NHTSA ID Number: 10169430
Manufacturer Communication Number: ZKA_TI-11_15MY-D
TSB/Document Date: 2019-12-16
Summary
Technical Instructions: TECHNICAL INSTRUCTIONS FOR CUSTOMER SUPPORT PROGRAM ZKA CERTAIN 2011 THROUGH 2015 MODEL YEAR TACOMA COVERAGE FOR VEHICLE FRAME CORROSION PERFORATION
TECHNICAL INSTRUCTIONS
FOR
CUSTOMER SUPPORT PROGRAM ZKA
*****************************
CERTAIN 2011 THROUGH 2015 MODEL YEAR TACOMA
*****************************
COVERAGE FOR VEHICLE FRAME CORROSION PERFORATION
The repair quality of covered vehicles is extremely important to Toyota
. All dealership technicians
performing this CSP are required to successfully complete the most current version of the E-Learning
course “Safety Recall and Service Campaign Essentials”. 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:
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•
•
•
Certified Technician (any specialty)
Expert Technician (any specialty)
Master Technician
Master Diagnostic Technician
Final repair must be signed off and validated by a MDT, Shop Foreman or Service Manager using the
Frame Replacement Inspection Form.
It is the dealership’s responsibility to select technicians with the above certification level or greater to
perform this CSP 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.
1
OPERATION FLOWCHART
Verify Vehicle Eligibility
1. Confirm vehicle VIN matches the R.O.
2. Check the TIS Vehicle Inquiry System
Not Covered
No further action required
Frame Rail Seal
ALREADY INSTALLED
No further action required
Covered
Perform pre-hoist inspection
Inspect for Frame Rail Seal
Frame Rail Seal
NOT FOUND
Please see to the K0D Technical
Instructions and Dealer Letter for
the next steps
Perform Frame Inspection utilizing the Inspection
application
Yes (to either question)
Was perforation 10mm or larger found in the
locations identified in Green below?
No
Are you located in a Cold Climate
State, or is the vehicle eligible for
K0D?
No (to both questions)
Yes
Inspection Application submits report for FTS
approval
No
No further action required
Was approval received from the FTS?
Yes
Order parts and complete frame replacement
Campaign completed, return the vehicle
to the customer
Cold Climate States Include - CT, DE, IL, IN, KY, MA, MD, ME, MI, MN, NH, NJ, NY, OH, PA, RI, VA, VT, WI, WV
and District of Columbia
Background
Toyota has received a number of reports regarding vehicle frame corrosion perforation on certain
2011-2017 model year Tacoma vehicles. These reports have indicated that these vehicles, when
operated in specific cold climate areas (Cold Climate States1) with high road salt usage, or exposed
to other environmental factors, may exhibit more-than-normal corrosion to the vehicle’s frame.
2
PREPARATION
A. TOOLS & EQUIPMENT
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•
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•
•
•
•
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A/C service equipment
Alignment rack
Brake bleeder
Engine hanger
1GR-FE Engine
− 12281-31060 – Engine hanger No. 1 (Qty: 1)
− 12282-31040 – Engine hanger No. 2 (Qty: 1)
− 90119-08A87 – Bolt (Qty: 4)
2TR-FE Engine
− 12281-75050 – Engine hanger (Qty: 2)
− 91672-81025 – Bolt (Qty: 2)
Engine hoist (Qty: 2) or Hydraulic mini crane (Qty 2)
Engine sling (Qty: 2)
Protective eyewear
Protective gloves
Ratcheting tie down strap (2 in X 27 ft, minimum work load capacity: 3,000 lbs)
Special Service Tools (SST)
09325-40010 – Transmission oil plug (Transmission A340E)
09610-20012 – Pitman arm puller (2WD)
09628-62011 – Ball joint puller (4WD, Pre-Runner)
09520-32040 – A component of SST 09520-24010, Differential side gear shaft puller
09520-01010 – Drive shaft remover attachment
09628-00011 – Ball joint puller
09922-10010-01 – Variable open wrench
Standard hand tools
Techstream
Torque wrench
Torx® T55H socket
Socket wrench 35mm
Hexagon wrench 8, 10
Deep socket wrench 10, 12, 14, 17, 19mm
Union Nut Wrench 10mm
Weights
B. SUPPLIES
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•
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Toyota Genuine ATF WS or DEXRON® lll (DEXRON® ll) – As needed
Hypoid gear oil API GL-5 SAE 75W-90 – 1.5 liter (4WD Only)
R134a refrigerant – As needed
Toyota DOT 3 brake fluid – 3 pints
Toyota long life coolant – 2 gallons
Paint Marker
MP Grease
3
THE PARTS SHOWN BELOW WERE INCLUDED IN ZH6 2005-2010MY FRAME
REPLACEMENT PARTS BUT WILL NOT BE INCLUDED IN ZKA 2011-2015
• When removing the reusable parts, be careful to NOT damage and make them non-reusable.
Judge if the following parts are reusable or not on the actual vehicle, and order the part
individually as needed.
4
C. PARTS
To assist dealers in determining the correct part number(s) to order, a website has been set up to look up
part numbers by VIN. Please go to https://tacoma-2011-2017-frames.imagespm.info/ select the appropriate
campaign/vehicle, enter the VIN, and the correct part numbers to order will be displayed. The website is
for part(s) application reference only and won’t order the parts, confirm campaign completion status,
or confirm campaign applicability.
• The parts will need to be ordered through the Dealer Daily Parts System.
• ETAs for the parts will be available via the normal system.
• Frame ETAs will be made available on the Dealer Daily website, in the MAC reference area.
Note: When first logging in; enter your dealer code and the default password; xxxxx. Upon logging in
the website will ask for you to reset the password and provide an email address.
An illustration of the parts replaced and their location(s) have been provided. Please reference the
“Illustration Name” and ”Page” columns in the parts tables below.
Individual Parts:
Part Number
04006-63304
04008-15104
04006-63704
04008-15204
04006-63604
04008-15304
04006-64504
04008-15404
04006-64304
04008-15504
04006-64104
04008-15604
04006-64404
04008-15704
04006-63104
04008-16504
04008-16604
04008-16704
04006-63204
04008-16804
04008-16904
04008-17104
04006-63404
04008-17204
04008-17404
04008-17504
04006-63504
04008-17604
04008-17804
04008-17904
04008-18204
04008-18304
Part Description
(GRN225 2011-2012MY)
(GRN225 2013-2015MY)
(GRN245 DCB 2011-2012MY)
(GRN245 DCB 2013-2015MY)
(GRN245 LCB 2011-2012MY)
(GRN245 LCB 2013-2015MY)
(GRN250 2011-2012MY)
(GRN250 2013-2015MY)
(GRN265 DCB 2011-2012MY)
(GRN265 DCB 2013-2015MY)
(GRN265 LCB 2011-2012MY)
(GRN265 LCB 2013-2015MY)
(GRN270 2011-2012MY)
(GRN270 2013-2015MY)
(TRN220 2011-2012MY)
(TRN220 2013-2014MY)
(TRN225 DCB 2011-2012MY)
(TRN225 DCB 2013-2015MY)
(TRN225 LCB 2011-2012MY)
(TRN225 LCB 2013-2015MY)
(TRN240 4AT 2011-2012MY)
(TRN240 4AT 2013-2014MY)
(TRN240 5MT 2011-2012MY)
(TRN240 5MT 2013-2014MY)
(TRN245 4AT 2011-2012MY)
(TRN245 4AT 2013-2015MY)
(TRN245 5MT 2011-2012MY)
(TRN245 5MT 2013-2015MY)
(TRN265 DCB 2011-2012MY)
(TRN265 DCB 2013-2015MY)
(TRN265 LCB 2011-2012MY)
(TRN265 LCB 2013-2015MY)
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Illustration Name
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Page
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
13
5
Individual Parts (Continued):
Part Number
Part Description
43425-04040
47313-04210
47313-04241
47315-04180
47315-04191
47323-04180
47323-04191
47324-04140
47324-04151
47325-04190
47325-04191
47325-04200
47325-04201
47325-04210
47325-04211
47326-04160
47326-04161
47326-04170
47326-04171
47326-04180
47326-04181
48068-04030
48068-04040
48069-04030
48069-04040
48304-04090
48304-04090
48304-AD010
48304-AD010
51900-35410
51900-35420
82711-16830
82715-04160
82715-04200
82715-04200
82715-04220
82715-04230
82715-04240
82715-04290
82715-04290
82715-04350
82715-3D680
82715-04250
82715-04260
90105-A0064
90105-A0066
90119-08A91
90119-A0141
90119-A0148
90119-A0151
90119-A0161
90119-A0169
90119-A0169
90119-A0169
90119-A0169
90119-A0193
90178-A0001
90178-A0013
90179-08241
90240-08054
90468-14033
90469-A0004
90469-A0004
90469-A0004
Ring, Shaft Snap (For Front Drive Inner Shaft Outer)
Tube, Front Brake, No.3
Tube, Front Brake, No.3
Tube, Front Brake, No.5
Tube, Front Brake, No.5
Tube, Rear Brake, No.3
Tube, Rear Brake, No.3
Tube, Rear Brake, No.4
Tube, Rear Brake, No.4
Tube, Rear Brake, No.5
Tube, Rear Brake, No.5
Tube, Rear Brake, No.5
Tube, Rear Brake, No.5
Tube, Rear Brake, No.5
Tube, Rear Brake, No.5
Tube, Rear Brake, No.6
Tube, Rear Brake, No.6
Tube, Rear Brake, No.6
Tube, Rear Brake, No.6
Tube, Rear Brake, No.6
Tube, Rear Brake, No.6
Arm Sub-Assy, Front Suspension, Lower No.1 RH
Arm Sub-Assy, Front Suspension, Lower No.1 RH
Arm Sub-Assy, Front Suspension, Lower No.1 LH
Arm Sub-Assy, Front Suspension, Lower No.1 LH
Bumper, Front Spring, LH
Bumper, Front Spring, RH
Bumper, Front Spring, LH
Bumper, Front Spring, RH
Carrier Assy, Spare Wheel
Carrier Assy, Spare Wheel
Clamp (For Rear Differential Lock)
Bracket (For 2TR-FE 4WD Front Differential Wire)
Bracket (For 2TR-FE A/F Sensor Wiring)
Bracket (For Frame Wire No.2)
Bracket (For Frame Wire)
Bracket (For Frame Wire)
Bracket (For Frame Wire No.2)
Bracket (For Frame Wire No.2)
Bracket (For 2TR-FE A/F Sensor Wiring)
Bracket (For Frame Wire No.2)
Bracket (For 1GR-FE 4WD Front Differential Wire)
Bracket (For Rear Differential Lock)
Bracket (For Rear Differential Lock)
Bolt (For Skid Control Sensor)
Bolt (For Rear Differential Lock)
Bolt (For Rear Stabilizer Bracket Cover)
Bolt (For Front Differential Wire Bracket)
Bolt (For W/ Frame Wire No.2)
Bolt (For Heat Insulator of Propeller Shaft)
Bolt (For Front Stabilizer Bracket)
Bolt (For Brake Tube)
Bolt (For 1GR-FE W/O Frame Wire No.2)
Bolt (For 2TR-FE W/O Frame Wire No.2)
Bolt (For W/ Frame Wire No.2)
Bolt (For Front Hook, No.1 W/ Fuel Tank Protector)
Nut (For 4WD, Pre-Runner Front Suspension Camber Adjust Cam)
Nut (For 2WD Front Suspension Camber Adjust Cam)
Nut (For Fuel Tank Protector)
Pin, W/ Hole (For Transmission Control Rod)
Clip (For Transmission Control Rod)
Clamp, Brake Tube, No.11 (For Regular Cab)
Clamp, Brake Tube, No.11 (For Access Cab)
Clamp, Brake Tube, No.11 (For Double Cab)
Quantity
Illustration Name
Page
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
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TSB/Document ID: ZKA_TI-11_15MY-D
Replacement Service Bulletin Number:
MFR Communication Date: 2019-11-07
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: STRUCTURE
MFR Component System:
MFR Component Subsystem:
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