XXXXXXXXXXXXXXXXXXXXXXX IMPORTANT UPDATE XXXXXXXXXXXXXXXXXXXXXX

COLD CLIMATE STATES ONLY
CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI & WV and District of
Columbia

TECHNICAL INSTRUCTIONS
FOR
LIMITED SERVICE CAMPAIGN H0F
CERTAIN 2007 - 2008 MODEL YEAR TUNDRA
CORROSION-RESISTANT COMPOUND APPLICATION

COLD CLIMATE STATES ONLY
CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI & WV and District of
Columbia

UPDATED 12-8-2017
Update 12.8.17
• Update to Technician Certification Requirements
The repair quality of covered vehicles is extremely important to Toyota. All dealership technicians performing
this repair are required to successfully complete the most current version of the E-Learning course “Safety
Recall and Service Campaign Essentials”. The Technician must also be fitted for a NIOSH approved
respirator. 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:
• Maintenance Certified Technician and above
Always check which technicians can perform the recall remedy by logging on to
https://www.uotdealerreports.com. It is the dealership’s responsibility to select technicians with the above
certification level or greater to perform this 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.

For a complete list of site selection guidelines and, applicable fire, building, and zoning
code information for your state, please refer to the Dealer Information Packet. Please
ensure your dealership complies with all requirements and regulations set forth in the
applicable Dealer Information Packets and any Supplements.
Keep records to comply with Federal/State/Local regulations and requirements. See the
Dealer Packet for C0D and any Supplements to that Guide.

OPERATION FLOW CHART
Verify Vehicle Eligibility:
1. Check the TIS vehicle Inquiry system

No

No further action required.

No

Contact your regional
representative for assistance.

Yes
Is the vehicle registered in one of the Cold Climate States?
Yes
Did the vehicle pass the ZH7 frame inspection?

No

Yes
Remove the rust and clean the frame.

Was perforation 10mm or larger found in the locations identified in
green below (during the rust removal and/or cleaning process)?
Yes

Apply the 712AM Internal CRC to the areas of the frame outlined in the
Technical Instructions.

Proceed with Frame
Replacement as outlined in the
ZH7 TI.

Install the Body Plugs after applying the 712AM
and before applying the Noxudol 300S.
Apply Noxudol 300S (External Application) to the top, bottom and
sides of the frame as outlined in the TI.

After applying the CRCs place a CRC Customer Information
Hang Tag on the rear-view mirror.

After 24 hours, return the vehicle to the customer.

Campaign Completed.

Note: Ensure to follow the entire procedure and perform all steps completely (e.g. inspection,
cleaning/rust removal, CRC application, one kit per vehicle, etc.); any deviation will be subject to
warranty claim debit.

2

II.

IDENTIFICATION OF COVERED VEHICLES
A.
•

•
•

COVERED VIN RANGE
Vehicles currently registered in the Cold Climate States* or the District of Columbia (D.C.) that do
not have significant corrosion found are eligible for Corrosion-Resistant Compound (CRC)
application to the frame if it did NOT previously have the frame sprayed and/or had the frame
previously replaced.
Check TIS to confirm the VIN is covered in H0F. This will verify the vehicle is covered and 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.
* CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, and WV
**Refer to section V. for inspection procedures and criteria

III. PREPARATION
A.

PARTS
Please be aware that only dealers in Cold Climate States will be allowed to order the following CRC kit.
The necessary CRC kits can be ordered through the chemical program provided by Dealer Tire
(Complete Maintenance Care). The CRC kits will be shipped directly from AMREP. Your dealership
should not order kits until you have confirmed an appointment. However, please keep in mind it will take
at least 5 business days for CRC kit delivery. Deliveries are only scheduled on business days.
Saturday deliveries are not available.
Model
Tundra

Part No.
00289-T00KT-DS

Part Description
T00-Corros Res Kit (CRC Kit)

Qty/Unit
1

The kit above includes the following parts:
Noxudol 300S – 3 Liters
Parker 712AM – 1 Liter
1. When Ordering CRC Kits Please Note:
• Each kit will contain the exact amount of CRC for one vehicle.
• The CRC kits listed will be drop-shipped from AMREP, not your local PDC. Do not order
more than your immediate needs, as these materials are not returnable or refundable.
• Orders for these parts should be placed separately from orders of other drop ship
chemicals.
• Refer to the Appendix for the Safety Data Sheet (SDS).
2. When Storing the CRC Kits Please Note:
• Follow local, state and federal regulations for hazardous materials storage and disposal
that are explained in the Hazardous Waste Management Section of the Federal, State and
Local Requirements Guide of the Dealer Information Packet.
• Store the CRC kits at room temperature (refer to the SDS for detailed instructions).

3

B.

SUPPORT MATERIALS
•

The following support materials can be ordered through the dealer’s facing PDC:
Part Number
Part Description
04007-18234

Tundra Plug Kit

Qty
1 per vehicle

The kit listed above includes the following parts:

Part Number
90950-01A24
90950-01987
90950-01990
90950-01994
90950-01993
90950-01988
90950-01A09
90950-01A11
90950-01A06
90950-01986
90950-01826
90480-19374

•

Part Description
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE
PLUG,HOLE

Qty
2
8
3
6
8
2
10
2
2
2
2
1

The following support materials can be ordered through the dealer’s facing PDC:
Part Number
Part Description
04007-23234
Plug Kit

Qty
1 per vehicle

The kit listed above includes the following parts:

Part Number
90950-01A31
90480-A0002

•

Qty
2
4

The following support materials can be ordered through the MDC:
Part Number
Part Description
00411-11004

*

Part Description
PLUG,HOLE
PLUG,HOLE

Corrosion-Resistant Compound Customer Information Hang Tag*

Qty
1 per
vehicle

Additional CRC Customer Information Hang Tags can be ordered in packages of 50 through the MDC.

4

C.

STANDARD TOOLS & EQUIPMENT
• Standard hand tools
• Flat chisel
• Scraper
• Wire brush
• Air nozzle
• Infrared thermometer
• Air coupler (quantity 2)
SPECIAL EQUIPMENT
The following equipment was shipped to your dealership prior to the launch of LSC H0F.
Note: Due to federal, state and local regulations, each dealer is only allowed to have one set of
spray guns. Any old previous spray guns from previous campaigns should be disposed of in
accordance with local regulations.
As a result, each participating dealer will have 2 total spray guns in their possession:
Equipment
Purpose
Application Area
Spray Gun
Noxudol 300S
Exterior Frame CRC Application
Spray Gun
712AM
Interior Frame CRC Application
The items below were previously shipped to your dealership for previous CRC campaigns.
Magnet Kit
• 30 Rare Earth Magnets – See section VI.C.1 “Attach Plastic Sheet” for details.
*Follow the CRC Support link located in the left bottom corner of the C.L.E.A.N DEALER webpage.

D.

MATERIALS & SUPPLIES (Locally Procured by Dealer)
• Protective eyewear
• Dust mask
• Appropriate NIOSH approved respirator** (Follow all Federal, State, Local
Environmental, Health and Safety Requirements such as OSHA Regulations. Please
refer to the SDS for details on the appropriate mask for each CRC.)
Example of a NIOSH**Notes:
approved respirator
• Refer to the SDS located in the Appendix for additional information on respirator use.
• It is up to the individual dealership to ensure compliance with OSHA regulations.
• If you require further assistance in regards to NIOSH approved respirators, we have found
3M® to be a useful reference/source.
3M® Technical Assistance:
1-800-243-4630
3M® Customer Service:
1-800-328-1667
3M® Web Site:
www.3m.com/occsafety
• Protective gloves
• Chemical Resistant Gloves (refer to SDS for specific type)
• Masking tape
• Duct tape
• Fire-retardant poly sheeting (tarp) or covering (if you cannot purchase the tarp from a local supplier,
please refer to CRC Tips and Examples located on the C.L.E.A.N. DEALER website
(http://cleandealer.com) for a list of possible suppliers)
• Plastic (Saran Wrap) sheet (for spray gun storage)
• Partitions (The type, size, and number of partitions used will depend on each dealer’s facility.)
• Shop cloth/paper towels
• Funnel (quantity = 2)
• Plastic sheet to contain the dripping 712AM during frame application, 3m x 3m (118in x 118in)
• Garbage Bags

5

IV. BACKGROUND
Toyota has received a number of reports regarding Frame Corrosion on 2005 – 2010 model year Tacoma vehicles,
2007-2008 Tundra vehicles, and 2005-2008 Sequoia vehicles. In these reports, customers have indicated that
vehicles operated in specific cold climate areas with high road salt usage may exhibit more-than-normal corrosion
to the vehicle’s frame. This condition 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.
• Because of variations in state and local laws, dealerships conducting H0F in certain states may
require government approvals prior to starting the campaign. Depending upon the state, dealerships
also may be subject to restrictions on the number of vehicles to which the CRC can be applied in any
single day, week, or month. Please refer to Dealer Informaton Packet and any Supplements for
important information about any such approvals or restrictions that may apply to your dealership.
Your dealership must adhere strictly to these requirements.
• For a complete list of site selection guidelines, and fire, building, and zoning code information for
your state, please refer to the Dealer Information Packet (provided at the time of launch) as well as
any Supplements. Please ensure your dealership complies with all regulations and all issued
packets and instructions.

V.

VEHICLE INSPECTION WORK PROCEDURE

Vehicle frame inspection is performed under WEP ZH7. Reference
the Technical Instructions for WEP ZH7 to determine the repair
procedure for each vehicle.
VI. FRAME APPLICATION WORK PROCEDURE
•

A.

Due to the flash point of the CRC materials, allow sufficient time for the vehicle and
exhaust to cool down before beginning the application process. By following the
FRAME APPLICATION WORK PROCEDURE in these Technical Instructions, the
vehicle will have additional time to cool before the CRC’s are applied. Please refer to
the SDS (Located in the Appendix) for flash point temperatures.

WORK AREA SETUP (SUGGESTED)
1. INITIAL SETUP CONSIDERATIONS & GUIDELINES
a) Work with your Service Manager to locate a dedicated work area and lift with the following
requirements.
i. In well ventilated area.
ii. Away from other vehicles to minimize the possibility of overspray.
iii. In a location that can be sectioned off by partitions.
iv. In an area that provides sufficient distance from neighboring stalls.
v. In an area that meets the minimal space requirements as outlined in Site Selection Guide of the
Dealer Information Packet (provided at the launch of H0F) and any Supplements.
• A fire extinguisher, rated “B”, “AB” or “ABC”, must be located in an area that is within
at least 30’ of application area.
• Important Reminder: Because of specific fire and building code requirements, make
sure to review the Site Selection Guide of the Dealer Information Packet (provided at
the launch of H0F) and any Supplements to ensure that the area where you will
conduct the CRC application is compliant with the appropriate requirements.
Note: area set up may vary depending on dealership layout. The following information is just
one example of how an area might be set up for frame CRC application.

6

1. MASK THE LIFT SWING ARMS
a) Cover the lift swing arms with fire-retardant poly sheeting (tarp).
b) Secure the tarp with masking tape.
Notes:
• A two post above-ground lift is shown for reference
purposes.
• Inspect the tarp on a daily basis for damage (cuts, tears,
etc.) and replace as necessary.
• Dispose of old tarps in the same manner as other regulated
waste at your dealership. Refer to the Dealer Information
Packet for more info.
2. WORK AREA SETUP
a) Cover any exposed section(s) of the lift with fire-retardant poly
sheeting (tarp), and secure with masking tape.
b) Place the fire-retardant tarp(s) as shown in the illustration to
protect the floor.
Notes:
• When laying out the tarp on the floor, be sure it is secure
and does not create a slipping hazard when walked upon.
• Inspect the tarp on a daily basis for damage (cuts, tears,
etc.) and replace as necessary.
• Dispose of old tarps in the same manner as other regulated
waste at your dealership. Refer to the Dealer Information
Packet for more information.
• A two post above-ground lift is shown for reference purposes.
a) Setup partitions according to the facility needs of your
dealership.
Notes:
• The type, size, and number of partitions used will depend on
each dealer’s facility.
• Set up partitions according to the guidelines established in
the Fire, Building, and Zoning Code section of the Dealer
Information Packet (provided at the time H0F launch) and
any Supplements.
• Partitions should minimize any overspray to nearby stalls,
while ensuring adequate ventilation.
• Inspect the partition(s) on a daily basis for damage (cuts,
tears, etc.) and repair/replace as necessary.
• Dispose of used partitions in the same manner as other
regulated waste at your dealership. Refer to the Dealer
Information Packet for more information.
c) Position the partitions around the vehicle to prevent overspray,
as shown in the illustration.
Note: The partitions shown are just an example of what can be
used.

7

B.

VEHICLE PREPARATION AND REMOVAL OF FRAME RUST
1. PREPARE THE VEHICLE
a) It may be necessary to pressure wash the vehicle’s

frame, depending on its cleanliness.
Note: Time has been allotted to pressure wash the frame in the
flat rate time.
b) Place the vehicle on the lift.
Strap the vehicle to the lift with safety straps. Once
the vehicle is raised to the desired height, install
screw jacks to the front and back of the vehicle.
c)
d)
e)
f)
g)
h)
i)
j)

Raise up the vehicle and remove the wheels.
Remove the engine under cover.
Remove the rear mudguards. (IF Equipped)
Remove the license plate light assy LH/RH
Remove the rear bumper plate. (With Trailer Hitch)
Remove the rear bumper assy.
Cover any identifying label (i.e., VIN label, etc.) on the frame
with tape.
Cover all exposed electrical connectors with tape to protect
from over spray.

2. REMOVE RUST FROM THE FRAME AND CROSS-MEMBERS.
a) Using a scraper / chisel or any power tools (ex : Air needle
scaler), remove loose rust and rust scales from the frame and
cross-members shown on the left.
b) If rust perforation of 10mm or larger and/or component corrosion
damage is found in the blue area during the rust removal
process proceed to the appropriate campaign for repairs.
Notes:
• Be careful not to damage the wire harness or brake line and
fuel line when removing rust.
• Make sure to wear protective eyewear, gloves, and a dust
mask when removing rust and cleaning frame.
• Be extremely cautious not to injure your hands.
• DO NOT scratch or remove the identifying labels (i.e., VIN
label, etc.) from the frame.

8

3. CLEAN THE FRAME
a) Use a wire brush and remove any remaining rust or dirt from the
frame.
Ensure to follow the procedure and perform all steps completely
(e.g. inspection, cleaning/rust removal, CRC application, one kit
per vehicle, etc.) any deviation will be subject to warranty claim
debit.
b) Use an air nozzle and remove any loose rust.
Notes:
• Make sure to wear protective eyewear, gloves, and a dust
mask when performing this step.
• A slightly wet frame surface (no water droplets) is
acceptable when applying the frame CRC.

Sample of Sufficient Frame Cleaning

Before

After

Note: A slightly wet frame surface (no water droplets) is acceptable when applying the frame CRC.

C.

FINAL FRAME RUST CORROSION PERFORATION INSPECTION
1. VISUALLY INSPECT FOR FRAME PERFORATION AFTER
RUST REMOVAL
a) Visually inspect the specific area highlighted in blue to ensure
no perforation was uncovered during the rust removal
process
b) If rust perforation of 10mm or larger is found in the blue
areas, proceed to Frame Replacement work procedure.

D.

VEHICLE PROTECTION
1. ATTACH MASKING MATERIALS
a) Using an infrared thermometer ensure the exhaust has cooled.
b) Cover the driveshaft(s) and exhaust, with fire-retardant poly
sheeting (tarp) and secure with masking tape.
c) Cover the front and rear brake/hub assemblies with garbage
bags and secure with masking tape.
Notes:
• Cover the air suspension, and shock absorber (if necesary)
with masking sheets.
• Overspray onto the driveshaft may cause vehicle vibration.

9

2. COVER SPARE TIRE CONTACT SURFACES ON REAR CROSSMEMBER
a) Cover the underside of the rear cross-member with duct tape
where the spare tire contacts the rear cross-member.
Notes:
• Tape will prevent Noxudol 300S from sticking to the tire.

Front

E.

PREPARE FOR APPLICATION OF CORROSION-RESISTANT COMPOUND (CRC)

Plastic Sheet Size

Attach to Floor Pan

• 3m x 3m(118inx118in)
• Thickness = 2 mil

1. ATTACH PLASTIC DRIP SHEET
a) Before spraying 712AM to the internal frame, fit the plastic sheet
on the frame utilizing the supplied magnet kit.

Magnet

2. SPRAY GUN SET UP FOR 712AM INTERNAL CRC
Notes:
• Use a dedicated spray gun for the 712AM internal CRC and
mark/label the gun for 712AM.
• Make sure to wear protective eyewear, impervious gloves
(Viton, PVOH, etc.) appropriate Niosh approved respirator,
and refer to the MSDS located in the Appendix when
handling and spraying CRC.
a) Check the temperature of the 712AM.
Note: If the 712AM is below 72º F, place the 712AM container in
a bucket of hot water (