR 5MT or 4AT 05-08MY)
(ACB 2WD 2TR 5MT or 4AT 05-08MY)
(ACB 2WD 1GR 6MT 05-08MY)
(RCB 4WD 2TR 5MT 05-08MY)
(ACB 4WD 2TR 5MT 05-08MY)
(ACB 4WD 1GR 6MT or 5AT 05-08MY)
(DCB 4WD 1GR 6MT or 5AT 05-08MY)
(RCB Prerunner 2WD 2TR 5MT 05-08MY)
(ACB 2WD 2TR 5MT 05-08MY)
(ACB 2WD 1GR 5AT 05-08MY)
(ACB 2WD 1GR 6MT 05-08MY)
(DCB 2WD 1GR 5AT 05-08MY)
(DCB 2WD 1GR 5AT Super Long 05-08MY)
(DCB 4WD 1GR 5AT super long 05-08MY)
(RCB 2WD 2TR 5MT or 4AT 09 -10 MY)
(ACB 2WD 2TR 5MT or 4AT 09 -10 MY)
(ACB 2WD 1GR 6MT 09 -10 MY)
(RCB 4WD 2TR 5MT 09 -10 MY)
(ACB 4WD 2TR 5MT 09 -10 MY)
(ACB 4WD 1GR 6MT or 5AT 09 -10 MY)
(DCB 4WD 1GR 6MT or 5AT 09 -10 MY)
(RCB Prerunner 2WD 2TR 5MT 09-10 MY)
(ACB 2WD 2TR 5MT 09-10 MY)
(ACB 2WD 1GR 5AT 09-10 MY)
(ACB 2WD 1GR 6MT 09-10 MY)
(DCB 2WD 1GR 5AT 09-10 MY)
(DCB 2WD 1GR 5AT Super Long 09-10 MY)
(DCB 4WD 1GR 5AT Super Long 09-10 MY)
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Illustration Name
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Page
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
3
Individual Parts (Continued):
Part Number
Part Description
Quantity
Illustration Name
Page
43425-04040
47323-04160
47324-04120
47325-04160
47325-04170
47325-04180
47325-04190
47325-04200
47325-04210
47326-04130
47326-04140
47326-04150
47326-04160
47326-04170
47326-04180
Ring, Drive Shaft Snap
Tube, RR Brake, No.3
Tube, RR Brake, No.4
Tube, RR Brake, No.5 (05-08MY)
Tube, RR Brake, No.5 (05-08MY)
Tube, RR Brake, No.5 (05-08MY)
Tube, RR Brake, No.5 (09-10MY)
Tube, RR Brake, No.5 (09-10MY)
Tube, RR Brake, No.5 (09-10MY)
Tube, RR Brake, No.6 (05-08MY)
Tube, RR Brake, No.6 (05-08MY)
Tube, RR Brake, No.6 (05-08MY)
Tube, RR Brake, No.6 (09-10MY)
Tube, RR Brake, No.6 (09-10MY)
Tube, RR Brake, No.6 (09-10MY)
Arm Sub-Assy, Suspension LWR RH w/ Bush
Arm Sub-Assy, Suspension LWR RH w/ Bush
Arm Sub-Assy, Suspension LWR LH w/ Bush
Arm Sub-Assy, Suspension LWR LH w/ Bush
Spring Assy, RR RH
Spring Assy, RR RH
Spring Assy, RR RH
Spring Assy, RR LH
Spring Assy, RR LH
Spring Assy, RR LH
Bumper Sub-Assy, FR Spring
Bumper Sub-Assy, FR Spring
Wire, Skid Control Sensor
Wire, Skid Control Sensor
Wire, Skid Control Sensor
Wire, Skid Control Sensor
Bolt, U
Bolt, U
Bolt, U
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Bolt, w/ Washer
Nut, Flange
Nut
Pin, w/ Hole
Clip
Clamp
Clamp
Clamp
Carrier Assy, Spare Wheel
Carrier Assy, Spare Wheel
Seal, Frame Side Rail, RH*
Seal, Frame Side Rail, LH*
Nut w/Flange*
Bolt with Washer*
Clip
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Front Suspension
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
10
12-14
12-14
12,15
13,16
14,17
1
1
1
1
Front Suspension
Front Suspension
Front Suspension
Front Suspension
9
10
9
10
1
1
1
1
1
1
2
2
1
1
1
1
4
4
4
4
2
4
9
2
4
4
1
1
2
3
4
1
1
1
1
2
2
2
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Front Suspension
Front Suspension
ABS
ABS
ABS
ABS
Rear Suspension
Rear Suspension
Rear Suspension
Rear Suspension
Propeller Shaft
Front Suspension
Brake Tubes
Under Cover
Front Suspension
Fuel Tank
Shift Lever
Shift Lever
Brake Tubes
Brake Tubes
Brake Tubes
Spare Tire Carrier
Spare Tire Carrier
No Illustration
No Illustration
No Illustration
No Illustration
No Illustration
11
11
11
11
11
11
9
9
19
19
19
19
11
11
11
11
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TSB/Document ID: ZH6_Tacoma Frame
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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