N/A
N/A

11

D. PARTS ILLUSTRATION
Frame

Cab Mounting

Under Cover

Spare Tire Carrier

12

Front Suspension

13

Front Suspension Continued…

14

Rear Suspension

15

Brake Tubes

16

Brake Tubes Continued…

17

Brake Tubes Continued…

18

Brake Tubes Continued…

19

Brake Tubes Continued…

20

Brake Tubes Continued…

Fuel Tank

Fuel Tubes

21

ABS

Wire Harness Brackets

22

Power Steering

Front Differential

Engine Mounting

23

Propeller Shaft

1GR-FE Exhaust System

2TR-FE Exhaust System

24

Shift Lever

Radiator

Air Conditioning

Front Bumper

Rear Bumper

Rear Wheel House Liner

25

Moulding

Moulding Continued…

Moulding Continued…

26

FRAME INSPECTION
PERFORM INITIAL PRE-HOIST INSPECTION
1.

INSPECT THE FRAME FOR EXCESSIVE FRAME CORROSION THAT COULD AFFECT THE STRUCTURAL
INTEGRITY OF THE FRAME

FRAME INSPECTION
All frame inspection must be performed using the 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. INSPECT FOR FRAME RAIL SEAL
a. Inspect if the frame already has a frame rail seal installed as shown in the image below

Is the frame rail seal already
installed?

YES

No further action required. Campaign is
complete

NO

Proceed to the next step in the
frame inspection

27

2. ACCESS INSPECTION APPLICATION
a. Run the VIN in TIS and click on the Warranty Tab.
b. Click on the “Frame Inspection” link on TIS.

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

28

4. 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.

Select NO CRC Previously Applied: Select Frame Button

5. INSPECT THE FRAME SECTIONS
a. Inspect the frame in the colored areas below and use the application to document the results of the
inspection.
Tacoma 11 to 17

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

29

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
“Perforation of the Frame”.
Note: You must click the bubble next to the image to select the condition.
c.

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 reset section.
h. Select Next to move onto the next section.

30

Each image attached has a size limit of 3 MB and all images cannot exceed
15 MB total. If 3MB is uploaded the system will display the error shown below.
User using Chrome browser may receive intermittent errors when uploading
several high-quality images, IE is recommended.

i. Once all sections have been completed, select the Submit button.
Note: When completed it will be indicated by all sections being grayed out and the submit button will
appear.

31

NO Perforation Found
j. If no perforation was 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 inspection technician’s
TIS inbox and Service and Parts Manager email.

32

FRAME REPLACEMENT WORK PROCEDURE
A. PERFORM PRELIMINARY VEHICLE INSPECTION
1. Perform health check and record any preexisting DTCs
2. Test drive the vehicle and inspect the following vehicle functions/current operating conditions prior to vehicle
repair.
•
•
•
•
•
3.

4WD System (4WD Only)
Interior Lights
Exterior Lights
HVAC System
Audio System

•
•
•
•

Power Windows
Power Door Locks
All Gauges, Indicators and Warning Lights
Etc.

Documents the current vehicle operating condition on the Frame Replacement Inspection Sheet.
B. SAFETY CHECKLIST & PRECAUTIONS WHEN DRAINING THE FUEL SYSTEM
•
•
•
•

1.

Always remember “SAFETY FIRST”.
Be extremely careful when handling fuel to prevent fires from occurring.
Before beginning work on the fuel system, perform the following safety check list.
Before removing any fuel system part, drain all fuel to prevent spilling.

AIR VENTILATION
Perform work in a well-ventilated area.
DO NOT work underground or in an area where fuel vapors may fill the room due to poor ventilation.
Quickly clean up any spilled fuel with a dry cloth and dissipate the fuel vapors.
Dry all cloths that have come in contact with fuel in a well-ventilated area and dispose of them
properly (according to applicable local regulations).

2.

FIRES AND IGNITION SOURCES ARE STRICTLY PROHIBITED
Fires and ignition sources are prohibited while working on the fuel system.
Clearly display the sign found on the next page stating “WORKING WITH GASOLINE, NO FIRES OR IGNITION SOURCES”.
Smoking is prohibited near the work area.
DO NOT work in areas where there are welders, grinders, drills, electric motors, heaters, etc.
DO NOT use work lamps or any other electrical appliance due to the risk of sparks flying from the power switch or a rise in temperature.
DO NOT use metal hammers while working, due to the risk of flying sparks.
DO NOT start any engines or perform any of the above in neighboring work bays.

3.

FIRE EXTINGUISHER
Have a fire extinguisher ready and available before beginning work.

4.

PREVENT STATIC ELECTRICITY
To help prevent static electricity, lightly wet the floor with water, but not to the point where it creates a hazardous working condition.
Place appropriate warning cones or stand signs around the area as a caution.

5.

PRECAUTIONS WHEN USING A LIFT
For bays equipped with auto lifts, cover all access cover joints with duct tape.
In the event that fuel has leaked inside the auto lift, remove the access cover and clean up any spilled fuel. Dissipate fuel vapors until the
smell is gone.

6.

PREVENT THE FUEL FROM SPRAYING
When disconnecting any fuel tubes, pipes, hoses or connectors there may still be some pressure remaining, even after discharging the
system. To prevent the fuel from spraying, cover the tubes, pipes or connectors with a shop rag before disconnecting.
Remember to always wear protective goggles especially when disconnecting fuel tubes, pipes, hoses or connectors.

7.

PREVENT THE FUEL FROM CONTACTING OTHER PARTS
DO NOT allow the fuel to come in contact with any parts made of rubber or leather.

8.

ASSIGN A SAFETY SUPERVISOR
Assign a safety supervisor to be in charge of all safety precautions and fire hazards around the work area.

33

34

35

C. DISCHARGE THE FUEL SYSTEM PRESSURE
• DO NOT disconnect any part of the fuel system until you have discharged the fuel system
pressure.
• Even after discharging the fuel system pressure, place a piece of cloth around the tubes,
pipe, hoses and connectors as you separate them to reduce the risk of fuel spraying on
yourself, in the engine compartment and onto other parts.
• For additional repair information, please reference the appropriate repair manual in TIS for
the vehicle you are working on.
1.

CHECK FOR DTCs

2.

RECORD THE RADIO STATION PRESETS

3.

DISCONNECT THE NEGATIVE (-) BATTERY TERMINAL
NOTE: Wait 90 seconds after the negative (-) terminal cable is disconnected from the battery before
proceeding. Doing so will prevent the SRS from being deployed (i.e. airbag, seat belt pretensioner,
etc.).
4.

DISCHARGE THE FUEL SYSTEM PRESSURE
Remove the upper relay block cover.
Remove the circuit opening relay.
Connect the negative (-) battery terminal.
Start the engine.
Turn the ignition switch to ON after the engine stops.
NOTE: DTC P0171 (system too lean) may be present.
Crank the engine again, and check that the engine stops.
Remove the fuel tank cap, and discharge the pressure in
the fuel tank completely.
Disconnect the negative (-) battery terminal.
Reinstall the circuit opening relay.
Reinstall the upper relay block cover.

NOTE: Reinstall the No.1 upper relay block cover to not let foreign
objects enter.

36

D. REMOVE THE BED ASSY
• If the frame is perforated, ONLY raise the vehicle high enough to remove the tires.
• For added safety and support place jack stands under the front and rear portions of the
frame.
• DO NOT work directly underneath the vehicle when performing bed assy removal.
• The actual vehicle specs, equipment and parts required may differ than what is shown.
Please use the correct specifications and parts for the model you are working on.
• For additional repair information, please reference the appropriate repair manual found on
TIS for the vehicle you are working on.
1.

CENTER THE VEHICLE BETWEEN THE LIFT ARMS
Verify the vehicle is aligned with the center point of the lift to prevent interference and damage to the frame
and/or lift.
REMOVE THE FOLLOWING PARTS

2.
•
•
•
•
•

•
•
•
•
•

Rear Tail/Combination Light LH/RH
Rear Bumper Assy
Rear Mudguard LH/RH (If Equipped)
Side Step Assy LH/RH (If Equipped)
Rocker Panel Molding LH/RH (If Equipped)

Body Rocker Panel Molding Assy LH (If Equipped)
Outside LH Back Door Molding Sub-Assy (If Equipped)
Quarter Panel Wheel Opening Molding LH (If Equipped)
Left Rear Wheel Well Liner
Power Outlet Socket Assy (If Equipped)

When removing the parts, be careful not to damage them and surrounding
components.
3.

DISCONNECT THE FRAME WIRE HARNESS
Disconnect the clamps, connectors and the frame wire
harness from the bed assy.
NOTE:
• The number of connectors may differ depending
on the vehicle specification.
• Be careful not to damage the wire harness clamps
when removing them.

4.

DISCONNECT THE FUEL INLET PIPE SUB-ASSY
Remove the bolt and disconnect the fuel inlet pipe subassy.

5.

REMOVE THE BED ASSY
Using a Torx® T55H Socket, remove the 6 Torx ® bolts
from the bed assy.
NOTE:
• Use 4 or more people to remove the bed assy from
the frame.
• Evenly support the bed assy when removing it.
• Be careful not to damage the filler tubes when
removing the bed.
• Protect the front side of the bed assy to not
damage the cab assy.
37

E. REMOVE THE CAB BODY ASSY
• If the frame is perforated, ONLY raise the vehicle high enough to remove the tires.
• For added safety and support place jack stands under the front and rear portions of the
frame.
• DO NOT work directly underneath vehicle when performing cab assy removal, unless noted.
• The actual vehicle specs, equipment and parts required may differ than what is shown.
Please use the correct specs and parts for the model you are working on.
• For additional repair information, please reference the appropriate repair manual in TIS for
the vehicle you are working on.
1.

REMOVE THE ENGINE UNDER COVERS
NOTE: Use precaution when performing this step, as you will need to work underneath the vehicle.

2.

EVACUATE THE REFRIGERANT FROM THE AIR CONDITIONING SYSTEM

3.

DRAIN THE FOLLOWING FLUIDS
• Coolant
• Brake Fluid

4.

• Clutch Fluid (1GR-FE Manual Trans Only)
• Front Differential Fluid (4WD Only)

NOTE: DO NOT remove the radiator cap while the radiator and engine are hot, doing so may cause
the coolant to spray out causing potential injuries.
REMOVE THE FOLLOWING BODY COMPONENTS
• Radiator Grille
• Front Bumper Filler LH/RH (Except 2011MY)
• Front Fender Mudguard LH/RH

5.

• Front Bumper Assy
• Front Bumper Reinforcement
• Front No.2 Bumper Extension Sub-assy LH/RH

REMOVE THE FOLLOWING INTERIOR COMPONENTS
• Front Door Scuff Plate LH/RH
• Front Floor Footrest

• Cowl Side Trim Board LH/RH
6.

REMOVE THE INSTRUMENT PANEL BOX

7.

DISCONNECT THE FRAME WIRE HARNESS
Disconnect the 5 clamps.
Disconnect the connector(s).
NOTE: The number of connectors may differ depending
on the model.
Remove the frame wire harness grommet from the cab
assy.
Pull out the frame wire harness from the vehicle cab assy.

38

8.

DISCONNECT THE NO.2 FRAME WIRE HARNESS
(IF EQUIPPED)

For Frame Connecting Type:
Remove the 2 bolts and cover.

Disconnect the 2 connectors and clamp.

For Floor Connecting Type:
Remove all 4 passenger side seat rail bolts.
Tilt the passenger side seat backwards.
Turn back the floor carpet.
Remove the bolt and wiring harness protector.

Disconnect the 2 connectors.
Remove the No.2 frame wire harness grommet from the
cab assy.
Pull out the No.2 frame wire harness from the cab assy.

9.

REMOVE THE GLOVE BOX AND LOWER INSTRUMENT
PANEL FINISH PANEL
Remove the glove box.
Remove the bolt and the lower instrument panel finish
panel.
Disconnect the radio setting condenser connector. (If Equipped)

10. DISCONNECT THE ENGINE WIRE HARNESS
Disconnect each connector and clamp from the ECM and
remove the engine wire harness.
NOTE: The number of connectors may differ depending
on the model.

39

11. REMOVE THE FOLLOWING PARTS
• Rear Console Box (for Separate Seat Type)
• Front Console Box (Manual Trans Only)

• Voltage Inverter Assy (If Equipped)
• Manual Transmission Shift Lever (Manual Trans Only)
12. DISCONNECT THE PARKING BRAKE CABLES
For Separate Seat Type:
Remove the 2 clips.
Disconnect the 2 parking brake cables.

For Bench Seat Type:
Turn back the floor carpet.
Remove the 3 bolts and the parking brake cable joint
protector.

Remove the 2 clips.
Disconnect the 2 parking brake cables.

13. REMOVE THE FOLLOWING PARTS
• V-Bank Cover (1GR-FE Only)
• Air Cleaner Hose and Air Cleaner Assy (2TR-FE Only)

• Air Cleaner Assy (1GR-FE Only)