14. DISCONNECT THE NO.2 ENGINE WIRE HARNESS
Remove the nut and disconnect the (+) positive battery
cable.
Remove the bolt and disconnect the ground wire.
Disconnect the 2 clamps.

Remove the upper relay block cover.
Disconnect the 3 connectors.
Remove the nut and disconnect the fuse box wire harness.
Reinstall the upper relay block cover.

40

LH Side

15. DISCONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS
Disconnect the harness clamp and front skid control sensor
connector.
Repeat the procedure on the opposite side.

RH Side

RH Side

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

Disconnect the harness clamp and connector.

17. DISCONNECT THE FRONT DIFFERENTIAL BREATHER
TUBES (4WD ONLY)
Disconnect the front differential breather tubes.
NOTE: There may be 2 front differential breather tubes
depending on the vehicle model.
18. DISCONNECT THE FUEL PIPES AND VAPOR FEED HOSE
Remove the 2 fuel pipe clamps.
Disconnect the No. 1 and No. 2 fuel pipe.
Remove the clip and disconnect the fuel vapor feed hose.
NOTE: Put a shop towel under the fuel pipe to catch
any spilled fuel.

19. DISCONNECT THE VACUUM HOSE
Disconnect the vacuum hose.

41

20. DISCONNECT THE RADIATOR HOSES AND AUTO TRANS COOLING LINES (Auto Trans Only)
Disconnect the inlet and outlet radiator hoses from engine.
Disconnect the inlet and outlet auto transmission cooling lines from the radiator
Be careful not to damage the radiator hoses.

21. REMOVE THE FOLLOWING PARTS
• Radiator Support to Frame Seal
• Fan Shroud

• Radiator Assy
22. DISCONNECT THE NO.1 HOSE
2TR-FE Only (Shown):
Disconnect the No.1 hose from the air pump assy.
Remove the bolt and disconnect the ground wire.
2012-2015MY (1GR-FE Only):
Disconnect the No.1 hose from the air pump assy.
23. DISCONNECT THE POWER STEERING PUMP OIL
RESERVOIR ASSY (1GR-FE ONLY)
Disconnect power steering pump oil reservoir assy.
24. DISCONNECT THE GROUND WIRE (1GR-FE ONLY)
Remove the bolt and disconnect the clamp and the ground
wire.
25. DISCONNECT THE ENGINE WIRE HARNESS
Disconnect the clamp.
Remove the engine wire harness container from the cowl
panel.
26. DISCONNECT THE WATER / HEATER HOSES, ENGINE
SIDE

LH Side

27. REMOVE THE FRONT FENDER APRON SEALS
4WD, Pre-Runner Only (Shown):
Remove the 20 clips and 4 front fender apron seals.

2WD Only:
RH Side

Remove the 22 clips and 4 front fender apron seals.

42

28. DISCONNECT THE AIR CONDITIONING DISCHARGE AND
SUCTION HOSES FROM THE COMPRESSOR

29. DISCONNECT THE SUCTION HOSE BRACKET

LH Side

30. DISCONNECT THE FRONT BRAKE TUBES
Disconnect the front brake tube.
Repeat the procedure on the opposite side.

RH Side

31. DISCONNECT THE STEERING SLIDING YOKE
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
Make sure the front wheels are in a straight-ahead position
and the steering wheel is centered.
Using the seat belt, hold the steering wheel in position as
shown in the illustration, to prevent damage to the spiral
cable.
Place match marks on the steering sliding yoke and No.2
intermediate shaft.
Loosen bolt (A) and remove bolt (B).
Disconnect the steering sliding yoke from the No.2
intermediate shaft.
NOTE: If the steering sliding yoke is stuck, tap it from
below with a brass hammer to disconnect it.
32. DISCONNECT THE SHIFT CABLE (AUTO TRANS ONLY)
Cable Type (Shown):
Remove the clip.
Remove the nut and disconnect the shift cable.
Rod Type:
Remove the pin and clip, disconnect the shift cable.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
43

33. DISCONNECT THE CLUTCH RELEASE CYLINDER ASSY
(2TR –FE MANUAL TRANS ONLY)

Remove the bolt and disconnect the clutch hose.
Remove the 2 bolts and disconnect the clutch release
cylinder.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
34. DISCONNECT THE NO.1 CLUTCH HOSE
(1GR-FE MANUAL TRANS ONLY)

Disconnect the clutch release cylinder tube from the clutch
hose.
Remove the clip and disconnect the clutch hose.

35. DISCONNECT THE NO.2 FUEL HOSE
Remove the clip and disconnect the No.2 fuel hose.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
36. DISCONNECT THE FUEL TANK TUBES
Remove the fuel pipe clamp.
Disconnect the 2 fuel tank tubes.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
37. DISCONNECT THE REAR BRAKE TUBES
Disconnect the 2 rear brake tubes.
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.
38. DISCONNECT THE PARKING BRAKE CABLES
NOTE: Use precaution when performing this step, as
you will need to work underneath the vehicle.

39. REMOVE THE FOLLOWING PARTS (ACCESS CAB ONLY)
• Floor Board No.1/No.2
• Seat Floor Box
• Rear Floor Side Service Hole Cover LH/RH)

• Rear Lower Console Box
• Rear Seat Cushion Assy
• No.1 w/ Box Speaker Assy (If Equipped)

44

40. REMOVE THE CAB BODY ASSY USING AN ABOVE GROUND LIFT
Remove the 4 hole plugs.
Remove the 6 nuts, 6 washers and 6 bolts.
Set the lift arms under the cab body assy so they DO NOT interfere with the frame or cab mounts.
Check that all wire harnesses, hoses, cables and the steering shaft are disconnected.
Mark the location of the tires so it will be easier to install the cab onto the new frame.
Lift the cab assy up slowly, making sure it does not interfere with anything while being raised.
Raise the cab assy high enough so that the top of the engine clears the lowest point of the cab assy.
Pull the frame assy out from under the vehicle.
Lower the cab assy all the way down and leave it on the lift.
Reinstall the 6 bolts, they will be used as guides during cab assy reinstallation.
NOTE:
• Center the cab assy weight on the lift arms so that it does not slant/tilt to one side.
• Raise the cab assy slightly off the frame and verify that it is held securely by the lift arms.
• The center of gravity of the cab body may become nose heavy depending on placement of the lift
arm which could cause the cab to fall when lifted. To prevent this, use weights to establish a
balance and secure the cab body to the lift arm using ratchet tie down belts.
• DO NOT work directly underneath the vehicle when pulling the frame assy out from under.

F. DISASSEMBLE THE FRAME
1. PLACE THE FRAME ON A LIFT
Place the 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 removed.
• Ratcheting Tie Downs: Qty 1 (Length: 2 in X 27 ft and Min. Work Load Capacity: 3,000 lbs)
2.

DISCONNECT THE FRONT PROPELLER SHAFT ASSY
(4WD ONLY)

Remove the 4 nuts from transfer case side of the front
propeller shaft assy.

3.

REMOVE THE FOLLOWING PARTS
• Wheels
• Propeller Shaft Heat Insulator (If Equipped)
• Rear Propeller Shaft Assy
• Exhaust Pipe Stopper Bracket (If Equipped)
• Insert SST 09325-40010 into trans after the Rear Prop Shaft is removed to prevent oil leakage (2WD Only)
45

NOTE: Place match marks on the front (if equipped) and rear propeller shafts prior to removal.

4.

REMOVE THE EXHAUST SYSTEM

(1GR-FE ONLY)

Remove the 2 bolts and 2 springs.
Disconnect the 4 exhaust pipe supports from the frame and
remove the center exhaust pipe assy.
Remove the exhaust pipe gasket.

Disconnect the 2 exhaust pipe supports from the frame.

5.

REMOVE THE EXHAUST SYSTEM

(2TR-FE ONLY)

Remove the 2 bolts and 2 nuts.
Disconnect the 4 exhaust pipe supports from the frame and remove the center exhaust pipe assy.
Remove the exhaust pipe gasket.
Disconnect the 2 oxygen sensor wire harness clamps.
Disconnect the exhaust pipe support from the frame.

6.

REMOVE THE FOLLOWING PARTS

• No.2 Fuel Tank Protector (If Equipped)
• V-belt
• No.1 Fuel Tank Protector Assy (If Equipped)
• Fuel Tank
• Fuel Tank Straps
• Charcoal Canister Assy
7. REMOVE AND SET ASIDE THE POWER STEERING VANE PUMP
Disconnect the connector.
Disconnect the clamp. (1GR-FE Only)
Remove the bolt and disconnect the ground wire. (1GR-FE Only)
Remove the 2 bolts and the power steering vane pump.
NOTE:
• DO NOT disconnect the power steering vane pump hoses or tubes.
• Keep the power steering pump reservoir upright to prevent the fluid from leaking out.
8. REMOVE THE FOLLOWING PARTS
• Intake Air Surge Tank (1GR-FE Only)

• Intake Air Connector (2TR-FE Only)

46

9.

LH Side

DISCONNECT THE OIL COOLER TUBE (AUTO TRANS ONLY)
Remove the bolts and disconnect the oil cooler tube.

10. REMOVE THE ENGINE AND TRANSMISSION ASSY
Remove the bolt and disconnect the ground wire. (LH Side)
Disconnect the connector and clamp. (4WD Only)
Disconnect the clamp. (2TR-FE Only)
Disconnect and remove the necessary items/parts to
prepare the engine and transmission assy for removal.
Install the engine hanger.

RH Side (4WD Only)

For 1GR-FE:
12281-31060 = No.1 Engine Hanger
12282-31040 = No.2 Engine Hanger
90119-08A87 = 4 Bolts

RH Side (2TR-FE Only)

For 2TR-FE:
12281-75050 = 2 Engine Hangers
91672-81025 = 2 Bolts

Remove the engine and transmission assy.
NOTE:
• Hang up the front exhaust pipe with string to avoid
applying pressure at the joint part. (2TR-FE only)
• ALWAYS use 2 engine hoists/cranes to lift it.
• DO NOT use 1 engine hoist/crane to lift the engine
& transmission assy, as the unbalanced weight
may lead to an accident or injury.
• ONLY use engine hoists/cranes that can properly
support the weight of the engine and transmission
assy.
• Carefully adjust the 2 engine hoists/cranes used
so that the engine and transmission assy is
properly balanced.
47

Be careful not to damage exhaust system while removing the engine and trans mission assy.
11. REMOVE THE FRONT PROPELLER SHAFT ASSY (4WD ONLY)
12. DISCONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS (2WD ONLY)
2011MY RH Side:
Remove the bolt, disconnect the clamp and skid control
sensor wire harness.

Except 2011MY RH Side:
Remove the 2 bolts and skid control sensor wire harness.
Repeat the procedure on the opposite side.

13. DISCONNECT THE FRONT SKID CONTROL SENSOR
WIRE HARNESS (4WD, PRE-RUNNER ONLY)
Remove the bolt and disconnect the skid control sensor
wire harness.
Repeat the procedure on the opposite side.

14. DISCONNECT THE FRONT BRAKE HOSE (2WD ONLY)
Disconnect the front brake tube from the brake hose.
Remove the 2 bolts and disconnect the front brake hose
and flexible hose bracket.
Repeat the procedure on the opposite side.

15. DISCONNECT THE FRONT BRAKE HOSE
(4WD, PRE-RUNNER ONLY)

Disconnect the front brake tube from the brake hose.
Remove the bolt and disconnect the front brake hose and
flexible hose bracket.
Repeat the procedure on the opposite side.
16. REMOVE THE FOLLOWING PARTS
• Front Axle Hub Grease Cap (4WD Only)
• Front Axle Shaft Nut (4WD Only)
• Tie Rod End*

• Front Stabilizer Link Assy
• Lower Ball Joint Attachment**
48

* SST 09610-20012 (2WD), SST 09628-62011 (4WD, Pre-Runner) disconnect the tie rod end.
**SST 09628-00011

17. REMOVE THE FRONT SUSPENSION UPPER ARM AND
STEERING KNUCKLE ASSY (2WD ONLY)
Remove the 2 bolts, 2 nuts, 2 washers and front
suspension upper arm w/ steering knuckle.
Repeat the procedure on the opposite side.

18. REMOVE THE FRONT SUSPENSION UPPER ARM AND
STEERING KNUCKLE ASSY (4WD, PRE-RUNNER ONLY)
Remove the bolt, nut, 2 washers and front suspension
upper arm w/ steering knuckle.
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.
19. REMOVE THE FOLLOWING PARTS
• Front Drive Shaft Assy (4WD Only) *
• Front Shock Absorber Assy
• Front Suspension Member Brace Sub-Assy
• Power Steering Link Assy w/ Pump
• Front Stabilizer Bar
• Front Differential Carrier (4WD Only)
*SST 09520-24010 (09520-32040),09520-01010
NOTE:
• When removing the power steering link with the pump, have one person support the power
steering link and the other support the pump and keep it upright to avoid fluid leakage.
• If the drive shaft is difficult to remove tap it with a plastic hammer.
• Be careful not to damage the dust cover and oil seal.
20. DISCONNECT THE PARKING BRAKE CABLES
Remove the 6 bolts and parking brake cables.

21. REMOVE THE FRAME WIRE HARNESS
Remove the bolt and disconnect the ground wire
(If Equipped).
Disconnect the clamps 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.

49

22. REMOVE THE NO.2 FRAME WIRE HARNESS (IF EQUIPPED)
Disconnect the clamps 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.
23. REMOVE THE NO.2 FLEXIBLE HOSE BRACKET
Disconnect the No.5 rear brake tube.
Disconnect the No.6 rear brake tube.
Remove the 2 clips and disconnect the 2 brake hoses.
Remove the 2 bolts and No.2 flexible hose bracket.

24. REMOVE THE FOLLOWING PARTS
• Spare Tire Carrier Assy (2012-2015MY)
• No.1 Rear Spring Bumper (2WD Only)

• Rear Stabilizer Bar (If Equipped)
25. REMOVE THE LEAF SPRINGS AND SHOCK ABSORBER
ASSY

For this campaign, the leaf springs will not be replaced. However, if eligible, replace leaf springs
under E02. If the vehicle is not eligible for E02, or already had E02 performed, there is no need
to separate the rear differential from the leaf springs, remove the leaf springs and rear diff as an
assembly.
26. REMOVE THE SKID CONTROL SENSOR WIRE BRACKET
(W/ REAR DIFFERENTIAL LOCK ONLY)

Remove the bolt.
Cut the clamp (A) using nippers.
Disconnect the 2 clamps and 2 connectors to remove the 2
brackets.
Remove the clamp (A) from the bracket.

27. REMOVE THE NO.2 CHARCOAL CANISTER PIPE
Disconnect the clamps and remove the No.2 charcoal
canister pipe.

50

28. REMOVE THE FRAME AUXILIARY CROSSMEMBER
EXTENSIONS (IF EQUIPPED)
Remove the 2 bolts and frame auxiliary crossmember
extensions.

29. REMOVE THE HOOK
Remove the 2 bolts and hook.

30. REMOVE THE REAR ENGINE MOUNTING REINFORCES
(1GR-FE ONLY)

Remove the 2 bolts and 2 rear engine mounting reinforces.

31. REMOVE THE PARKING BRAKE CABLE HEAT
INSULATOR (IF EQUIPPED)
Remove the 2 bolts and parking brake cable heat insulator.

32. REMOVE THE NO.1 RECEIVER HITCH ATTACHMENT
REINFORCEMENT (IF EQUIPPED)
Remove the 2 bolts and No.1 receiver hitch attachment
reinforcement.

33. REMOVE THE CAB MOUNTS
34. REMOVE THE FRAME FROM THE LIFT
Remove the ratcheting tie down strap and the frame from the lift.

51

G. PLUG HOLES IN REPLACEMENT FRAME (see Appendix)
1.

PLACE THE NEW FRAME ON THE LIFT
Place the NEW frame on the lift, and secure it with a ratcheting tie down strap.
• Ratcheting Tie Downs: Qty 1 (Length: 2 in X 27 ft and Min. Work Load Capacity: 3,000 lbs)
Install all plugs. Use the picture found in appendix to reference the plug installation.
NOTE:
• You may have to remove certain stickers to install optional equipment.
• You may not install all the plugs in plug kit.
• Make sure all the plugs are flush with the frame.
• Make sure the surface of the frame is clean before you apply stickers.

52

H. ASSEMBLE THE FRAME
Part #
51719-04010

NEW Replacement Parts
Part Name
Kit #
Holder, Body Support Bracket
2

Qty
2

1.

INSTALL THE NEW CLIPS

2.

REINSTALL THE NO.1 RECEIVER HITCH ATTACHMENT
REINFORCEMENT (IF EQUIPPED)
Reinstall the No.1 receiver hitch attachment reinforcement
with the 2 bolts and torque to spec.
Torque Spec: 45 N∙m (459 kgf∙cm, 33 ft∙lbf)
Repeat the procedure on the opposite side.

3.

REINSTALL THE NO.1 REAR SPRING BUMPER
(2WD ONLY)

Reinstall the rear spring bumper with the 2 nuts and torque
to spec.
Torque Spec: 15 N∙m (153 kgf∙cm, 11 ft∙lbf)
Repeat the procedure on the opposite side.
4.

REINSTALL THE PARKING BRAKE CABLE HEAT
INSULATOR (IF EQUIPPED)
Reinstall the parking brake cable heat insulator with the 2
bolts and torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)

Part #
82715-04290
82715-04200
90119-A0169

NEW Replacement Parts
Part Name
Bracket
Bracket
Bolt
*Individual Part(s)

Kit #
NA*
NA*
NA*

Qty
1
1
2

5.

INSTALL THE NEW OXYGEN SENSOR BRACKETS
(2TR-FE ONLY)