“from folded strap edge

30 mm (1.1811 in.) yy \
from folded strap Cage 4
’ Inspect for rust |

se Conte y pe af]
Po SE — . Genter of comert | SS “T
- al i
Inspection Standard: ;
Rusting occurs continuously Rusting does not occur continuously
along the entire width of the strap. along the entire width of the strap.

Rust Paint

Judgment Criteria Action
NG Replace the fuel tank strap(s)
For part number information, please reference Section V “Parts Information”
OK Replacement not required

2. INSPECT THE LSPV

a) lf there are signs of excessive rust and brake fluid
leakage on the LSPV, replace ihe damaged parts.

b) With one hand using minimal force, attempt to wiggle
the valve bracket (b).

e Ifthe valve bracket is loose, replace the damaged
part.

c) With one hand using minimal force, attempt to wiggle
the valve body (c).

« |f the valve body and/or associated components
are loose or show any signs of leakage, replace
the damaged parts.

For part number information, please reference Section V “Paris Information"

3. INSPECT THE SPARE TIRE CARRIER FOR DETERIORATION

a) Inspect the spare tire carrier lift plate as shown.

Judgment Criteria | Result Ce. Action
Deterioration NG i Replace the spare tire carrier
Found For, part number information please reference Section. V “Parts Information”
No Deterioration OK

Carrier ft Piste

Conlacl Locaton (tispection Area) “ Ceti
‘ Deterioration S

Cetancration or holes prasent

4. INSPECT SURROUNDING GOMPONENTS AND ADJACENT AREAS
q |
a) Inspect the...

e Brake lines * Steering components and power steering lines
e Fuel line e Suspension mounts
e Exhaust pipe brackets
NOTE: If there is perforation, breakage, and/or fluid Jeakage of the specified components or adjacent
areas due to corrosion replace the damaged part(s).

e lf parts are NOT available for the components requiring replacement (i.e. brake components,
fuel lines, LSPV, spare tire carrier, etc.,) inform the customer and provide them with a rental
vehicle. Contact the customer when parts become available.

« Follow the Toyota Transportation Assistance Program (TTAP) guidelines for rentals.

V. PARTS INFORMATION

s Rear Frame Cross Member

MY Description Part Number Part Name Oty
2000 - 2002 - 51209-0C010 | Rear Frame Cross Member Sub-assembly 1
2003 - 51209-00012 | Rear Frame Cross Member Sub-assembly 1
All - 90080-11288 Bolt 13
All - 90178-A0082 Nut 13
* Fuel Tank Straps
MY Description Part Number Part Name Qty
oD 77601-34030 Fuel Tank Strap Sub-assembly No.1 1
2000 77603-34070 Rue! Tank Strap Sub-assembly No.2 1
ia 77601-34040 Bus) Tank Strap Sub-assembly No.1 1
77603-34060 Fuel Tank Strap Sub-assembly No.2 1
2WD 77601-34030 Fuel Tank Strap Sub-assembly No.1 1
Except UCK30 =
2001 — 2003 | ff Road Package 77603-34070 Fuel Tank Strap Sub-assembly No.2 1
4WD | -#7601-34040 Fuel Tank Strap Sub-assembly No.1 1
Includes UCK30 «F ; 7
Off Road Package.| 77603-34060 Fuel Tank Strap Sub-assembly No.2 1
* Load Sensing Proportioning Valve (LSPV) _.__
MY Description | Part Number d Part Name Qty
2000 — 2002 WO/ABS 47910-34060 LSPV Assembly 1
2000 — 2003” WABS _|..47910-34070 LSPV Assembly 1
«Spare Tire (Wheel) Carrier
MY Description Part Number © Part Name Qty
All 3 51900-00010. Spare Wheel Carrier Assembly 1
NOTE:

« Depending on the vehicle condition, additional parts may be required.
« Correct part number(s) should be confirmed with the parts catalog.

VI. REAR FRAME CROSS MEMBER REPLACEMENT WORK PROCEDURE

A. TOOLS & EQUIPMENT ~
Air hammer with...

and WY

Flat chisel bit
Tapered punch bit

Dust mask

Ear plugs

Frame expansion bar*
Protective eyewear

B. MATERIALS
e Black paint (chassis black or black anti-corrosive paint)
® Sandpaper 80 grit

Protective work gloves

Standard hand tools

Steel tape measure

Torque wrench

Torx ® T55H Tamper Resistant Socket
Pencil Type Grinder — 1/8” Chuck

e Cone Shaped Grinding Stone

*NOTE: One Frame Expansion Bar will be provided to each region covering: AK, AL, AR, AZ, CA,
CO, FL, GA, Hi, IA, ID, KS, LA, MO, MS, MT, NC, ND, NE, NM, NV, OK, OR, SC, SD, TN, TX, UT, WA,

Cc. COMPONENTS

x2 | 3

wa

LOAD SENSING PROPORTIONING
VALVE ASSEMBLY

SPARE WHEEL
CARRIER ASSEMBLY

NOTE:
Please follow all work procedure instructions and notes
when tightening the bolts and nuts.

94 (551,49) {
xi3@—El BOLT
& NO.1 REAR SHOCK

oo NUT g ABSORBER CUSHION

@ REAR FRAME
CRCSSMEMBER

x

\4a8 RETAINER CUSHION

-REAR SHOCK ABSORBER LH

Hi Additional sart
® New replacement part

N*m (kaftcm, ft.*Ibf) |: Specifiec torque

D. LOCATION AND TORQUE SPECIFICATIONS FOR SURROUNDING COMPONENTS IF REPLACED

Location reference diagram and torque values for replacing brake harness and LSPV.

,
2-9

j
:
oy
ti
e
o
e

©
8

~

\Peswna] Ce

[ease] x

©

oS
aS Oo
Exe }O.

45 (153, 11)

[-.45 (453, 11)

i'm (kgrem, fp]: Specified torque ®

E. REAR FRAME CROSS MEMBER REMOVAL
1. REMOVE THE LICENSE PLATE LIGHTS
2. REMOVE THE CENTER REAR BUMPER PAD
3. REMOVE THE REAR BUMPER ASSEMBLY

4. REMOVE THE TRAILER HITCH (IF EQUIPPED)

5. DISCONNECT THE FRAME WIRE HARNESS

a) Disconnect the connectors.
b) Disconnect the clips and the frame wire harness from
the bed assembly.

NOTE:

e The number of connectors may differ depending on
the vehicle specification.

e Be careful not to damage the wire harness clips
when removing them.

6. REMOVE THE REAR MUDGUARDS (IF EQUIPPED)
7. REMOVE THE FUEL TANK FILLER PIPE SHIELD

8. DISCONNECT THE FUEL INLET PIPE

a) Remove the 2'nuts and disconnect the fuel inlet pipe.

Regular Cab: , y Access Cab: