Front Suspension
Front Bumper
Brake Tubes
Brake Tubes
Exhaust System
Brake Tubes
Brake Tubes

5

Parts Kits (Continued):
Part Number

Part Description

Quantity

04004-19334

Parts Kit No.3 – JPN Source Parts Kit 4WD

1

The kit listed above includes the following parts:
Part Number
12157-10010
43514-34020
43514-34020
90311-47012
Or
90311-47027
90311-47013
90430-24003
95381-04050

Part Description
Gasket, Front Differential Filer Plug
Cap, Front Axle Hub Grease, RH
Cap, Front Axle Hub Grease, LH

Qty
1
1
1

Illustration Name
Front Differential
Front Suspension
Front Suspension

Seal, Oil (For Differential Side Gear Shaft) RH

1

Front Differential

Seal, Oil (For Differential Side Gear Shaft) LH
Gasket (For Front Differential Drain Plug)
Cotter Pin

1
1
2

Front Differential
Front Differential
Front Suspension

Part Number

Part Description

Quantity

04004-1940C

Parts Kit No.4 – USA Source Parts Kit 4WD

1

The kit listed above includes the following parts:
Part Number
43425-0C010
90105-A0193
90119-A0151
90464-00897

Part Description
Ring, Shaft Snap (For Front Drive Inner Shaft Outer)
Bolt
Bolt
Clamp

Qty
2
1
2
1

Illustration Name
Front Suspension
Front Differential
Propeller Shaft
Front Differential

Part Number

Part Description

Quantity

04004-20334

Parts Kit No.5 – Air Suspension Kit 1

1

The kit listed above includes the following parts:
Part Number
48932-30010
48932-30010
48933-30010
48934-30010
48934-30010
90301-04004
90301-04011
90301-04011
90301-04011
90467-07201
90468-12012
82711-1E360
82711-26380

Part Description
Plate, Height Control Tube
Plate, Height Control Tube
Holder, Air Connector Clip
Connector, Height Control Tube
Connector, Height Control Tube
Ring, O (For Height Control Tube No.2)
Ring, O (For Rear Pneumatic Cylinder RH)
Ring, O (For Rear Pneumatic Cylinder LH)
Ring, O (For Height Control No.6 Tube)
Clip
Clamp
Clamp, Wiring Harness
Clamp, Wiring Harness

Qty
2
1
2
2
1
2
2
2
2
3
2
1
4

Illustration Name
Rear Spring & Shock Absorber
Height Control (Auto Leveler)
Height Control (Auto Leveler)
Rear Spring & Shock Absorber
Height Control (Auto Leveler)
Height Control (Auto Leveler)
Rear Spring & Shock Absorber
Rear Spring & Shock Absorber
Height Control (Auto Leveler)
Height Control (Auto Leveler)
Height Control (Auto Leveler)
Electronic Modulated Suspension
Electronic Modulated Suspension

6

Parts Kits (Continued):
Part Number

Part Description

Quantity

04004-20434

Parts Kit No.6 – Air Suspension Kit 2

1

The kit listed above includes the following parts:
Part Number
48932-30010
48932-30010
48933-30010
48934-30010
48934-30010
89269-34010
89269-34020
90110-05004
90301-04004
90301-04011
90301-04011
90301-04011
90467-07201
90468-12012
82711-1E360
82711-26380

Part Description
Plate, Height Control Tube
Plate, Height Control Tube
Holder, Air Connector Clip
Connector, Height Control Tube
Connector, Height Control Tube
Bracket, Suspension Control RH
Bracket, Suspension Control LH
Bolt
Ring, O (For Height Control Tube No.2)
Ring, O (For Rear Pneumatic Cylinder RH)
Ring, O (For Rear Pneumatic Cylinder LH)
Ring, O (For Height Control No.6 Tube)
Clip
Clamp
Clamp, Wiring Harness
Clamp, Wiring Harness

Qty
2
1
2
2
1
1
1
4
2
2
2
2
3
2
1
4

Illustration Name
Rear Spring & Shock Absorber
Height Control (Auto Leveler)
Height Control (Auto Leveler)
Rear Spring & Shock Absorber
Height Control (Auto Leveler)
Electronic Modulated Suspension
Electronic Modulated Suspension
Electronic Modulated Suspension
Height Control (Auto Leveler)
Rear Spring & Shock Absorber
Rear Spring & Shock Absorber
Height Control (Auto Leveler)
Height Control (Auto Leveler)
Height Control (Auto Leveler)
Electronic Modulated Suspension
Electronic Modulated Suspension

Part Number

Part Description

Quantity

04004-2060C

Parts Kit No.7 – Air Suspension Kit 3

1

The kit listed above includes the following parts:
Part Number
48958-0C010
90080-11180
90119-A0266

Part Description
Clip, Pneumatic Cylinder
Bolt
Bolt

Qty
2
2
3

Illustration Name
Rear Spring & Shock Absorber
Height Control (Auto Leveler)
Height Control (Auto Leveler)

Part Number

Part Description

Quantity

04007-18434

Plug, Hole Kit

1

The kit listed above includes the following parts
Part Number
90950-01993
90950-01A06
90950-01A09
90950-01987
90950-01994
90950-01986
90950-01990
90950-01992
90950-01A24

Part Number

Part Description
Plug, Hole
Plug, Hole
Plug, Hole
Plug, Hole
Plug, Hole
Plug, Hole
Plug, Hole
Plug, Hole
Plug, Hole

Qty
8
2
10
6
5
2
2
10
2

Part Description
Parts Kit No.8

04004-2060C

Quantity

1

The kit listed above includes the following parts
Part Number
48958-0C010
90080-11180
90119-A0266

Part Description
PNEUMATIC CYLINDER

BOLT, W/WASHER
BOLT, W/WASHER

Qty
2
2
3

7

D. PARTS ILLUSTRATION
Frame

Suspension Crossmember & Under Cover

8

Spare Tire Carrier

9

Front Suspension

10

Rear Spring & Shock Absorber

11

Height Control (Auto-Leveler)

12

Brake Tubes

13

Fuel Tank & Tubes

14

Wire Harness Clamps

ABS & VSC

15

Electronic Modulated Suspension

Power Steering

16

Front Differential

Engine Mounting

Propeller Shaft

17

Exhaust System

18

AT Shift Cable

Radiator

Air Conditioning

19

Front Bumper

Rear Bumper

Front Fender Apron

20

III.

FRAME INSPECTION

1. PERFORM INITIAL PRE-HOIST INSPECTION

2. VISUALLY INSPECT THE FRAME
a) Visually inspect the specific areas (highlighted in blue) of the frame assembly as shown for visible signs
of perforation.
Judgement Criteria

Result

Perforation (hole) of 10 mm or more

NG

Perforation (hole) of less than 10 mm

OK

Action
•

• Replace the frame
Proceed to section IV. VEHICLE INSPECTION
below to begin the frame replacement process.

•

No action required

NOTE:
Use protective eyewear and gloves when performing the under vehicle inspection as rusted
metal may flake off.

21

I.

FRAME INSPECTION

1. PERFORM INITIAL PRE-HOIST INSPECTION
1. INSPECT THE FRAME FOR EXCESSIVE FRAME CORROSION THAT COULD AFFECT THE
STRUCTURAL INTEGRITY OF THE FRAME

2. FRAME INSPECTION
All frame inspection must be performed using the NEW frame inspection
application on TIS. Ensure you inspect the frame and properly document the
inspection. Failure to perform this will result in denial of the claim.
1. ACCESS INSPECTION APPLICATION
a. Run the VIN in TIS and click on the Warranty Tab
b. Click on the “Frame Inspection” link on TIS

2. LOG INTO THE INSPECTION APPLICATION
a. Reenter your TIS password

22

3. ENTER VEHICLE INFORMATION
a. Enter the vehicle mileage.
b. Select the state from the drop-down menu that the vehicle is registered.
Note: Do NOT select the state the dealership is located.
c.

Inspect the frame for CRC compound that could have been previously applied:
CRC was Previously Applied: Select the CRC Bottle Button
NO CRC Previously Applied: Select Frame Button

Note: CRC could only be previously applied to 2005 to 2008 Tacoma vehicles.

4. INSPECT THE FRAME SECTIONS
a. Inspect the frame in the colored areas below and use the application to document the results of
the inspection.
Note: Crossmember mounting locations should be inspected 6” into the crossmember.
Sequoia 2008

b. Select Section A
Note: The frame inspection application must be completed in alphabetical order.

23

c.

Inspect the frame section and inspect all surfaces of the frame rail and crossmember. Select the
photo that best represents the frame condition. If perforation of 10mm or larger is identified select
“Peroration of the Frame”.
Note: You must click the bubble next to the image to select the condition.

d. If you selected Perforation of the Frame, the application will request more information about the
size of perforation(s) and location.
e. The section with perforation will split into 2 sub-sections to further identify the perforation location.
f. Select the size of the perforation in each sub-section.
g. Upload a photo for each area containing perforation and describe the location in the comments
section.
Note:
• Include the R.O. in the image of at least one of the perforation holes.
• If both sub-sections have perforation, it will require two pictures to be uploaded.
• If perforation was accidentally selected use the back button to reselect the correct frame
condition.
h. Select Next to move onto the next section.

24

i.

Once all sections have been completed, select the Submit button.

NO Perforation Found
j. If no perforation was not found, follow the directions as provided.

Perforation Found
k.

If perforation was found, this application will be submitted to your Regional Office for review. The
region office will review the inspection and provide feedback if the frame replacement is approved
for future repair.
DO NOT proceed with frame replacement or parts ordering until you are provided
with approval from the Regional Office. Approval will be sent to the TIS inbox for the
inspection, Service Manager and Parts Manager.

25

II.

VEHICLE INSPECTION
•
•

Visually inspect both the vehicle interior and exterior. Note any damage found during the visual
inspection prior to beginning work.
As you disassemble the vehicle you may encounter parts that are in need of replacement, which
are not covered by this repair procedure. If this is the case, please take the time to inform the
customer that these parts can be replaced with minimal labor cost.

26

III.

FRAME REPLACEMENT WORK PROCEDURE
A. PERFORM PRELIMINARY VEHICLE INSPECTION