TOYOTA

Toyota Motor Sales, U.5S.A., Inc.
19001 South Westem Avenue
Torrance, CA 90501

(310) 468-4000

To: All Toyota Dealer Principals, Service Managers, Parts Managers

Subject: Update — Limited Service Campaign 9SM

This Campaign Expired on December 31, 2012.

TECHNICAL INSTRUCTIONS
FOR
LIMITED SERVICE CAMPAIGN 9SM

FOR VEHICLES
CURRENTLY REGISTERED IN AND/OR ORIGINALLY SOLD.IN

AK, AL, AR, AZ, CA, CO, FL,.GA; HI, 1A, ID, KS, LA, MO, MS, MT, NC,
ND, NE, NM, NV, OK,,OR, SC, SD, TN, TX, UT, WA, and WY

REAR FRAME CROSS MEMBER REPLACEMENT
ON

2000 THROUGH 2003 MODEL YEAR TUNDRA
lL.

OPERATION FLOW CHART

Verify Vehicle Eligibility
1, Check the VIN range.
2. Check the TIS Vehicle Inquiry System

Covered
y

Perform initial pre-hoist frame inspection.

y

i— Not Covered->

No further action required.

Inspect the specific areas of the frame rails and cross members as shown in
green for rust perforation. Was rust perforation found in the areas inspected?

Proceed to LSC AOF.

f—Yes] expires December 31, 2012)

Directed to SSC 95M from LSC AGF.

No

Remove the spare tire and visually inspect.

members shown in red for rust perforation.
AND

The rear frame cross member and fuel tank mounting cross

& 4

z ‘ ‘ ‘be
The Fuel Tank Mounting Straps, Load Sensing Proportianing. *# ele K, =e
Valve (LSPV), spare tire carrier and surrounding components for \ i

corrosion damage

Case 1: No or only minor (less than 10 san)
perforation found on the rear frame cross member
and fuel tank mounting cross memibers.

No corrosion damage or deterioration found on the.

af == A bs ~~

Pi
f i

Case 2: Perforation found on the rear frame cross
member andior fuel fen Kk mounting cross member(s)

Corrosion dama: age found. on Oke fuel tank mounting

Campaign Complete

(TTAP) guidelines.

fuel tank straps, LSPV, spare tire carrier and other» | © Straps LSPV, spare tire cartier and/or other
surrounding components. é sure founding camponents
*F |
¥ y
—— a Rear frame cross
Replace applicable member cannot be
ie igen corrosion damaged replaced due to
a o component{s} excessive rust
. aT - ' perforation.
Reinstall the spare.tire. | AND/OR
: Fuel tank mounting
| y cross member(s) have
| Rear frame cross rust perforation.
——- member replacement
Replacement parts are j unsuccessful, due to
unavailable the damage caused by
Refer to the Technica! the repair process.
| Instructions for specific |
\ criteria and handling. =
. Replacement parts are
Includes making a rental unavailable, ¥
vehicle available based -
upon the inspection Provide the customer loaned me
results. with a rental vehicle, [—*
and contact the
customer when paris
become available,
Follow the Toyota ¥
¥ Transportation
Assistance Program Campaign completed,

return the vehicle to
the customer.

IDENTIFICATION OF AFFECTED VEHICLES
A. AFFECTED VIN RANGE

VIN Range
Model WMI Year VDS Range
| BN441 $001001 - S124211
BN481 $001001 - $001001
BI441 $001001 - $125901
BT481 $001001 - $125894
JN321 $001001 - S125878
5000 KN421 $001001 - $001003
KN441 $001001 - S051314
KT441 _ $001001 - $125833
RN341. $001001 - $125859
RN381 $001001 - S001003
RT341. $001001 - $125904
RT381 $001001 - $125897
> BN441 $127099 - 220170
_BT441 $125911-$220327
BT481 $064335 - $220350
, JN321 $126112 - $220343
een KN441 $064852 - $064852
_KT421 §090565 - S090565
KT444 $125953 - $220297
eS ome RN341 $125909 - $220341
RT341 $125907 - S220347
RT381 $064333 - S220345
BN441 $220461 - $332258
BI441 $220352 - 332710
BT481 $219295 - S332685
ah JN321 $220351 - 332714
KT444 $220754 - S332680
RN341 $220353 - $332719
RT341 $220360 - $332721
RT381 $220365 - $332666
BN441 $332744 - $434008
BI444 $316368 - $439612
BT481 $306031 - 439593
ans JN321 $332750 - S436014
KT441 $330788 - 439601
RN341 $307943 - $436915
RT341 $306032 - S439732
RT381 $308386 - $439716
NOTE:

Check the TiS Vehicle Inquiry System to confirm the VIN is covered by this Limited Service

Campaign, and that the campaign has not already been completed prior to dealer shipment or by
another dealer.

TMS warranty will not reimburse dealers for repairs conducted on vehicles that are not covered or

were completed by another dealer.

IV.

BACKGROUND

Toyota has received reports that certain 2000 through 2003 model year Tundra vehicles operated in cold
climate areas with high road salt use, may exhibit excessive corrosion on the rear cross member and the
fuel tank mounting system.

Exposure to cold climate and high road salt usage conditions are primary contributors. This is unrelated to,
and separate from, normal surface rust which is commonly found on metallic surfaces after some years of
usage and/or exposure to the environment.

VEHICLE INSPECTION WORK PROCEDURE
A. INITIAL PRE-HOIST FRAME INSPECTION

INSPECT THE FRAME FOR RUST PERFORATION

a) If NG (rust perforation found), use a drive on vehicle lift to inspect the frame & cross members. DO NOT
lift vehicle by the frame.

b) If OK (no rust perforation), you may use a frame contacting vehicle lift to inspect the frame & crass
members.

VISUALLY INSPECT THE FRAME AND CROSS MEMBERS

a) Visually inspect the specific areas (highlighted in green) of the frame assembly as shown for visible signs
of perforation.

Judgement Criteria | Re | Action
Perforation (hole) of 10 mm or more NG “|e Replace the frame under AQF

* Noaction required

ee aOR ar * Proceed to Rear Cross Member Inspection

*
yr

B. INSPECT THE REAR FRAME CROSS MEMBER

REMOVE THE SPARE TIRE AND INSPECT THE REAR FRAME CROSS MEMBER FOR RUST
PERFORATION

Judgment Criteria Result Action
: Replace the rear frame cross member
A perforation (hole) of over 10 mm NG For part number information, please reference Section V “Parts Information”

C. INSPECT THE FUEL TANK MOUNTING STRAPS, LSPV, SPARE TIRE CARRIER AND
SURROUNDING COMPONENTS

1. INSPECT THE FUEL TANK STRAPS FOR CORROSION DAMAGE

a) Using a piece of cloth, clean the outside surface of the front and rear fuel tank mounting straps to remove
any dirt and debris.

b) Inspect the outside surface of the fuel tank mounting straps, does the rust span the width (front to rear) of
either fuel tank strap as shown.

Inspection Area: a jer DT ——i
SSSR 30 mm (1.1811 in.) “) XS Fg