will need to work underneath the vehicle.
31. DISCONNECT THE NO.1 CLUTCH HOSE
(1GR-FE MANUAL TRANS ONLY)
a) Disconnect the clutch release cylinder tube from the
clutch hose.
b) Remove the clip and disconnect the clutch hose.
32. DISCONNECT THE NO.2 FUEL HOSE
a) Remove the clip and disconnect the No.2 fuel hose.

NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.

33. DISCONNECT THE FUEL TANK TUBES
a) Remove the fuel pipe clamp.
b) Disconnect the 2 fuel tank tubes.

NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.

34. DISCONNECT THE REAR BRAKE TUBES
a) Disconnect the 2 rear brake tubes.
b) Remove the bolt and disconnect the 2 way.

NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.

35. DISCONNECT THE PARKING BRAKE CABLES
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.

41

36. REMOVE THE FOLLOWING PARTS
• Floor Board No.1/No.2 (Access Cab Only)
• Seat Floor Box (Access Cab Only)
• Rear Floor Side Service Hole Cover LH/RH

•
•

Luggage Compartment Side Tray (Double Cab Only)
No.1 w/ Box Speaker Assy (If Equipped)

(Access Cab Only)
37. REMOVE THE CAB BODY ASSY USING AN ABOVE GROUND LIFT
a)
b)
c)
d)
e)
f)
g)
h)

Remove the 6 nuts and 6 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.
Mark the location of the tires so it will be easier to install the cab onto the new frame.
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 vehicle.
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.
• The center of gravity of the cab body may become nose heavy depending on placement of the lift
arm which could cause the cab to fall when lifted. To prevent this, use weights to establish a
balance and secure the cab body to the lift arm using ratchet tie down belts.
• DO NOT work directly underneath the vehicle when pulling the frame assy out from under.
• DO NOT remove the cab mount bolts, they will be used as guides during cab assy reinstallation.

42

F. DISASSEMBLE THE FRAME
1. PLACE THE FRAME ON A LIFT
a) Place the 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 removed.
•

Ratcheting Tie Downs: Qty 1 (Length: 2 in X 27 ft and Min. Work Load Capacity: 3,000 lbs)

2. REMOVE THE FOLLOWING PARTS
• Wheels
• Propeller Shaft Heat Insulator (If Equipped)
• Front Propeller Shaft Assy (4WD Only)
• Exhaust Pipe Stopper Bracket (If Equipped)
• Rear Propeller Shaft Assy
• Insert SST 09325-40010 into trans after the Rear Prop Shaft is removed to prevent oil leakage (2WD Only)

NOTE: Place match marks on the front (if equipped) and rear propeller shafts prior to removal.
3. REMOVE THE EXHAUST SYSTEM (1GR-FE ONLY)
a) Remove the 2 bolts and 4 exhaust pipe supports.
b) Remove the center exhaust pipe assy and exhaust pipe
supports.
c) Remove the exhaust pipe gasket.

d) Disconnect the 2 oxygen sensor connectors.
e) Remove the 6 nuts and 2 exhaust pipe supports.
f) Remove the front exhaust pipe assy and exhaust pipe
supports.
g) Remove the 2 exhaust pipe gaskets.

4. REMOVE THE EXHAUST SYSTEM (2TR-FE ONLY)
a)
b)
c)
d)
e)
f)
g)
h)

Remove the 2 bolts and 4 exhaust pipe supports.
Remove the center exhaust pipe assy and exhaust pipe supports.
Remove the exhaust pipe gasket.
Disconnect the 2 oxygen sensor connectors.
Disconnect the 2 oxygen sensor wire harness clamps.
Remove the 2 bolts and exhaust pipe support.
Remove the front exhaust pipe assy and exhaust pipe supports.
Remove the 2 exhaust pipe gaskets.

43

5. REMOVE THE FOLLOWING PARTS
• No.1 Fuel Tank Protector Assy (If Equipped)
• Fuel Tank Strap
• Fan /V-belt

• Fuel Tank
• Charcoal Canister Assy

6. REMOVE AND SET ASIDE THE POWER STEERING PUMP ASSY
a) Disconnect the connector.
b) Disconnect the clamp. (1GR-FE Only)
c) Remove the bolt and disconnect the ground wire. (1GR-FE Only)
d) Remove the 2 bolts and the power steering vane pump.
NOTE:
• DO NOT disconnect the power steering pump hoses or tubes.
• Keep the power steering pump reservoir upright to prevent the fluid from leaking out.
7. REMOVE THE FOLLOWING PARTS
•
•

Intake Air Surge Tank (1GR-FE Only)
Intake Air Connector (2TR-FE Only)
8. DISCONNECT THE OIL COOLER TUBE (AUTO TRANS
ONLY)
a) Remove the bolts and disconnect the oil cooler tube.

LH Side

9. REMOVE THE ENGINE AND TRANSMISSION ASSY
a) Remove the bolt and disconnect the ground wire.
(LH Side)
b) Disconnect the connector and clamp. (4WD Only)
c) Disconnect and remove the necessary items/parts to
prepare the engine and transmission assy for removal.
d) Install the engine hanger.

4WD Only

For 1GR-FE:
12281-31060 = No.1 Engine Hanger
12282-31040 = No.2 Engine Hanger
90119-08A87 = 4 Bolts
For 2TR-FE:
12281-75040 = No.1 Engine Hanger
12281-75040 = No.2 Engine Hanger
91552-A1020 = 2 Bolts

44

e) Remove the engine and transmission assy.
NOTE:
• ALWAYS use 2 engine hoists/cranes to lift it.
• DO NOT use 1 engine hoist/crane to lift the engine
& transmission assy, as the unbalanced weight
may lead to an accident or injury.
• ONLY use engine hoists/cranes that can properly
support the weight of the engine and transmission
assy.
• Carefully adjust the 2 engine hoists/cranes used so
that the engine and transmission assy is properly
balanced.
10. DISCONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS (2WD ONLY)
a) Remove the bolt, disconnect the clamp and skid control
sensor wire harness.
b) Repeat the procedure on the opposite side.

11. DISCONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS (4WD, PRE-RUNNER ONLY)
a) Remove the bolt and disconnect the skid control sensor
wire harness.
b) Repeat the procedure on the opposite side.

12. DISCONNECT THE FRONT BRAKE HOSE (2WD ONLY)
a) Disconnect the front brake tube from the brake hose.
b) Remove the 2 bolts and disconnect the front brake
hose and flexible hose bracket.
c) Repeat the procedure on the opposite side.

13. DISCONNECT THE FRONT BRAKE HOSE
(4WD, PRE-RUNNER ONLY)
a) Disconnect the front brake tube from the brake hose.
b) Remove the bolt and disconnect the front brake hose
and flexible hose bracket.
c) Repeat the procedure on the opposite side.

45

14. REMOVE THE FOLLOWING PARTS
•
•

•
•

Front Axle Hub Grease Cap (4WD Only)
Front Axle Shaft Nut (4WD Only)

Tie Rod End*
Front Stabilizer Link Assy

* SST 09610-20012 (2WD), SST 09628-62011 (4WD, Pre-Runner) disconnect the tie rod end.
15. REMOVE THE FRONT SUSPENSION UPPER ARM AND
STEERING KNUCKLE ASSY (2WD ONLY)
a) Remmove the 2 bolts (A).
b) Remove the 2 bolts (B), 2 nuts, 2 washers and front
suspension upper arm w/ steering knuckle.
c) Repeat the procedure on the opposite side.

16. REMOVE THE FRONT SUSPENSION UPPER ARM AND
STEERING KNUCKLE ASSY (4WD, PRE-RUNNER ONLY)
a) Remove the 2 bolts (A).
b) Remove the bolt (B), nut, 2 washers and front
suspension upper arm w/ steering knuckle.
c) Repeat the procedure on the opposite side.
NOTE: If the drive shaft is difficult to disconnect, tap
the drive shaft loose with a plastic hammer.
17. REMOVE THE FOLLOWING PARTS
•
•
•
•

Front Drive Shaft Assy (4WD Only) *
Front Suspension Member Brace Sub-Assy
Front Stabilizer Bar
Front Shock Absorber Assy
°
°
°

•
•
•
•

Power Steering Link Assy w/ Pump
Front Differential Carrier (4WD Only)
Lower Ball Joint**
Front Spring Bumper***

*SST 09520-24010 (09520-32040),09520-01010
**SST 09628-00011
***SST 09922-10010-01

NOTE:
• When removing the power steering link with the pump, have one person support the power
steering link and the other support the pump and keep it upright to avoid fluid leakage.
• 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.
18. REMOVE THE PARKING BRAKE CABLES
a) Remove the 8 bolts and parking brake cables.

46

19. REMOVE THE FRAME WIRE HARNESS
a) Remove the bolt and disconnect the ground wire
(If Equipped).
b) Disconnect the clamps and remove the frame wire
harness.
NOTE:
• The number of wire harness clamps will differ
depending on the vehicle specification.
• Take care not to damage or break the wire harness
clamps during removal.
Front Side

20. REMOVE THE HARNESS BRACKETS
a) Remove the 2 bolts and 2 brackets.

Rear Side

21. DISCONNECT THE BRAKE HOSE
a) Disconnect the No.5 rear brake tube.
b) Disconnect the No.6 rear brake tube.
c) Remove the 2 clips and 2 bolts, disconnect the brake
hose and the No.2 flexible hose bracket.

22. REMOVE THE FOLLOWING PARTS
• Rear Stabilizer Bar (If Equipped)
• Rear Shock Absorber Assy

•
•

Rear Differential Assy
No.1 Rear Spring Bumper (2WD Only)

4WD and PreRunner vehicles will not have leaf springs replaced or will have them replaced
under E02. If the vehicle already had E02 performed there is no need to separate the rear
differential from the leaf springs, remove the leaf springs and rear diff as an assembly.
23. REMOVE THE NO.2 CHARCOAL CANISTER PIPE
a) Disconnect the clamps and remove the No.2 charcoal
canister pipe.

47

24. REMOVE THE FRAME AUXILIARY CROSSMEMBER
EXTENSIONS (IF EQUIPPED)
a) Remove the 2 bolts and frame auxiliary crossmember
extensions.

25. REMOVE THE HOOK
a) Remove the 2 bolts and hook.

26. REMOVE THE REAR ENGINE MOUNTING
REINFORCES (1GR-FE ONLY)
a) Remove the 2 bolts and 2 rear engine mounting
reinforces.

27. REMOVE THE PARKING BRAKE CABLE HEAT
INSULATOR (IF EQUIPPED)
a) Remove the 2 bolts and parking brake cable heat
insulator.

28. REMOVE THE OXYGEN SENSOR BRACKETS
(2TR-FE ONLY)
a) Remove the 2 bolts and 2 brackets.

29. REMOVE THE NO.1 RECEIVER HITCH ATTACHMENT
REINFORCEMENT (IF EQUIPPED)
a) Remove the 2 bolts and No.1 receiver hitch attachment
reinforcement.

48

30. REMOVE THE CLIPS

31. REMOVE THE FOLLOWING PARTS
•
•
•

Front Suspension Lower Arm
Cab Mounts (QTY:6)
Rear Leaf Spring Assy

32. REMOVE THE FRAME FROM THE LIFT
a) Remove the ratcheting tie down strap and the frame from the lift.

49

G. PLUG HOLES IN REPLACEMENT FRAME
1. PLACE THE NEW FRAME ON THE LIFT
Place the NEW frame on the lift, and secure it with a ratcheting tie down strap.
• Ratcheting Tie Downs: Qty 1 (Length: 2 in X 27 ft and Min. Work Load Capacity: 3,000 lbs)
a)

2. INSTALL THE BODY PLUGS (YOU MAY NOT USE ALL THE BODY PLUGS DEPENDING ON THE
FRAME DESIGN)
Note: The illustration shows only the right side if the body plug installation points are positioned similarly for both sides.

Step 4 & 7
Step 3, 5, & 6

Front

STEP ③

Front
90080-46327

Step 3 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.

90950-01983
90950-01987

4WD ONLY

90950-01983×4 90950-01989×2
TLL: 6 or 8 plugs

90950-01989

STEP ④

Front

Front

90950-01992

90950-01990

90950-01989

STEP ⑥

90950-01987×2

90080-46327x2

Step 4 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.

90950-01987×4
TLL: 4 plugs

90950-01987

STEP ⑤

4WD ONLY

Front

Step 5 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.

90950-01989×2
TLL: 6 plugs

90950-01990×2

90950-01992×2

Step 6 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.

90950-01991×2
TLL: 2 plugs
90950-01991

50

STEP ⑦

Front

90950-01991

Step 7 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.
2WD ONLY

2WD ONLY

90950-01A09

90950-01A09×2

90950-01991×2

TLL: 2 or 4 plugs
Step 8 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.

90950-01631×4
TLL: 4 plugs
Step 8 (refer to the following illustration):
b) Install the body plugs as follows into the side-rail.

90950-01984×2
TLL: 4 plugs

90950-01987
TTL: 2 plugs

Step 9 (refer to the following illustration):
c) Install the body plugs as follows into the side-rail.

90950-01931×1
*1) RH is for 2TR engine.
LH is for 1GR engine

TLL: 1 plug

51

Step 10 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.
NOTE:
DO NOT INSTALL THE LOWER TWO PLUGS IF THE VEHICLE HAS
A 120V OUTLET OPTION IN THE BED

90333-20001 (Stickers)
TLL: 10 plugs (4WD and PreRunner) or 2 plugs (2WD)
Step 11 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.

90333-30002 (Stickers)
TLL: 28 plugs (4WD) or 36 plugs (2WD)
Step 12 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.

90950-01990×2
TLL: 2 plugs
Step 13 (refer to the following illustration):
a) Install the one way plug with the channel opening the sides of the
vehicle so that water cannot enter the frame form tire spray.

90950-01A24×2
TLL: 2 plugs

52

Step 14 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.

2WD ONLY

90950-01A09×2
TLL: 2 plugs
Step 15 (refer to the following illustration):
a) Install the body plugs as follows into the side-rail.

2WD ONLY

90950-01A11×2
TLL: 2 plugs

3. INSTALL FRAME RAIL SEAL
a) Inspect the replacement frame on both sides with the
frame seal temporally installed as identified in the
picture. Depending on when the service frame was
produced will determine if the following are present:
•
•
•

Predrilled hole w/weld nut: Proceed to step b)
Predrilled hole w/o weld nut: Proceed to step c)
No hole is present: Proceed to step d)

Note: Both sides of the frame must be inspected
because the hole status may differ from side to
side.

b) Install Frame Seal with Predrilled Hole with Weld Nut
1. Install the frame seal with the bolt.
Torque Spec: 29 N∙m (21.5 ft∙lbf)
Part #
90119-A0170

Part Name