NHTSA ID Number: 10166366
Manufacturer Communication Number: ZKA-TI-090519
TSB/Document Date: 2019-10-21
Summary
Technical Instructions: TECHNICAL INSTRUCTIONS FOR CUSTOMER SUPPORT PROGRAM ZKA CERTAIN 2011 THROUGH 2015 MODEL YEAR TACOMA COVERAGE FOR VEHICLE FRAME CORROSION PERFORATION
Install the 2 NEW brackets with the 2 NEW bolts and
torque to spec.
Torque Spec: 29 N∙m (296 kgf∙cm, 21 ft∙lbf)
53
6.
REINSTALL THE REAR ENGINE MOUNTING
REINFORCES (1GR-FE ONLY)
Reinstall the rear engine mounting reinforces with the 2
bolts and torque to spec.
Torque Spec: 31 N∙m (316 kgf∙cm, 23 ft∙lbf)
Part #
90119-A0192
90119-A0193
NEW Replacement Parts
Part Name
Kit #
Bolt
8
Bolt
NA*
*Individual Part(s)
7.
Qty
2
2
REINSTALL THE HOOK
Reinstall the hook with the 2 NEW bolts and torque to
spec.
Torque Spec: 70 N∙m (714 kgf∙cm, 52 ft∙lbf)
8.
REINSTALL THE FRAME AUXILIARY CROSSMEMBER
EXTENSION (IF EQUIPPED)
Reinstall the 2 frame auxiliary crossmember extensions
with the 2 bolts and torque to spec.
Torque Spec: 45 N∙m (459 kgf∙cm, 33 ft∙lbf)
9.
REINSTALL THE CAB MOUNTS
Reinstall cab mounts No.1
Reinstall cab mounts No.2 and No.3 with the 8 bolts and
torque to spec.
Torque Spec: 61 N∙m (622 kgf∙cm, 45 ft∙lbf)
10. INSTALL THE NEW FRONT SUSPENSION LOWER ARM (2WD ONLY)
Install the NEW front suspension lower arm with the 2 NEW nuts, 2 NEW No.1 camber adjust cams and 2
NEW No.2 camber adjust cams, then torque to spec.
Torque Spec: 210 N∙m (2141 kgf∙cm, 155 ft∙lbf)
Repeat the procedure on the opposite side.
54
2WD Only
Part #
48069-04030
48068-04030
48190-25010
48198-25010
90178-A0013
NEW Replacement Parts
Part Name
Arm Sub-Assy, Front
Suspension, Lower No.1, LH
Arm Sub-Assy, Front
Suspension, Lower No.1, RH
Cam, Front Suspension
Camber Adjust, No.1 LH/RH
Cam, Front Suspension
Camber Adjust, No.2 LH/RH
Nut
*Individual Part(s)
Kit #
Qty
NA*
1
NA*
1
4
4
4
4
NA*
4
11. INSTALL THE NEW FRONT SUSPENSION LOWER ARM (4WD, PRE-RUNNER ONLY)
Install the NEW front suspension lower arm with the NEW bolt, NEW nut, NEW toe adjust cam, NEW No.2
toe adjust cam, NEW No.1 camber adjust cam and NEW No.2 camber adjust cam, then torque to spec.
Torque Spec: 135 N∙m (1377 kgf∙cm, 100 ft∙lbf)
Repeat the procedure on the opposite side.
Part #
48069-04040
48068-04040
48190-60020
48198-60011
48409-60020
48452-35020
90119-A0166
90178-A0001
NEW Replacement Parts
Part Name
Arm Sub-Assy, Front
Suspension, Lower No.1, LH
Arm Sub-Assy, Front
Suspension, Lower No.1, RH
Cam, Front Suspension
Camber Adjust, No.1 LH/RH
Cam, Front Suspension
Camber Adjust, No.2 LH/RH
Cam, Sub-Assy, Front
Suspension Toe Adjust
Plate, Front Suspension Toe
Adjust, No.2
Bolt
Nut
*Individual Part(s)
Kit #
Qty
NA*
1
NA*
1
5
2
5
2
5
2
5
2
8
NA*
2
2
NEW Replacement Parts (2WD Only)
Part Name
Kit # Qty
NA*
2
Bumper, Front Spring,
LH/RH**
NA*
2
*Individual Part(s)
**Only 1 part used, part number varies by vehicle type.
Part #
48304-AD010
48304-04090
4WD, Pre-Runner Only
12. INSTALL THE NEW FRONT SPRING BUMPER
Using the SST 09922-10010-01, install the NEW front
spring bumpers and torque to spec.
Torque Spec: 31 N∙m (316 kgf∙cm, 23 ft∙lbf)
Repeat the procedure on the opposite side.
Part #
48304-04100
NEW Replacement Parts
(4WD, Pre-Runner Only)
Part Name
Kit #
Bumper, Front Spring, LH/RH
8
Qty
2
13. INSTALL THE NEW REAR BRAKE TUBES
Install the NEW rear brake tubes with the NEW clamp(s).
55
Part #
47325-*****
47326-*****
NEW Replacement Parts
Part Name
Kit #
Tube, Rear Brake, No.5
NA*
Tube, Rear Brake, No.6
NA*
NA*
90469-A0004
Clamp, Brake Tube, No.11**
NA*
NA*
90949-A1006
Qty
1
1
2
or
3
or
4
3
Clamp, Brake Tube, No.10
2
*Individual Part(s)
** Only 1 part used, part number varies by vehicle type.
14. REINSTALL THE NO. 2 CHARCOAL CANISTER PIPE
Reinstall the fuel return and main tube support.
Reinstall the No.2 charcoal canister pipe.
NEW Replacement Parts
Part Name
Kit # Qty
Bolt
2
4
NA*
1
Carrier
Assy, Spare Wheel**
NA*
1
*Individual Part(s)
** Only 1 part used, part number varies by vehicle type.
Part #
90119-A0169
51900-35410
51900-35420
15. INSTALL THE NEW SPARE TIRE CARRIER ASSY
(2011MY ONLY)
Install the NEW spare tire carrier assy with the 4 NEW
bolts and torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
16. REINSTALL THE SPARE TIRE CARRIER ASSY
(2012-2015MY ONLY)
Reinstall the spare tire carrier assy with the 4 NEW bolts
and torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
Part #
82715-04250
82715-04260
82711-16830
90105-A0066
NEW Replacement Parts
Part Name
Bracket
Bracket
Clamp
Bolt
*Individual Part(s)
Kit #
NA*
NA*
NA*
NA*
Qty
1
1
1
1
17. INSTALL THE NEW SKID CONTROL SENSOR WIRE
BRACKET (W/ REAR DIFFERENTIAL LOCK ONLY)
Install the NEW clamp (A).
Install the 2 NEW brackets with the 2 clamps and 2
connectors.
Install the NEW bolt.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
Part #
90177-A0010
NEW Replacement Parts
Part Name
Kit #
Nut
2
*Individual Part(s)
Qty
2
18. REINSTALL THE LEAF SPRINGS AND SHOCK
ABSORBER ASSY
Reinstall the leaf springs with the 4 bolts, 4 washers and 4
nuts, then torque to spec.
Torque Spec: 120 N∙m (1224 kgf∙cm, 89 ft∙lbf)
Reinstall the shock absorber assy with the 2 NEW nuts, 2
retainers and 2 cushions, then torque to spec.
Torque Spec: 20 N∙m (204 kgf∙cm, 15 ft∙lbf)
56
19. REINSTALL THE REAR STABILIZER BAR (IF EQUIPPED)
Part #
90119-08A91
Part #
90468-A0007
90119-A0169
NEW Replacement Parts
Part Name
Kit #
Bolt
NA*
*Individual Part(s)
NEW Replacement Parts
Part Name
Clip
Bolt
Qty
4
20. REINSTALL THE NO.2 FLEXIBLE HOSE BRACKET
Kit #
2
14 or
15
or
NA*
Qty
2
2
*Individual Part(s)
Part #
82715-04200
82715-04290
82715-04240
82715-04350
90119-A0169
Reinstall the rear stabilizer bar with the 2 brackets and 4
NEW bolts, then torque to spec.
Torque Spec: 30 N∙m (306 kgf∙cm, 22 ft∙lbf)
Reconnect the 2 stabilizer bar links with the 4 nuts, then
torque to spec.
Torque Spec: 65 N∙m (663 kgf∙cm, 48 ft∙lbf)
NEW Replacement Parts
Part Name
Bracket
Bracket
Bracket
Bracket
Bolt
*Individual Part(s)
Kit #
NA*
NA*
NA*
NA*
NA*
Qty
1
1
1
1
4
Reinstall the No.2 flexible hose bracket with the 2 NEW
bolts.
Reconnect the 2 brake hoses with the 2 NEW clips.
Connect the No.5 and No.6 rear brake tubes, then torque
to spec.
Torque Spec:
Flexible hose bracket - 29 N∙m (296 kgf∙cm, 21 ft∙lbf)
Rear brake tube - 15.2 N∙m (155 kgf∙cm, 11 ft∙lbf)
21. INSTALL THE NEW NO.2 FRAME WIRE HARNESS
BRACKETS (IF EQUIPPED)
Install the NEW bracket (A) with the NEW bolt and torque
to spec. (Except 2TR-FE)
Torque Spec: 29 N∙m (296 kgf∙cm, 21 ft∙lbf)
Install the NEW bracket (B) with the NEW bolt and torque
to spec. (Except 2TR-FE)
Torque Spec: 29 N∙m (296 kgf∙cm, 21 ft∙lbf)
For Floor Connecting Type:
Rear Side
(Floor Connecting Type)
Rear Side
(Frame Connecting Type)
Install the NEW bracket with the NEW bolt and torque to
spec.
Torque Spec: 29 N∙m (296 kgf∙cm, 21 ft∙lbf)
For Frame Connecting Type:
Install the NEW bracket with the 2 NEW bolts and torque to
spec.
Torque Spec: 29 N∙m (296 kgf∙cm, 21 ft∙lbf)
22. REINSTALL THE NO.2 FRAME WIRE HARNESS
(IF EQUIPPED)
Reconnect the clamps to install the No.2 frame wire
harness.
NOTE: The number of wire harness clamps will differ
depending on the vehicle spec.
Part #
82715-04220
NEW Replacement Parts
Part Name
Kit #
Bracket
NA*
Qty
1
23. INSTALL THE NEW HARNESS BRACKETS
57
82715-04230
90119-A0169
Front Side
Bracket
Bolt
*Individual Part(s)
NA*
NA*
1
2
Rear Side
Install the 2 NEW brackets with the 2 NEW bolts and
torque to spec.
Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft∙lbf)
24. REINSTALL THE FRAME WIRE HARNESS
Reconnect the clamps to install the frame wire harness.
Reconnect the ground wire with the bolt and torque to spec
(If Equipped).
Torque Spec: 14 N∙m (143 kgf∙cm, 10 ft∙lbf)
NOTE: The number of wire harness clamps will differ
depending on the vehicle spec.
25. RECONNECT THE PARKING BRAKE CABLES
Reinstall the 2 parking brake cables with the 6 bolts, then
torque to spec.
Torque Spec: 12.5 N∙m (127 kgf∙cm, 9 ft∙lbf)
Access Cab Parking Brake Cable Routing
58
NEW Replacement Parts
Part Name
Kit # Qty
NA*
1
Bracket**
NA*
1
Bolt
NA*
1
*Individual Part(s)
** Only 1 part used, part number varies by vehicle type.
Part #
82715-04160
82715-3D680
90119-A0141
2TR-FE
1GR-FE
26. REINSTALL THE FRONT DIFFERENTIAL CARRIER
(4WD ONLY)
Apply adhesive to the serration bolt.
Reinstall the front differential carrier with the 2 bolts, 4
stoppers and 3 nuts, then torque to spec.
Torque Spec: Except TMMTX Made
Bolt - 137.3 N∙m (1400 kgf∙cm, 101 ft∙lbf)
Nut - 87.2 N∙m (889 kgf∙cm, 64 ft∙lbf)
Torque Spec: TMMTX Made
Bolt - 128.5 N∙m (1310 kgf∙cm, 95 ft∙lbf)
Nut - 81.5 N∙m (831 kgf∙cm, 60 ft∙lbf)
Disconnect the connector from the bracket.
Remove the bolt and bracket.
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TSB/Document ID: ZKA-TI-090519
Replacement Service Bulletin Number:
MFR Communication Date: 2019-09-05
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL
MFR Component System:
MFR Component Subsystem:
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