• Floor Board No.1/No.2 (Access Cab)
31. RECONNECT THE PARKING BRAKE CABLES
For Separate Seat Type:
a) Reconnect the 2 parking brake cables.
b) Reinstall the 2 clips.

For Bench Seat Type:
c) Reconnect the 2 parking brake cables.
d) Reinstall the 2 clips.

e) Reinstall the parking brake cable joint protector with the
3 bolts and torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
f)

Turn back the floor carpet.

75

32. REINSTALL THE FOLLOWING PARTS

•
•
•

Manual Transmission Shift Lever (Manual Trans)
Voltage Inverter Assy (If Equipped)
Front Console Box

•
•

Front Console Box
Rear Console Box (for Separate Seat Type)

33. RECONNECT THE ENGINE WIRE HARNESS
a) Reconnect each connector and clamp to the ECM and
engine wire harness.
NOTE: The number of connectors may differ
depending on the model.

34. REINSTALL THE GLOVE BOX AND THE LOWER
INSTRUMENT PANEL FINISH PANEL
a) Reinstall the lower instrument panel finish panel with
the bolt.
b) Reinstall the glove box.

35. RECONNECT THE FRAME WIRE HARNESS
a) Insert the frame wire harness into the cab assy.
b) Reinstall the frame wire harness grommet to the cab
assy.
c) Reconnect the 3 connectors.
d) Reconnect the 3 harness clamps.
e) Reconnect the 2 clamps.

76

36. REINSTALL THE FOLLOWING PARTS

•
•

•
•

Instrument Panel Box
Cowl Side Trim Board LH/RH

Front Floor Footrest
Front Door Scuff Plate LH/RH

37. REINSTALL THE FOLLOWING PARTS

•

NEW Replacement Parts

•

Front No.2 Bumper Extension Sub-Assy LH/RH
Part #
90176-A0044

Part Name
Nut, Flange

Kit #
2

Qty
6

•
•
•
•

Front No.2 Bumper Extension Sub-assy LH/RH
° Reinstall the No.2 front bumper extension with 6
NEW nuts and torque to spec.
° Torque Spec: 58 N∙m (591 kgf∙cm, 43 ft∙lbf)
Front Bumper Reinforcement
° Reinstall the front bumper reinforcement with 6 nuts
and torque to spec.
° Torque Spec: 58 N∙m (591 kgf∙cm, 43 ft∙lbf)
Front Bumper Assy
° Reinstall with the 6 screws and 9 clips.
Front Fender Mudguard LH/RH
Front Bumper Filler LH/RH
Radiator Grille

77

J. REINSTALL THE BED ASSY
1. REINSTALL THE BED ASSY
a) Using a Torx® T55 Socket, reinstall the bed assy Torx ®
bolts and torque to spec.
Torque Spec: 49 N∙m (500 kgf∙cm, 36 ft∙lbf)
NOTE:
• Use 4 or more people to lift the bed assy.
• Evenly support the bed assy when reinstalling it.
• Be careful not to damage or hit the fuel inlet pipe
when reinstalling the bed assy.
2. REINSTALL THE FUEL INLET PIPE SUB-ASSY
a) Reinstall the fuel inlet pipe sub-assy with the 2 nuts and
torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)

3. RECONNECT THE FRAME WIRE HARNESS
a) Reconnect the 6 wire harness clamps to the bed assy.
NOTE:
• The number of connectors will differ depending on
the vehicle spec.
• Use new clamps if the original ones are damaged.
NEW Replacement Parts

Part #
90189-A0002
90189-A0002

Left Rear Wheel Well Liner
Part Name
Grommet, Screw (X-Runner)
Grommet, Screw

4. REINSTALL THE FOLLOWING PARTS
Kit #
9
8

Qty
6
8

Quarter Panel Wheel Opening Molding
Part #
Part Name
Kit #
75395-35070
Clip, Outside Molding, No. 1
8
75396-35020
Clip, Outside Molding, No. 2
8
90189-A0002
Grommet, Screw
8

Qty
3
7
2

Body Rocker Panel Molding Assy LH
Part #
Part Name
Kit #
75395-35070
Clip, Outside Molding, No. 1
9
75396-35020
Clip, Outside Molding, No. 2
9
90189-A0002
Grommet, Screw
9

Qty
2
1
1

Outside LH Back Door Molding Sub-Assy
Part #
Part Name
Kit #
75395-35070
Clip, Outside Molding, No. 1
9
75396-35020
Clip, Outside Molding, No. 2
9
90189-A0002
Grommet, Screw
9

Qty
2
1
1

Part #
75395-04010
75396-04010

Rocker Panel Molding LH/RH
Part Name
Clip, Outside Molding, No. 1
Clip, Outside Molding, No. 2

Kit #
9
9

Qty
4
14

Rear Bumper Assy
Part Name
Bolt, w/ Washer

Kit #
2

Qty
6

Part #
90119-A0192

•
•
•
•
•
•
•
•
•

Left Rear Wheel Well Liner
Quarter Panel Wheel Opening Molding LH
Body Rocker Panel Molding Assy LH (If Equipped)
Outside LH Back Door Molding Sub-Assy (If Equipped)
Side Step Assy LH/RH (If Equipped)
Rocker Panel Molding LH/RH (If Equipped)
Rear Mudguard LH/RH (If Equipped)
Rear Tail/Combination Light LH/RH
Rear Bumper Assy
° Reinstall the rear bumper assy with the 10 bolts and
torque to spec. (Trailer Hitch Equipped Vehicles Only)
° Reinstall the rear bumper assy with the 6 NEW bolts
and torque to spec.
° Torque Spec: 90 N∙m (918 kgf∙cm, 66 ft∙lbf)

78

K. FINAL ASSEMBLY
1. REINSTALL THE NEGATIVE (-) BATTERY TERMINAL
2. REFILL THE FOLLOWING FLUIDS
•

NEW Replacement Parts
Front Differential
Part #
12157-10010
90430-24003

Part Name
Gasket, Drain Plug
Gasket

Kit #
3
3

Qty
1
1

Brake Fluid
° Remove the brake tubes from the master cylinder.
° Refill with Toyota Dot 3 Brake Fluid.
° Bleed the master cylinder.
° Reinstall the brake tubes to the master cylinder and
torque to spec.
° Torque Spec: 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
° Refill with Toyota Dot 3 Brake Fluid.
° Bleed the brake system at each wheel and torque
the bleeder screws to spec.
° Torque Spec: 10.8 N∙m (110 kgf∙cm, 8 ft∙lbf)
• Clutch Fluid (1GR-FE Manual Trans Only)
° Refill with Toyota Dot 3 Brake Fluid.
° Bleed the clutch system and torque the bleeder
screws to spec.
° Torque Spec: 10.8 N∙m (110 kgf∙cm, 8 ft∙lbf)
NOTE: 2TR Manual Trans uses master cylinder
reservoir for clutch.
• Coolant
° Refill with Toyota Long Life Coolant.
° Bleed the cooling system.
• Front Differential
° Install NEW drain plug washer and torque to spec.
° Torque Spec: 64.7 N·m (660 kgf·cm, 48 ft·lbf)
° Refill with Hypoid Gear Oil API GL-5 75W-90.
° Install a NEW filler plug washer and torque to spec.
° Torque Spec: 39.2 N·m (400 kgf·cm, 29 ft·lbf)

3. START THE VEHICLE AND INSPECT THE FOLLOWING FOR LEAKS
•
•
•
•
•

Fuel System
° Start the engine and let it run for 5 seconds, then stop the engine and inspect for leaks.
° If there are no leaks, restart the engine and re-inspect.
Cooling System
Brake System
Clutch System (1GR-FE Manual Trans Only)
Front Differential System

4. RECHARGE THE A/C SYSTEM AND CHECK FOR PROPER OPERATION AND REFRIGERANT LEAKS
5. CHECK THE OPERATION OF THE FOLLOWING SYSTEMS AND ADJUST AS NEEDED
Make sure to follow the procedure outlined in the appropriate repair manual for the vehicle
you are working on when checking, and if needed, adjusting the operation of the systems
listed below. This is an important step, and must be performed thouroughly to ensure proper
operation of these systems.
• Parking Brake Travel
• Shift Control Lever (Automatic Transmission Vehicles Only)
• Clutch Pedal (Manual Transmission Vehicles Only)
6. CHECK ALL FLUID LEVELS AND ADJUST AS NEEDED

79

Part #
43514-28010
95381-04045

NEW Replacement Parts
Part Name
Cap, FR Hub Grease
Pin, Cotter

Kit #
3
3

Qty
2
2

7. TORQUE THE FRONT AXLE NUT (4WD ONLY)
a) Remove the front wheels.
b) Torque the front axle nut to spec.
Torque Spec: 235 N∙m (2396 kgf∙cm, 173 ft∙lb)
c)
d)
e)
f)

Reinstall the lock cap with the NEW cotter pin.
Reinstall the NEW grease cap.
Repeat the procedure on the opposite side.
Reinstall the front wheels and torque to spec.

Torque Spec: 113 N∙m (1152 kgf∙cm, 83 ft∙lbf)
NOTE: If the holes for the cotter pin are not aligned,
tighten the axle nut further, up to 60°.
8. PERFORM A WHEEL ALIGNMENT
9. CHECK THE HEADLIGHT AIM AND ADJUST AS NEEDED
10. REINSTALL THE ENGINE UNDER COVERS

NEW Replacement Parts
Purt Number
90080-11373

Purt Name
Bolt, w/ Washer

Kit #
8

Qty
8

a) Reinstall the engine under cover with 8 NEW bolts and
torque to spec.
Torque Spec: 30 N∙m (306 kgf∙cm, 22 ft∙lbf)

11. CHECK FOR DTC’S AND REPAIR AS NEEDED
12. PERFORM INITIALIZATION
13. FINAL INSPECTION
a) Check the operation of the following systems:
•
•
•
•
•
14.

4WD System (4WD Only)
• Power Windows
Interior Lights
• Power Door Locks
Exterior Lights
• All Gauges, Indicators and Warning Lights
HVAC System
• Cooling Fans
Audio System
• Etc.
TEST DRIVE THE VEHICLE AND DOCUMENT FINAL REPAIR STATUS
a) Test drive the vehicle and perform final repair sign off with the Frame Replacement Inspection Sheet.
This must be performed and signed off by an MDT, Shop Foreman or Service Manager and retained
with Final R.O.

15. RECORD THE FRAME SERIAL NUMBER
a) Log into the frame tracker website using your dealer code and password.
URL: https://zh-frame-tracker.imagespm.info/

Default password: xxxxx

80

b) Select 2005 to 2010 Tacoma ZH6 from the pick list.

c) Enter the VIN of the vehicle.

d) Enter the frame serial off of the case label along with the R.O. number and Approved Frame Inspection Case
Number.

Sample Case Label

e) Press submit and print a copy of the serial number and file with the R.O.

81

1. APPENDIX
As required by Federal Regulations, please make sure all recalled parts (original parts) removed from the vehicle
are disposed of in a manner in which they will not be reused. Adequate time has been provided in the repair time to
cut up and dispose of the perforated frame.

82

(100)

(100)

(100)
FRONT

(200)
115.9

------------------------:::---------------------------------+-------------------- -------------------------------- ---------- -------- ------------------------------------------- ------------------ ---------------------+---------------------------------------------------------- -----------;,
,,

I

----------r---

I

,,

------------------------ff'--------------------------------- -------------------- -------------------------------- ---------- ----------- ----------------------------------------- ------------------ ---------------------r-------------------------------------------------------,,

I

I

F ACE

TO

F

AME

,,

U PER EDGE

ii
(Y)

(D

EDGE

LO

,,
TO AVOLD INTERFE

FACE
f,::

,,
- - - - - - - - - - - --- - - - - - - - - ·\: :-_::::-_-_:: ---_=:== ::=== ::=======

P, .: ;: --------

:,

t - ·J. t:J: :::
I

,

TO

RAME LOWER EDGE

-----------

:: :::: : 1
:

11

I

-;--------

''

ENCE

-------------

il:::::: ::::::::::::--: ::::::::::::::::::::::::::::: = --- =

:

:-:- = = :-:- = = t::::::::: :::: ::::::::::::::: ::

::

-

WITH LH BRAKE

TUBE

WAY