21

Propeller Shaft

22

1GR-FE Exhaust System

2TR-FE Exhaust System

23

Shift Lever

Radiator

Air Conditioning

Front Bumper

Rear Bumper

Molding

24

Rear Wheel House Liner

Molding

Moulding Continued…

25

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

26

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.
Tacoma 05 to 10

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

27

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:
• 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.

28

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.

29

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.

30

31

32

C. REMOVE THE BED ASSY
•
•
•
•
•

If the frame is perforated, ONLY raise the vehicle high enough to remove the tires.
For added safety and support place jack stands under the front and rear portions of the frame.
DO NOT work directly underneath the vehicle when performing bed assy removal.
The actual vehicle specs, equipment and parts required may differ than what is shown. Please
use the correct specifications and parts for the model you are working on.
For additional repair information, please reference the appropriate repair manual found on TIS for
the vehicle you are working on.

1. CENTER THE VEHICLE BETWEEN THE LIFT ARMS
a) Verify the vehicle is aligned with the center point of the lift to prevent interference and damage to the
frame and/or lift.
2. REMOVE THE FOLLOWING PARTS
•
•
•
•
•

Rear Bumper Assy
Rear Tail/Combination Light LH/RH
Rear Mudguard LH/RH (If Equipped)
Side Step Assy LH/RH (If Equipped)
Rocker Panel Molding LH/RH (If Equipped)

•
•
•
•

Body Rocker Panel Molding Assy LH (If Equipped)
Outside LH Back Door Molding Sub-Assy (If Equipped)
Quarter Panel Wheel Opening Molding LH
Left Rear Wheel Well Liner

NOTE: Be careful not to damage the rear tail/combination lights when removing them.
3. REMOVE THE WIRE HARNESS
a) Disconnect the clamps, connectors and the frame wire
harness from the bed assy.
NOTE:
• The number of connectors may differ depending on
the vehicle specification.
• Be careful not to damage the wire harness clamps
when removing them.
4. DISCONNECT THE FUEL INLET PIPE SUB-ASSY
a) Remove the bolt and disconnect the fuel inlet pipe subassy.

5. REMOVE THE BED ASSY
a) Using a Torx® T55H Socket, remove the 6 Torx ® bolts
from the bed assy.
NOTE:
• Use 4 or more people to remove the bed assy from
the frame.
• Evenly support the bed assy when removing it.
• Be careful not to damage the filler tubes when
removing the bed.

33

D. DISCHARGE THE FUEL SYSTEM PRESSURE
•
•
•

DO NOT disconnect any part of the fuel system until you have discharged the fuel system
pressure.
Even after discharging the fuel system pressure, place a piece of cloth around the tubes, 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.
For additional repair information, please reference the appropriate repair manual in TIS for the
vehicle you are working on.

1. CHECK FOR DTCs
2. RECORD THE RADIO STATION PRESETS
3. DISCHARGE THE FUEL SYSTEM PRESSURE

a) Remove the No. 2 fuel tank protector. (If Equipped)

b)
c)
d)
e)

Disconnect the fuel pump connector.
Start the engine.
After the engine, has stopped, turn the ignition switch OFF.
Crank the engine again to check that it does not start.

NOTE: Please make sure to follow the procedure listed
above. This will prevent a large amount of gasoline
from spilling out when high pressure fuel tube is
disconnected.

4. DISCONNECT THE NEGATIVE (-) BATTERY TERMINAL

NOTE: Wait 90 seconds after the negative (-) terminal cable is disconnected from the battery before
proceeding. Doing so will prevent the SRS from being deployed (i.e. airbag, seat belt pretensioner,
etc.).

34

E. REMOVE THE CAB BODY ASSY
•
•
•
•
•

If the frame is perforated, ONLY raise the vehicle high enough to remove the tires.
For added safety and support place jack stands under the front and rear portions of the frame.
DO NOT work directly underneath vehicle when performing cab 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 the appropriate repair manual in TIS for the
vehicle you are working on.

1. REMOVE THE ENGINE UNDER COVERS
NOTE: Use precaution when performing this step, as you will need to work underneath the vehicle.
2. EVACUATE THE REFRIGERANT FROM THE AIR CONDITIONING SYSTEM
3. DRAIN THE FOLLOWING FLUIDS
•
•

Coolant (including engine block)
Brake Fluid

•
•

Clutch Fluid (Manual Transmission Vehicles Of 1GR-FE Only)
Front Differential Fluid (4WD Only)

NOTE: DO NOT remove the radiator cap while the radiator and engine are hot, doing so may cause
the coolant to spray out causing potential injuries.
4. REMOVE THE FOLLOWING BODY COMPONENTS
•
•
•

Radiator Grille
Front Bumper Filler LH/RH
Front Fender Mudguard LH/RH

•
•
•

Front Bumper Assy
Front Bumper Reinforcement
Front No.2 Bumper Extension Sub-assy LH/RH

5. REMOVE THE FOLLOWING INTERIOR COMPONENTS
•
•

Front Door Scuff Plate LH/RH
Front Floor Footrest

•

Cowl Side Trim Board LH/RH

6. REMOVE THE INSTRUMENT PANEL BOX

35

7. DISCONNECT THE FRAME WIRE HARNESS
a) Disconnect the 5 clamps.
b) Disconnect the connector(s).
c) Remove the frame wire harness grommet from the cab
assy.
d) Pull out the frame wire harness from the vehicle cab
assy.
NOTE: The number of connectors may differ
depending on the model.

8. REMOVE THE GLOVE BOX AND LOWER INSTRUMENT
PANEL FINISH PANEL
a) Remove the glove box.
b) Remove the bolt and the lower instrument panel finish
panel.

9. DISCONNECT THE ENGINE WIRE HARNESS
a) Disconnect each connector and clamp from the ECM
and remove the engine wire harness.
NOTE: The number of connectors may differ
depending on the model.

10. REMOVE THE FOLLOWING PARTS
• Rear Console Box (for Separate Seat Type)
• Front Console Box

•
•

Voltage Inverter Assy (If Equipped)
Manual Transmission Shift Lever (Manual Trans Vehicles Only)

36

11. DISCONNECT THE PARKING BRAKE CABLES
For Separate Seat Type:
a) Remove the 2 clips.
b) Disconnect the 2 parking brake cables.

For Bench Seat Type:
c) Turn back the floor carpet.
d) Remove the 3 bolts and the parking brake cable joint
protector.

e) Remove the 2 clips.
f) Disconnect the 2 parking brake cables.

12. REMOVE THE FOLLOWING PARTS
•

V-Bank Cover (1GR-FE Only)

•

Air Cleaner Hose and Air Cleaner Assy

13. DISCONNECT THE NO.2 ENGINE WIRE HARNESS
a) Remove the nut and disconnect the (+) positive battery
cable.
b) Remove the bolt and disconnect the ground wire.
c) Disconnect the 2 clamps.

d) Remove the No.1 upper relay block cover.
e) Disconnect the 3 connectors.
f) Remove the nut and disconnect the fuse box wire
harness.

37

LH Side

14. DISCONNECT THE SKID CONTROL SENSOR WIRE
HARNESS
a) Disconnect the harness clamp and front skid control
sensor connector.
b) Repeat the procedure on the opposite side.

RH Side

15. DISCONNECT THE FRONT DIFFERENTIAL BREATHER
TUBES (4WD ONLY)
a) Disconnect the front differential breather tubes.
NOTE: There may be 2 front differential breather tubes
depending on the vehicle model.

16. DISCONNECT THE FUEL PIPES AND VAPOR FEED
HOSE
a) Remove the 2 fuel pipe clamps.
b) Disconnect the No. 1 and No. 2 fuel pipe.
NOTE: Put a shop towel under the fuel pipe to catch
any spilled fuel.

17. DISCONNECT THE VACUUM HOSE
a) Disconnect the vacuum hose.

38

18. REMOVE THE FOLLOWING PARTS
• Radiator Support to Frame Seal
• Radiator Inlet Hose
• Radiator Outlet Hose

•
•

Fan Shroud
Radiator Assy

19. DISCONNECT THE NO.1 HOSE (2TR-FE ONLY)
a) Disconnect the No.1 hose.
20. DISCONNECT THE GROUND WIRE (2TR-FE ONLY)
a) Remove the bolt and disconnect the ground wire.
21. DISCONNECT POWER STEERING PUMP OIL
RESERVOIR ASSY (1GR-FE ONLY)
a) Disconnect power steering pump oil reservoir assy.
22. DISCONNECT THE GROUND WIRE (1GR-FE ONLY)
a) Remove the bolt and disconnect the clamp and the
ground wire.
23. DISCONNECT THE ENGINE WIRE HARNESS
a) Disconnect the clamp.
b) Remove the engine wire harness container from the
cowl panel.

24. DISCONNECT THE WATER / HEATER HOSES, ENGINE SIDE
LH Side

25. REMOVE THE FRONT FENDER APRON SEALS
4WD, Pre-Runner Only (Shown):
a) Remove the 20 clips and 4 front fender apron seals.

2WD Only:
b) Remove the 22 clips and 4 front fender apron seals.

RH Side

39

26. DISCONNECT THE AIR CONDITIONING DISCHARGE AND SUCTION HOSES FROM THE
COMPRESSOR
LH Side

27. DISCONNECT THE FRONT BRAKE TUBES
a) Disconnect the front brake tube.
b) Repeat the procedure on the opposite side.

RH Side

28. DISCONNECT THE STEERING SLIDING YOKE
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
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, to prevent damage to the
spiral cable.
c) Place match marks on the steering sliding yoke and
No.2 intermediate shaft.
d) Loosen bolt (A) and remove bolt (B).
e) Disconnect the steering sliding yoke from the No.2
intermediate shaft.
NOTE: If the steering sliding yoke is stuck, tap it from
below with a brass hammer to disconnect it.

29. DISCONNECT THE SHIFT CABLE (AUTO TRANS ONLY)
Cable Type:
a) Remove the clip.
b) Remove the nut and disconnect the shift cable.
Rod Type:
c) Remove the pin and clip, disconnect the shift cable.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.

40

30. DISCONNECT THE CLUTCH RELEASE CYLINDER ASSY
(2TR –FE MANUAL TRANS ONLY)
a) Remove the bolt and disconnect the clutch hose.
b) Remove the 2 bolts and disconnect the clutch release
cylinder.
NOTE: Use precaution when performing this step, as you