Take care not to damage or break the clamps during
removal.

45

18. REMOVE THE ABSORBER CONTROL ACTUATORS
(W/ AIR SUSPENSION)
a) Disconnect the clamp.
b) Using a hexagon wrench, remove the 2 bolts and the
absorber control actuator.

c) Remove the nut and the suspension control bracket.
d) Repeat the procedure on the opposite side.

19. DISCONNECT THE SKID CONTROL SENSOR WIRES
a) Remove the 2 bolts and disconnect the skid control
sensor wire. (LH Side)
b) Remove the bolt and disconnect the skid control sensor
wire. (RH Side)

20. DISCONNECT THE FRONT BRAKE HOSES
a) Remove the clip.
b) Remove the bolt and disconnect the front brake hose.
c) Repeat the procedure on the opposite side.

46

21. REMOVE THE FOLLOWING PARTS
•
•
•
•

Front Stabilizer Bar
Front Axle Shaft Nut (4WD Only)
Tie Rod End Sub-Assy
° Remove the cotter pin and nut.
° Using the SST 09610-20012, disconnect the tie rod end.
Lower Ball Joint
° Remove the 2 bolts and disconnect the lower ball joint from the steering knuckle.
22. REMOVE THE FRONT SUSPENSION UPPER ARM AND
STEERING KNUCKLE ASSY
a) Remove the bolt, nut, 2 washers and front suspension
upper arm and steering knuckle assy.
b) Repeat the procedure on the opposite side.
NOTE:
If the drive shaft is difficult to disconnect, tap the drive
shaft loose with a plastic hammer (4WD Only).

23. DRAIN THE FRONT DIFFERENTIAL OIL (4WD ONLY)
24. REMOVE THE FOLLOWING PARTS
•
•

Front Shock Absorber Assy
Front Drive Shaft Assy (4WD Only)
° Using the SST 09520-24010 (09520-32040), 09520-01010, remove the front drive shaft.
NOTE:
Be careful not to damage the dust cover and oil seal.
• Power Steering Link Assy w/ Power Steering Vane Pump
NOTE:
• When removing the power steering link with the vane pump attached, have one person support
the power steering link and the other support the vane pump.
• Make sure to keep the power steering pump reservoir in an upright position to prevent the fluid
from leaking out.
•
•

Front Differential Carrier Assy (4WD Only)
Front Suspension Lower Arm Sub-Assy
NOTE:
If the bolt is seized and the front suspension lower arm cannot be removed, remove the lower ball
joint with the front suspension lower arm left on the frame.

•

Lower Ball Joint
NOTE:
When the front suspension arm can be removed, this work is not required.
° Remove the cotter pin and nut.
° Using the SST 09950-40010 (09951-04010,09953-04020,09954-04010,09955-04031,
09958-04011,09952-04010),09955-04090, remove the lower ball joint.

•

No.1 Front Spring Bumper (Qty: 4)
° Using the SST 09922-10010-01, remove the front spring bumper.

47

25. DISCONNECT THE PARKING BRAKE CABLES
a) Remove the 12 bolts and disconnect the parking brake
cables.

26. REMOVE THE REAR HEIGHT CONTROL SENSORS
(W/ AIR SUSPENSION)
a) Put matchmarks on the rear height control sensor link
and bracket.
b) Disconnect the rear height control sensor connector.
c) Remove the nuts and the rear height control sensor.
d) Repeat the procedure on the opposite side.

27. DISCONNECT THE REAR BRAKE HOSES
a) Disconnect the rear brake tube.
b) Remove the clip.
c) Repeat the procedure on the opposite side.

28. DISCONNECT THE SKID CONTROL SENSOR WIRES
a) Disconnect the 2 connectors and 5 clamps.
b) Remove the 2 bolts and disconnect the skid control
wires.

48

29. DISCONNECT THE HEIGHT CONTROL TUBE
(W/ AIR SUSPENSION, TYPE1)
NOTE:

 Disconnect and connection of the height control
tube should be performed by hand to prevent
foreign objects from entering.

 Never damage the height control tube.

a) Disconnect the height control tube.
1) Pinch section "A" of the connector No. 1 and pull it
from the housing.

2) Set the SST 09730-00010 to the tube.

3) Insert SST into the housing to expand the claw of the
connector No.2 in the housing.
4) Pull out the tube with SST 09730-00010 inserted.
NOTE:
DO NOT pull on the tube with excessive force.

5) Insert a screwdriver into the circular hole on the
housing, and remove the connector No.2, the 2 Orings and the plate from the housing.
NOTE:
The O-rings, plate and connector No.2 are
nonreusable parts.
30. DISCONNECT THE HEIGHT CONTROL TUBE
(W/ AIR SUSPENSION, TYPE2)
NOTE:

 Disconnecting and connecting the height control
tube should be performed by hand to prevent dust
or foreign objects from entering it.

 Be careful not to damage the height control tube.
a) Disconnect the height control tube.
1) Remove the holder.

49

2) Spread the clip and slowly pull the height control
tube straight out.
NOTE:
DO NOT completely remove the clip except when
replacing it.

3) Remove the 2 O-rings.
NOTE:
Some tubes are equipped with only one O-ring.

31. REMOVE THE FOLLOWING PARTS
•
•
•

Rear Shock Absorber Assy
Rear Coil Spring
° Using the SST 09727-30021, remove the rear coil spring.
Rear Pneumatic Cylinder (w/ Air Suspension)

32. REMOVE THE SPARE WHEEL STOPPER
a) Remove the 4 bolts and spare wheel stopper.

33. DISCONNECT THE REAR SUSPENSION UPPER ARMS
a) Disconnect the 2 bolts and 2 nuts.
b) Repeat the procedure on the opposite side.

50

c) Fix the upper arm with a rope etc. to restrain expansion
of the upper arm in order to prevent the drive shaft from
coming off.

34. DISCONNECT THE REAR SUSPENSION LOWER ARMS
a) Disconnect the bolt and nut. (Front Side Only)
b) Repeat the procedure on the opposite side.

35. REMOVE THE REAR DIFFERENTIAL ASSY
a) Remove the 4 bolts and 4 nuts.
b) Remove the rear differential assy.

36. REMOVE THE No.1 HEIGHT CONTROL COMPRESSOR
ASSY (W/ AIR SUSPENSION)
a) Remove the 3 clips and height control compressor
cover.

51

b) Disconnect the 2 connectors and tube.

c) Remove the 3 bolts and No.1 height control compressor
assy.

37. REMOVE THE No.2 HEIGHT CONTROL VALVE
ASSY (W/ AIR SUSPENSION)

SUB-

a) Disconnect the connector.
b) Disconnect the tubes.

c) Remove the 2 bolts and No.2 height control valve subassy.

52

38. REMOVE THE HEIGHT CONTROL TUBES
(W/ AIR SUSPENSION)
a) Remove the 6 clips and height control tubes.
NOTE:
Take care not to damage or break the clamps during
removal.

w/ Towing Hitch

39. REMOVE THE No.3 FRAME WIRE HARNESS
a) Disconnect the clamp.
b) Remove the 2 bolts and No.3 frame wire harness.

w/o Towing Hitch

40. REMOVE THE FRAME WIRE HARNESS
a) Remove the bolt and disconnect the ground wire
(If Equipped).
b) Disconnect each clamp and remove the frame wire
harness.
NOTE:
• The number of wire harness clamps will differ
depending on the vehicle specification.
• Take care not to damage or break the wire harness
clamps during removal.

53

41. REMOVE THE BRAKE TUBE HEAT INSULATOR
a) Remove the 2 bolts and brake tube heat insulator.

42. REMOVE THE REAR BUMPER BRACKETS
a) Remove the 2 bolts and 2 rear bumper brackets.

43. REMOVE THE No.1 REAR SPRING BUMPERS
a) Remove the nut and No.1 rear spring bumper.
b) Repeat the procedure on the opposite side.

44. REMOVE THE FRONT DIFFERENTIAL SUPPORT ASSY
(4WD ONLY)
a) Remove the bolt, nut and differential support assy.

54

45. REMOVE THE ENGINE WIRE CLAMP
46. REMOVE THE No.2 FRONT ENGINE MOUNTING
BRACKET LH

47. REMOVE THE CAB MOUNTS
48. REMOVE THE FRAME FROM THE LIFT
a) Remove the ratcheting tie down strap and the frame from the lift.

55

F. INSTALL FRAME PLUGS
1. INSTALL THE FRAME PLUGS AS SHOWN IN THE DIAGRAMS BELOW
PLUG DIAGRAM/ID

P/N

INSTALLATION INSTRUCTIONS

TOTAL QTY

Plug ‘9’
90950-01992

Push to seat installation

10

90950-01990

Push to seat install.

2

90950-01987

Push to seat install.

6

90950-01993

Push to seat install.

8

90950-01994

Push to seat install.

5

90950-01986

Push to seat install.

2

90950-01A06

Push to seat install.

2

90950-01A09

Push to seat install.

90950-01A31

Push to seat install.

Plug ‘8’

Plug ‘4’

Plug ‘F’

Plug ‘A’

Plug ‘3’

Plug ‘16’

Plug ‘2’
10

Plug ‘19’
2

Install this plug into the bottom of the frame rail as
shown.
90950-01A24

It must be installed with the channel opening facing the
outer portion of the frame to ensure road spray does
not enter the frame.

2

56

PLUG INSTALLATION 1/4

PLUG INSTALLATION 2/4

57

PLUG INSTALLATION 3/4

PLUG INTALLATION 4/4

58

ASSEMBLE THE NEW FRAME
1. PLACE THE NEW FRAME ON THE LIFT
a) Place the NEW frame on the lift, and secure it with a ratcheting tie down strap. This will prevent the
frame from tilting or falling off as parts are installed.
•

Ratcheting Tie Down: Qty 1
° Length: 2 in X 27 ft
° Minimum Work Load Capacity: 3,000 lbs

2. REINSTALL THE CAB MOUNTS
a) Reinstall cab mounts No.1 and No.2.
b) Reinstall cab mounts No.3 and No.4.

59

3. INSTALL THE FRONT SUSPENSION LOWER ARMS

NEW Replacement Parts
Part Number
48068-09100
48069-09090
90119-A0204
48190-34010
48452-34011
90178-18003
90201-19011
48198-34010
48409-34041

Part Name
Kit #
Arm Sub-Assy, Front Suspension,
NA*
Lower No.1 RH
Arm Sub-Assy, Front Suspension,
NA*
Lower No.1 LH
Bolt
2
Cam Assy, Camber Adjust
1
Plate, front Suspension Toe
1
Adjust, No.2
Nut
1
Washer
1
Cam, Camber Adjust, No.2
1
Cam Sub-Assy, Front Suspension
1
Toe Adjust
*Individual Part(s)

Qty
1
1
2
2
2
2
2
2

a) Install the NEW front suspension lower arm sub-assy
with NEW bolt, NEW toe adjusting cam, NEW toe
adjusting plate, NEW nut, NEW washer, NEW No.2
camber adjusting cam, NEW camber adjusting cam,
then torque to spec.
Torque Spec: 207 ft∙lbf (280N.m, 2855 kgf∙cm)
b) Repeat the procedure on the opposite side.

2

4. REINSTALL THE LOWER BALL JOINTS
NOTE:
• If the front suspension lower arm is to be replaced with a new one, install the lower ball joint on
the new front suspension lower arm.
• If the holes for the cotter pin are not aligned, tighten the axle nut further, up to 60 degree.
a) Reinstall the lower ball joint with the nut and torque to spec.
Torque Spec: 123 ft∙lbf (167 N∙m, 1703 kgf∙cm)
b) Install the NEW cotter pin.
c) Repeat the procedure on the opposite side.

60

5. INSTALL THE No.1 FRONT SPRING BUMPERS

NEW Replacement Parts
Part Number
48304-0C030
48304-0C030

Part Name
Bumper, Front Spring, No.1 RH
Bumper, Front Spring, No.1 LH

Kit #
2
2

Qty
2
2

a) Install the 2 NEW No.1 front spring bumpers to the
frame and torque to spec.
Torque Spec: 23 ft∙lbf (31 N∙m, 316 kgf∙cm)
b) Repeat the procedure on the opposite side.

6. REINSTALL THE ENGINE WIRE CLAMP

NEW Replacement Parts
Part Number
90119-A0170

Part Name
Bolt

Kit #
2

Qty
1

Torque Spec: 23 ft∙lbf (31 N∙m, 316 kgf∙cm)
7. REINSTALL THE No.2 FRONT ENGINE MOUNTING
BRACKET LH
Torque Spec: 24 ft∙lbf (32 N∙m, 326 kgf∙cm)

8. REINSTALL THE FRONT DIFFERENTIAL SUPPORT
ASSY (4WD ONLY)
a) Reinstall the front differential support assy with the nut
and bolt, then torque to spec.
Torque Spec: 83 ft∙lbf (113 N∙m, 1152 kgf∙cm)

61

9. REINSTALL THE No.1 REAR SPRING BUMPERS
a) Reinstall the No.1 rear spring bumper with the nut and
torque to spec.
Torque Spec: 22 ft∙lbf (30 N∙m, 306 kgf∙cm)
b) Repeat the procedure on the opposite side.

10. INSTALL THE REAR BUMPER BRACKETS

NEW Replacement Parts
Part Number
52173-0C080
52173-0C080
90119-A0050

Part Name
Bracket, Rear Bumper Bar, RH
Bracket, Rear Bumper Bar, LH
Bolt

Kit #
2
2
2

Qty
1
1
2

Part Name
Tube, Rear Brake, No.4
Tube, Rear Brake, No.5
Clamp, Brake Tube, No.6
Clamp, Brake Tube, No.7
Clamp, Brake Tube, No.8
*Individual Part(s)

Torque Spec: 71 in∙lbf (8.0 N∙m, 82 kgf∙cm)

11. INSTALL THE REAR BRAKE TUBES

NEW Replacement Parts
Part Number
47324-0C100
47325-0C120
90949-A1016
90469-A0004
90949-A1016

a) Install the rear 2 NEW bumper brackets with the 2
NEW bolts and torque to spec.

Kit #
NA*
NA*
2
2
2

Qty
1
1
2
6
2

a) Install the NEW rear brake tubes with the NEW
clamp(s).
NOTE:
The number of clamps will differ depending on the