NHTSA ID Number: 10145207
Manufacturer Communication Number: ZH9-Sequoia Fram
TSB/Document Date: 2018-10-09
Summary
TI: Technical Instructions for Warranty Enhancement Program ZH9 Certain 2008 Model Year Sequoia Frame Replacement.
TECHNICAL INSTRUCTIONS
FOR
WARRANTY ENHANCEMENT PROGRAM ZH9
*****************************
CERTAIN 2008 MODEL YEAR SEQUOIA
*****************************
FRAME REPLACEMENT
The repair quality of covered vehicles is extremely important to Toyota
. All dealership
technicians performing this recall are required to successfully complete the most current
version of the E-Learning course “Safety Recall and Service Campaign Essentials”. To ensure
that all vehicles have the repair performed correctly; technicians performing this repair are
required to currently hold at least one of the following certification levels:
• Certified Technician (any specialty)
• Expert Technician (any specialty)
• Master Technician
• Master Diagnostic Technician
Final repair must be signed off and validated by a MDT, Shop Foreman or Service Manager
using the Frame Replacement Inspection Form.
It is the dealership’s responsibility to select technicians with the above certification level or
greater to perform this recall repair. Carefully review your resources, the technician skill level,
and ability before assigning technicians to this repair. It is important to consider technician
days off and vacation schedules to ensure there are properly trained technicians available to
perform this repair at all times.
I.
OPERATION FLOWCHART
Verify Vehicle Eligibility:
1. Check the VIN range
2. Check the TIS vehicle Inquiry system
Yes
Perform pre-hoist inspection.
No
No further action required.
No
Contact your regional
representative for assistance.
Perform Frame Inspection utilizing the Inspection application.
Was perforation 10mm or larger found in the locations identified in
green below (during the rust removal and/or cleaning process)?
Is the vehicle applicable to LSC
H0F?
No
If No, no further action required;
return vehicle to customer.
Yes
Yes
Is your dealership located in a
cold climate state?
Inspection application submits report for FTS approval.
Was approval received from the FTS?
If No, H0F cannot be performed
at your facility; return vehicle to
customer.
Yes
Yes
Order parts and complete frame replacement.
Perform LSC H0F
Yes
WEP Complete
1
II.
PREPARATION
A. TOOLS & EQUIPMENT
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
A/C service equipment
Alignment rack
Brake bleeder
Engine Hanger
° 3UR-FE Engine
- 12281-38150 – Engine hanger no. 1 (Qty: 2)
- 90119-14120 – Bolt (Qty: 2) (Japan sourced parts)
- 90119-A0166 – Bolt (Qty: 2) (Local sourced parts)
Engine hoist (Qty: 2) or Hydraulic mini crane (Qty: 2)
Engine sling (Qty: 2)
Floor jack
Protective eyewear
Protective gloves
Ratcheting tie down strap (2 in X 27 ft, minimum work load capacity: 3,000 lbs)
Special Service Tools (SST)
° 09985-20010 – Air conditioner service tool set or Commercially available air conditioning
manifold gauge set
° 09325-40010 – Transmission oil plug (Transmission A750E)
° 09325-60010 – Transmission oil plug (Transmission AB60E)
° 09610-20012 – Pitman arm puller
° 09520-32040 – A component of SST 09520-24010, Differential side gear shaft puller
° 09520-01010 – Drive Shaft Remover Attachment
° 09951-04010,09952-04010,09953-04020,09954-04010,09955-04031,09958-04011,
– A component of SST 09950-40011, Puller B set
° 09727-30021-Coil spring compressor
° 09730-00010-Air tube separator
° 09955-04090 – Craw no.9
° 09922-10010-01 – Variable open wrench
Standard hand tools
Techstream
Torque wrench
Socket wrench 39mm
Hexagon wrench 4, 6, 10
Deep socket wrench 10, 12, 14, 17, 19, 24mm
Union nut wrench 10mm
Weights
B. SUPPLIES
•
•
•
•
•
•
•
•
Toyota Genuine ATF WS or DEXRON® lll (DEXRON® ll) – As needed
Hypoid gear oil API GL-5 SAE 75W-90 – 2.1 liters
R134a refrigerant – As needed
Toyota DOT 3 brake fluid – 3 pints
Toyota long life coolant – 2 gallons
Paint
MP Grease
Rope
2
C. PARTS
To assist dealers in determining the correct part number(s) to order, a website has been set up to look
up part numbers by VIN. Please go to http://toyota-frame-parts-lookup.imagespm.info (also linked
through TIS), enter the VIN, and the correct part numbers to order will be displayed. The website is for
part(s) application reference only and will not order the part, nor will it confirm campaign
completion status.
•
•
•
The parts will need to be ordered through the Dealer Daily Parts system.
ETAs for the parts will be available via the normal system.
Frame ETAs will be made available on the Dealer Daily website, in the MAC reference area.
Note: When first logging in; enter your dealer code and the default password; XXXXX. Upon
logging in the website will ask for you to reset the password and provide an email address.
Individual Parts:
Part Number
04004-1410C
04004-1420C
04004-1430C
04004-1440C
04004-1450C
04004-1460C
Part Description
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Frame, Sub-Assy
Quantity
1
1
1
1
1
1
Illustration Name
Frame
Frame
Frame
Frame
Frame
Frame
Quantity
1
1
1
1
1
1
1
1
1
3
3
6
1
1
1
1
1
1
1
1
2
Illustration Name
Brake Tubes
Brake Tubes
Front Suspension
Front Suspension
Spare Tire Carrier
Wire Harness Clamps
Wire Harness Clamps
Wire Harness Clamps
Exhaust System
Exhaust System
Exhaust System
Exhaust System
Front Suspension
Exhaust System
Exhaust System
Exhaust System
Brake Tubes
Brake Tubes
Brake Tubes
Brake Tubes
NA
Individual Parts (Continued):
Part Number
47324-0C101
47325-0C121
48068-09100
48069-09090
51900-34040
82164-0C200
82164-0C210
82164-0C220
90080-46263
90126-A0011
90126-A0011
90126-A0011
90178-A0052
90461-15017
90917-06085
90917-06093
47312-0C080
47313-0C090
47322-0C110
47323-0C090
90950-01A31
Part Description
Tube, Rear Brake, No.4
Tube, Rear Brake, No.5
Arm Sub-Assy, Front Suspension, Lower No.1 RH
Arm Sub-Assy, Front Suspension, Lower No.1 LH
Carrier Assy,Spare Wheel
Wire, Frame
Wire, Frame
Wire, Frame
Clamp No.1, Exhaust TAIL Pipe (For Rear)
Bolt, Stud (For Exhaust Manifold, RH)
Bolt, Stud (For Exhaust Manifold, LH)
Bolt, Stud (For Manifold To Exhaust Pipe)
Nut (For Front Suspension Support)
Clamp
Gasket, Exhaust Pipe, Center
Gasket, Exhaust Pipe, Center
BRAKE TUBE & CLAMP
BRAKE TUBE & CLAMP
BRAKE TUBE & CLAMP
BRAKE TUBE & CLAMP
PLUG, HOLE
3
Parts Kits:
Part Number
Part Description
Quantity
04004-20134
Parts Kit No.1 – Common Replacement Kit A
1
The kit listed above includes the following parts:
Part Number
48190-34010
48198-34010
48409-34041
48452-34011
77285-34370
77289-26010
90099-14120
90119-08782
90178-18003
90179-06178
90201-19011
90252-04003
90412-10266
90412-10267
90412-10268
94130-01202
Part Description
Cam Assy, Camber Adjust
Cam, Camber Adjust, No.2
Cam Sub-Assy, Front Suspension Toe Adjust
Plate, Front Suspension Toe Adjust, No.2
Clamp, Fuel Tube, No.2
Clamp, Fuel Tube, No.1
O-Ring
Bolt
Nut
Nut
Washer
Cotter Pin
Way, No.1 (For Front Brake Tube)
Way, No.2 (For Front Brake Tube)
Way (For Rear Brake Tube)
Nut
Qty
2
2
2
2
4
1
1
4
2
6
2
2
1
1
1
2
Illustration Name
Front Suspension
Front Suspension
Front Suspension
Front Suspension
Fuel Tank & Tubes
Fuel Tank & Tubes
Air Conditioning
Rear Spring & Shock Absorber
Front Suspension
Front Bumper
Front Suspension
Power Steering
Brake Tubes
Brake Tubes
Brake Tubes
Front Suspension
4
Parts Kits (Continued):
Part Number
Part Description
Quantity
04004-2020C
Parts Kit No.2 – Common Replacement Kit B
1
The kit listed above includes the following parts:
Part Number
16492-21050
47314-0C020
Or
47314-0C021
47315-0C030
Or
47315-0C031
48304-0C030
48304-0C030
51911-0C010
52173-0C080
52173-0C080
77296-0C010
Or
77296-0C020
90069-08009
90080-11555
90080-17187
90080-17229
90080-46327
90119-A0316
90119-A0380
90119-A0050
90119-A0050
90119-A0077
Part Description
Packing (For Radiator Drain Cock)
Qty
1
Illutration Name
Radiator
Tube, Front Brake, No.4
1
Brake Tubes
Tube, Front Brake, No.5
1
Brake Tubes
Bumper, Front Spring, No.1 RH
Bumper, Front Spring, No.1 LH
Bolt, Spare Wheel
Bracket, Rear Bumper Bar, RH
Bracket, Rear Bumper Bar, LH
2
2
2
1
1
Front Suspension
Front Suspension
Spare Tire Carrier
Rear Bumper
Rear Bumper
Support, Fuel Tube Protector, No.1
1
Fuel Tank & Tubes
O-Ring
Bolt
Nut
Nut
Clip (For Front Fender Apron Seal)
Bolt
Bolt
Bolt
Bolt
Bolt
1
1
6
1
22
2
1
2
5
2
90119-A0169
5
90119-A0169
90119-A0170
90119-A0184
90119-A0192
90119-A0204
90119-A0210
90119-A0222
90119-A0224
90178-A0044
90178-A0052
90178-A0067
90468-A0007
90469-A0004
90917-A6002
90949-A1016
90949-A1016
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Nut (For Front Suspension Support)
Nut
Clip
Clamp, Brake Tube, No.7
Gasket, Exhaust Pipe
Clamp, Brake Tube, No.6
Clamp, Brake Tube, No.8
4
1
1
4
2
4
6
4
8
8
6
4
6
2
2
2
Air Conditioning
Power Steering
Exhaust System
AT Shift Cable
Front Fender Apron
Spare Tire Carrier
Exhaust System
Rear Bumper
ABS & VSC
Fuel Tank & Tubes
Suspension Crossmember &
Under Cover
Spare Tire Carrier
Engine Mounting
Brake Tubes
Front Suspension
Front Suspension
Engine Mounting
Brake Tubes
Engine Mounting
Front Bumper
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TSB/Document ID: ZH9-Sequoia Fram
Replacement Service Bulletin Number:
MFR Communication Date: 2017-10-12
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: STRUCTURE
MFR Component System:
MFR Component Subsystem:
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