Bolt, Flange

Qty
2

2. Skip to step #4 on page 55

53

c) Install Frame Seal with Predrilled Hole w/o Weld Nut
1. Using tape secure bolt and washer to the back
of the frame as shown.
Note: Using the tape will prevent the bolt from falling back
into the frame rail when installing the seal and will
prevent the bolt from spinning when torqueing the
nut.
Part #
90119-A0170
90178-A0024

Part Name
Bolt, Flange
Nut

Qty
2
2

2. Install the frame seal and torque the nut to spec
Torque Spec: 18.5 N∙m (14.0 ft∙lbf)
3. Skip to Step #4 on page 55

d) Install Frame Seal with No Hole in Frame
1. Using the template in the appendix of this TI
mark the hole on the inner frame rail for both
the left and right side frame rail.
2. Use a center punch to give the drill bit a pilot to
prevent wandering while drilling.
3. Drill the frame with a 10mm bit (3/8”).
4. Debur the hole to remove all the sharp metal
burrs.
Note: A deburring tool was previously provided
for safety recall D0C. This tool works well to
remove these sharp burrs.
5. Using tape secure bolt and washer to the back
of the frame as shown.
Note: Using the tape will prevent the bolt from
spinning when torqueing the nut.
Part #
90119-A0170
90178-A0024

Part Name
Bolt, Flange
Nut

Qty
2
2

6. Install the frame seal and torque the nut to
spec.
Torque Spec: 18.5 N∙m (14.0 ft∙lbf)

54

H. ASSEMBLE THE FRAME
NEW Replacement Parts
Part Name
Holder, Body Support
51719-04010
Bracket
Part #

1. INSTALL THE NEW CLIPS
Kit #

Qty

2

2

2. REINSTALL THE NO.1 RECEIVER HITCH ATTACHMENT
REINFORCEMENT (IF EQUIPPED)
a) Reinstall the No.1 receiver hitch attachment
reinforcement with the 2 bolts and torque to spec.
Torque Spec: 45 N∙m (459 kgf∙cm, 33 ft∙lbf)

3. REINSTALL THE NO.1 REAR SPRING BUMPER
(2WD ONLY)
a) Reinstall the rear spring bumper with the 2 nuts and
torque to spec.
b) Repeat the procedure on the opposite side.
Torque Spec: 15 N∙m (153 kgf∙cm, 11 ft∙lbf
NEW Replacement Parts
Part #
90119-A0151

Part Name
Bolt, w/ Washer

*Individual Part(s)

4. REINSTALL THE PROPELLER SHAFT HEAT INSULATOR
(IF EQUIPPED)
Kit #
NA*

Qty
2

a) Reinstall the propeller shaft heat insulator with the 2
NEW bolts and torque to spec.
Torque Spec: 15.7 N∙m (160 kgf∙cm, 12 ft∙lbf)

5. REINSTALL THE PARKING BRAKE CABLE HEAT
INSULATOR (IF EQUIPPED)
a) Reinstall the parking brake cable heat insulator with
the 2 bolts and torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)

55

6. REINSTALL THE OXYGEN SENSOR BRACKETS
(2TR-FE ONLY)
a) Reinstall the 2 brackets with the 2 bolts and torque to
spec.
Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft∙lbf)
7. REINSTALL THE REAR ENGINE MOUNTING
REINFORCES (1GR-FE ONLY)
a) Reinstall the rear engine mounting reinforces with
the 2 bolts and torque to spec.
Torque Spec: 31 N∙m (316 kgf∙cm, 23 ft∙lbf)
NEW Replacement Parts
Part #
90119-A0192
90119-A0193

Part Name
Bolt, w/ Washer
Bolt, w/ Washer

*Individual Part(s)

8. REINSTALL THE HOOK
Kit #
8
NA*

Qty
2
2

a) Reinstall the hook with the 2 NEW bolts and torque
to spec.
Torque Spec: 70 N∙m (714 kgf∙cm, 52 ft∙lbf)

9. REINSTALL THE FRAME AUXILIARY CROSSMEMBER
EXTENSION (IF EQUIPPED)
a) Reinstall the 2 frame auxiliary crossmember

extensions with the 2 bolts and torque to spec.
Torque Spec: 45 N∙m (459 kgf∙cm, 33 ft∙lbf)
10. REINSTALL THE CAB MOUNTS
a) Reinstall cab mounts No.1
b) Reinstall cab mounts No.2 and No.3 with the 8 bolts
and torque to spec.
Torque Spec: 61 N∙m (622 kgf∙cm, 45 ft∙lbf)

56

11. INSTALL THE NEW FRONT SUSPENSION LOWER ARM (2WD ONLY)
a) Install the NEW front suspension lower arm with the 2 NEW nuts, 2 NEW No.1 camber adjust cams and 2
NEW No.2 camber adjust cams, then torque to spec. 2WD Only
Torque Spec: 210 N∙m (2141 kgf∙cm, 155 ft∙lbf)
b) Repeat the procedure on the opposite side.
Part #
48068-04030
48069-04030
48190-25010
48198-25010
90178-A0013

NEW Replacement Parts
Part Name
Arm Sub-Assy, Suspension
LWR RH w/Bush
Arm Sub-Assy, Suspension
LWR LH w/Bush
Cam Assy, Camber Adjust
Cam, Camber Adjust No. 2
Nut, Flange
*Individual Part(s)

Kit #

Qty

NA*

1

NA*

1

4
4
NA*

4
4
4

12. INSTALL THE NEW FRONT SUSPENSION LOWER ARM (4WD, PRE-RUNNER ONLY)
a) Install the NEW front suspension lower arm with the NEW bolt, nut, NEW toe adjust cam, NEW No.2 toe
adjust cam, NEW No.1 camber adjust cam and NEW No.2 camber adjust cam, then torque to spec.
Torque Spec: 135 N∙m (1377 kgf∙cm, 100 ft∙lbf)
b) Repeat the procedure on the opposite side.
4WD, Pre-Runner Only

NEW Replacement Parts
Part #
48068-04040
48069-04040
48190-60020
48198-60011
48409-60020
48452-35020
90119-A0166

Part Name
Kit #
Arm Sub-Assy, Suspension
NA*
LWR RH w/Bush
Arm Sub-Assy, Suspension
NA*
LWR LH w/Bush
Cam Assy, Camber Adjust
5
Cam, Camber Adjust No. 2
5
Cam Sub- Assy, Toe Adjust
5
Plate, Toe Adjust, No. 2
5
Bolt, w/ Washer
8
*Individual Part(s)

Qty
1
1
2
2
2
2
2

NEW Replacement Parts (2WD Only)
Part #
Part Name
Kit # Qty
48304-04090
NA*
2
Bumper, Sub-Assy FR
Spring**
48304-AD010
NA*
2
*Individual Part(s)
**Only 1 part used, part number varies by vehicle type.

13. INSTALL THE NEW FRONT SPRING BUMPER
a) Using the SST 09922-10010-01, install the NEW front
spring bumpers and torque to spec.
Torque Spec: 31 N∙m (316 kgf∙cm, 23 ft∙lbf)
b) Repeat the procedure on the opposite side.

NEW Replacement Parts
( 4WD, Pre-Runner Only )
Part #
Part Name
Bumper, Sub-Assy FR
48304-04100
Spring

Kit #

Qty

8

2

57

14. INSTALL THE NEW REAR BRAKE TUBES
a) Install the NEW rear brake tubes with the NEW clamp(s).
Part #
47325-*****
47326-*****
90469-A0004
90469-A0004
90469-A0004
90949-A1006

NEW Replacement Parts
Part Name
Tube, RR Brake, No.5**
Tube, RR Brake, No.6**
Clamp (Regular Cab)
Clamp (Access Cab)
Clamp (Double Cab)
Clamp
*Individual Part(s)

Kit #
NA*
NA*
NA*
NA*
NA*
2

Qty
1
1
2
3
4
3

Kit #

Qty

1

1

15. REINSTALL THE NO. 2 CHARCOAL CANISTER PIPE

NEW Replacement Parts
Part #
77285-35760

Part Name
Support, Fuel Return &
Main Tube

NEW Replacement Parts
Part #
90119-A0169
51900-35410
81900-35420

Part Name
Kit # Qty
Bolt, w/ Washer
2
4
NA*
1
Carrier Assy, Spare
Wheel**
NA*
1
*Individual Part(s)
**Only 1 part used, part number varies by vehicle type.

a) Install the NEW fuel return and main tube support.
b) Reinstall the No.2 charcoal canister pipe.

16. INSTALL THE NEW SPARE TIRE CARRIER ASSY
a) Install the NEW spare tire carrier assy with the 4 NEW
bolts and torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)

17. INSTALL LEAF SPRINGS
4WD and PreRunner
a) Reinstall leaf springs and shacke and torque to spec.
Torque Spec: 120 N∙m (1224 kgf∙cm, 89 ft∙lbf)
2WD
b) Install the NEW rear leaf springs with the all NEW parts
(shackle, bushings, bolts, washers and nuts) and torque
to spec.
Torque Spec: 120 N∙m (1224 kgf∙cm, 89 ft∙lbf)
Part #
04483-04080
90080-10138
90178-A0050
94622-51400
Varies**
Varies**

Part Name
Shackle Kit, RR Spring
Bolt, Flange
Nut, Flange
Washer, Plain
Spring Assy, RR RH
Spring Assy, RR LH

Kit #
2
2
2
1
NA*
NA*

Qty
2
2
2
2
1
1

c) Repeat the procedure on the opposite side.

58

18. REINSTALL THE FOLLOWING PARTS
•

NEW Replacement Parts
Rear Differential Assy
Part #
90117-A0001
90117-A0002
90117-A0005
90178-A0050
90178-51400

Part Name
Bolt, U**

Kit #
NA*
NA*
NA*
2
1

Qty
4
4
4
8
8

Kit #
2

Qty
2

•

Nut, Flange
Washer, Plain
*Individual Part(s)
**Only 1 part used, part number varies by vehicle type.
Rear Shock Absorber Assy

Part #
90117-A0010

Part Name
Nut, Lock

•

Rear Stabilizer Bar
Part #
90119-08A91

Part Name
Bolt, w/ Washer
*Individual Part(s)

Kit #
NA*

Qty
4

Kit #

Qty

2

1

NEW Replacement Parts
Part #
47355-04020
90119-A0169
90468-A0007

Front Side

Part Name
Bracket, Flexible Hose,
No. 2
Bolt, W/ Washer
Clip
*Individual Part(s)

Rear Differential Assy
° Reinstall with the 4 NEW U -bolts (2WD), 2 spring
seats, 2 spring bumpers (If Equipped), 8 NEW flange
nuts and 8 NEW plain washers, then torque to spec.
° Torque Spec: 50 N∙m (510 kgf∙cm, 37 ft∙lbf)
Rear Shock Absorber Assy
° Reinstall rear shock absorber assy with the bolt, nut
and washer. (Lower side)
° Torque Spec: Nut - 58 N∙m (591 kgf∙cm, 43 ft∙lbf)
° Reinstall the 3 retainers, 2 cushions and NEW nut,
then torque to spec. (Upper side)
° Torque Spec: Nut - 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
° Repeat the procedure on the opposite side.
Rear Stabilizer Bar (If Equipped)
° Reinstall with the 2 brackets and NEW 4 bolts, then
torque to spec.
° Torque Spec: 27 N∙m (275 kgf∙cm, 20 ft∙lbf)
° Reconnect the 2 stabilizer bar links with the 4 nuts,
then torque to spec.
Torque Spec: 65 N∙m (663 kgf∙cm, 48 ft∙lbf)

19. RECONNECT THE BRAKE HOSE

13
or
NA*
2

2
2

a) Install the NEW No.2 flexible hose bracket with the 2
NEW bolts.
b) Reconnect the 2 brake hoses with the 2 NEW clips.
c) Reconnect the No.5, No.6 rear brake tubes and torque to
spec.
Torque Spec:
Flexible hose bracket - 29 N∙m (296 kgf∙cm, 21 ft∙lbf)
Rear brake tube - 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)

Rear Side

20. REINSTALL THE HARNESS BRACKETS
a) Reinstall the 2 brackets with the 2 bolt and torque to
spec.