download
2. Interior Installation of Switch/Wire Harness (a) Locate the vehicle white 6-pin connector behind the lower instrument panel. (Fig. 2-1) (1) Note: The vehicle connector will be wrapped in gray foam tape. (b) Install the Off Road switch (Fig. 2-2) in the available knockout ( Location 1 or 2) and in the orientation shown. (Fig. 2-1) (c) Plug the white 6-pin connector into the switch. (1) Confirm the connector is securely attached. (d) Remove driver and passenger side sun visors. (1) Rotate and loosen the visor support shaft from the visor holder clips as shown. (Fig. 2-3) (2) Do not remove clips from headliner. (e) Remove sun visors (Fig. 2-4) (1) Remove the two (2) Phillips screws from driver and passenger side sun visors. (f) Remove the driver and passenger side assist grips. (1) Carefully remove the screw covers for all four (4) assist grips. (Fig. 2-5) (g) Remove the two (2) 10 mm hex head screws from driver and passenger side assist grips. (Fig. 2-6) (h) Remove front passenger side “A” pillar garnish. (1) Pull door seal down from around front pillar. (2) Disengage two (2) clips and one (1) claw and remove the front pillar garnish. (Fig. 2-7) (i) Remove front pillar garnish driver side. (1) Use the same procedure as for the passenger side. (j) Remove the rear view mirror. (1) Remove the mirror base mount cover by carefully inserting panel removal tool as shown. (Fig. 2-8)

download
1. 2. REMOVE ATF LEVEL GAUGE REMOVE ENGINE UNDER COVER Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) 3. 3RZ–FE: DISCONNECT THROTTLE CABLE Loosen the nut and disconnect the cable. Separate the throttle cable from the clamp. (a) (b) 4. REMOVE NO.1 FAN SHROUD Remove the 4 bolts and No.1 fan shroud. 5. REMOVE TRANSMISSION SHIFT LEVER ASSEMBLY AND TRANSFER SHIFT LEVER Remove the 2 bolts, 4 screws and rear console box. (a) (b) w/ One touch 2–4 selector: Remove the 3 screws and front console box with the transfer shift lever knob. (c) w/o One touch 2–4 selector: Remove the 2 screws and front console box with the transfer shift lever knob. Disconnect the connectors. (d) (e) Remove the nut and washer, and disconnect the shift control rod. (f) Disconnect the connector and remove the 8 screws and transmission shift lever assembly. (g) Using snap ring pliers, remove the snap ring and pull out the shift lever from the transfer. HINT: At the time of installation, apply MP grease to the transfer shift lever. 6. REMOVE OIL FILLER PIPE (a) 3RZ–FE: Remove the 2 bolts and oil filler pipe with the O–ring. HINT: At the time of installation, replace the used O–ring with a new one. (b) 5VZ–FE: Remove the bolt and oil filler pipe with the O–ring. HINT: At the time of installation, replace the used O–ring with a new one. 7. REMOVE FRONT AND REAR PROPELLER SHAFT (See page PR–11)

download
1. Vehicle Preparation. (FJ Cruiser shown) (a) Vehicle must be on level ground and not on an incline/decline. (b) Fully engage the parking brake. (c) Remove the shift lock release cover. Save for re-use. (Fig. 1-1) (d) Push in the shift lock release button. (Fig. 1-2) (e) Place the shifter in lowest gear. (Fig. 1-3) 2. Remove OE Shift Knob. (a) Remove the OE shift knob by turning counter-clock-wise. (b) Discard the OE shift knob 3. Install the Shift Knob. (a) Install the shift knob by turning clock-wise. (1) When fully installed there should be a 1/2” +/- 3/32” (12mm +/- 2mm) gap between the bottom of the shift knob shaft and the shift gate top surface. (2) The “barrel” of the shift knob should be oriented across the vehicle. (3) Place the shift lever in “Park”. (4) Replace the shift lock release cover. (5) Clean the shift knob with a non-scratch cloth.

download
INSTALLATION INSTRUCTIONS NOTE: For easier assembly and installation, vehicle and all snowplow components should be on a smooth, level, hard surface, such as concrete. 1. On the driver side of the truck, remove the outermost fastener securing the plastic bumper cover to the splash pan. Retain the fastener for reinstallation if the plow is removed. Then, fold the outermost tab on the plastic bumper cover up to allow for easier pushplate installation. 2. Trim the splash pan as shown to allow for easier pushplate installation. 3. Repeat Steps 1 and 2 on the passenger side. 4. On the driver side of the truck, remove the tow hook fasteners and tow hook. Retain the tow hook for reinstallation if the plow is removed. Retain the fasteners for reinstallation in the following step. 5. Attach the driver-side pushplate to the truck frame using the original tow hook fasteners. Tighten the fasteners so that the pushplate is firmly against the bottom of the frame, but do not fully tighten at this time. 8. Repeat Steps 4–7 on the passenger side of the truck. 9. Install the cross bar using four 1/2″ x 1-1/2″ cap screws and 1/2″ locknuts. Hand tighten fasteners. 10. Check for a connecting arm distance of 29-1/8″ ± 1/8″. If the connecting arm distance is not within 29-1/8″ ± 1/8″, then loosen the tow hook fasteners on one or both pushplates and shift the pushplate(s) in the appropriate direction to obtain

download
REMOVAL CAUTION: Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait for at least 90 seconds after disconnecting the cable to prevent the airbag from working. 2. REMOVE REAR FLOOR CARPET ASSEMBLY (a) Release the 2 knobs and remove the rear floor carpet. 3. REMOVE REAR DECK FLOOR BOX (a) Remove the rear deck floor box. 4. REMOVE DECK FLOOR BOX RH (a) Remove the 2 nuts and remove the deck floor box. 5. REMOVE DECK FLOOR BOX LH (a) Remove the 2 nuts and remove the deck floor box. 6. REMOVE REAR SEAT CUSHION WITH COVER PAD SUB-ASSEMBLY 7. REMOVE REAR SEATBACK ASSEMBLY RH 8. REMOVE REAR SEATBACK ASSEMBLY LH 9. REMOVE FRONT DOOR SCUFF PLATE RH

download
1. Clean Mudguard Mounting Areas. (a) Clean and degrease front and rear body panels where mudguard is to be located using 3MTM Prepsolvent-70. 2. Installation of Front Mudguards. (a) Put the front mudguard in place and install the grommet into the lower mounting hole (one location). (Fig. 2-1) (b) Secure the front mudguard to the inner panel using the tapping screws (four locations). (Fig. 2-1) NOTE: Turn the steering wheel to make it easier to work inside the wheel well. When tightening the screws, push the front mud guard onto the inner panel to remove the gap between the front mud guard and the inner panel. (c) Fully tighten the tapping screws so that they will not become loose. 3. Installation of Rear Mudguards. (a) Remove the screws and tapping screws securing the rear bumper to the inner panel. (Fig. 3-1) Screw (hexagonal): One location Tapping screw: One location

download
1) Securely block the front wheels of the vehicle. Use a jack to raise the rear end of the vehicle and support with jack stands. Remove the rear wheels. 2) Use a 14mm wrench and a 5mm Allen wrench to loosen and remove the nut on both end links where they meet the rear spindle assemblies. Use a 17mm wrench or socket to remove the bolt and nut holding the rear upper link to the spindle. Retain all stock hardware. 3) Use a 19mm and 17mm socket or wrench to remove the upper camber link bolt where it mounts to the sub-frame. Remove the stock suspension link and retain the stock hardware for later use. 4) Match the length of the Hotchkis arm to the center-to-center length of the stock arm. Use a 24mm wrench to loosen the jam nut and rotate the head. Lengthen the arm to add positive camber and shorten the arm to add negative camber. 5) Use the grease pack provided to apply a thick coat of grease to the bushing faces on the Hotchkis arm. You can also apply a light coat of grease to the bushing contact surfaces on the vehicle. Install the Hotchkis arm in the stock location and use the stock hardware to mount it.

download
This installation manual shows an example of an installation on a Toyota Tacoma; however, the installation may vary for your vehicle, so it may be necessary to consult the Toyota service manual for specific instructions for your year model. Tools Needed: 10mm nut driver or socket, #1 Phillips screwdriver, and Trim Removal Tools (Optional) Be advised: These instructions may not include specifics for all vehicle configurations. 1. Set Parking brake and adjust steering wheel to various settings to facilitate removing the Instrument panel. 2. Partially remove the driver’s side kick panel. a. Using your hands, gently pull straight back on the kick panel. There are 2 release clips; one is shown below. The other clip is directly below the one shown. 3. Remove the coin tray. a. There are 4 clips that hold the tray in place. Gently pull straight out from the dash to remove the tray 4. Remove the driver’s side, lower instrument panel. a. Using a 10mm socket, remove the two bolts shown in the following photos. b. It’s not necessary, but it makes room to pull the door seal out and away from the instrument panel. This allows room to get your fingers or trim removal tool behind the panels. c. Starting on the lower left-hand side, gently separate the lower instrument panel by pulling straight out from the dash. i. When it’s completely separated, lower it to the floorboard. d. Remove the Instrument Panel bezel. i. Using a #1 Phillips screwdriver, remove the screws shown in the photo below. Note: make sure that good contact between the screwdriver and screw is made to ensure that the head is not stripped.

download
2. Remove Existing Exhaust System. (a) Remove two bolts with springs from front flange located between catalytic converter and rear muffler. (Fig. 2-1) (b) Keep all original equipment (OE) bolts and springs. (Fig. 2-1) (1) Ensure that the original gasket remains on converter assembly flange NOTE: For DIO, installation gasket must be replaced – P/N 17451-74051. (c) Remove and discard two bolts from rear flange located between muffler assembly and rear tailpipe assembly. (Fig 2-2) (d) Pry the rear tailpipe exhaust bracket loose from the rubber hanger located near the rear bumper. (Fig. 2-3) (e) Remove the OE rear tailpipe assembly from the vehicle. Pry the two front muffler exhaust brackets loose from the rubber hangers. (Fig. 2-4) (g) Pry the two rear muffler exhaust brackets loose from the rubber hangers. (Fig 2-5) NOTE: Use of lubrication (such as “soap and water”) on the rubber exhaust hangers can facilitate removal and installation of rubber hangers. (h) Do not remove the five (5) original (OE) rubber hangers from the vehicle. (i) Remove the OE muffler assembly from the vehicle. 3. Installation of TRD Exhaust System. (a) Connect the two front muffler hangers of the TRD muffler assembly to OE rubber hangers. (Fig. 3-1)

download
hinges at the top of the mirror. Carefully pull at the bottom of the mirror until it unsnaps from the mirror mount. Tilt and lift the mirror out of the mirror housing. of the mirror. The heater wires are interchangeable. the bottom of the mirror sail. Separate the mirror housing from the mirror sail. 5 Unwrap the tape at the end of the mirror wire harness (seals it to the rubber sail gasket). This is required because the Signal® mirror wire will run through the rubber sail gasket in the same location. Pull away the rubber gasket from around the mirror sail. Remove the white plastic strain relief tab. Using the shorter of the two wire harnesses from the kit and starting from the inside of the mirror housing, route the wire through the mirror housing. You may need to use gopher wire to route the wire. Mirror Replacement Continued 8 9 Following along the existing factory wire, route the new wire through the mirror sail. Leave about 4 inches of wire in the mirror housing. Assemble the mirror housing and mirror. Replace the rubber gasket on the mirror sail. Remove any slack in the wire. Replace the strain relief tab. Connect the Signal® mirror mating connector to the Signal® mirror wire harness. If heated, connect the factory heater wires to the heater terminals on the Signal® mirror. NOTE: There is no polarity so the wires may be interchanged. 10 11 Tuck the wire harness behind the Signal® mirror. Align the hinges in the top of the mirror mount. Tilt the Signal® mirror down on the mirror mount. Press down on the bottom of the Signal® mirror until it snaps into position. Press down on all sides of the Signal® mirror to ensure proper operation.

download
1. Unscrew the shift knob and remove the boot. 2. Remove cover which houses the lighter assembly. There are four clips holding it to the center console, they just pop out. 3. Unplug the lighter assembly. Below you can see the cover off and the four clips which hold it to the center console. 4. Remove the two screws holding the power window controls (if applicable). Next unplug the locks to remove the assembly. 5. Remove the rubber mat, and the two bolts in the storage compartment of the center console. 6. Remove the two screws on either side of the center console. 7. Unscrew the 2 screws at the front of the center console. After the bolts and the screws have been removed the entire console will be free and can be taken out 8. Carefully slide an exacto knife under the clip on the right side of the assembly to remove it. CAUTION : Be extremely careful in this step, if the knife is torqued too hard the blade could break and become a dangerous projectile. 9. Insert a flat head screw driver into the gap created by the exacto knife to pry the clip off.

download
Using a hydraulic press, remove both bushing and sleeve. Clean and lube I.D of control arm, install poly bushings, lube I.D of poly bushings and install supplied sleeve. LOWER LINKS and SPINDLE When pressing out bushings, it is good practice to remove and replace one at a time to maintain good rear alignment. Mark cam eccentrics prior to removal to aid in re-alignment. Use a hydraulic press and a few different tubing sizes to press out bushings from different positions. 1.400”O.D for upper control arm and rear lateral link 1.500”O.D for rear toe link and lateral link. Use a puller tool (pictured below) with a 1-5/16”O.D tubing to press out the spindle to trailing arm bushing. This can be done without removing the rear spindle from car. Lubricate the inside diameter of spindle eye and install poly bushings, lubricate inside diameter of bushing and install supplied sleeve.

download
REMOVAL & INSTALLATION WHEEL BEARING Removal 1) Raise and support vehicle. Remove front wheels. Remove cotter pin, bearing lock nut cap and bearing lock nut (apply brakes when removing lock nut). Remove brake caliper. DO NOT disconnect brakeline. Secure caliper aside. 2) Remove disc brake rotor. Remove ABS speed sensor (if equipped). Loosen, but DO NOT remove, shock absorber lower mounting bolts. Remove cotter pin and castle nut from tie rod end. Using Puller (09628-62011), remove tie rod end from steering knuckle. 3) Remove nuts and bolt attaching lower ball joint to lower control arm. Using Puller (09950-20017), disconnect steering knuckle from axle shaft. See Fig. 1. Remove steering knuckle and axle hub as an assembly. Place steering knuckle in a vise. Remove dust deflector. 1) Raise vehicle, and place a wooden block with a height of 7.09-7.87″ (180.0-200.0 mm) under either front tire. Lower floor jack until about half vehicle load is on front struts. Place safety stands under vehicle. 2) Place front wheels in straight-ahead position, and block them. Use a rod to move control arm up and down. Check for vertical ball joint play. If ball joint is damaged or any vertical play is found, replace ball joint. See LOWER CONTROL ARM & BALL JOINT under REMOVAL & INSTALLATION.

download
engine type (i.e. I4 vs V6) 2. Remove Existing Exhaust System (I4 & V6) (a) Using a 14mm socket & box wrench, remove 2 bolts & 2 nuts from front flange (Fig. 2-1) (b) Keep all original hardware (OE) bolts & nuts. (c) FOR PPO ONLY: Ensure that the original gasket remains on converter assembly flange. (Fig. 2-2) (d) FOR DIO ONLY: Replace the original exhaust gasket with PN: 90080-43033 (e) Using a 14mm socket, remove & discard (either) 2 nuts (I4) OR 4 nuts (V6) from rear tailpipe/rear muffler(s) connection. (Fig. 2-3) (f) Using the exhaust hanger removal tool, release the center exhaust pipe from both supporting hangers. Discard center exhaust pipe properly. (g) Using the exhaust hanger removal tool, release the rear Passenger Side muffler from the 3 supporting hangers (I4 & V6). For V6, release the rear Drivers Side muffler from the 2 supporting hangers. Make sure to completely remove the hangers from the vehicle AND the muffler, prior to discarding the muffler. Discard muffler(s) properly. (Fig. 2-4) NOTE: Use of lubrication (such as WD40 or soap and water) on the rubber exhaust hangers can facilitate removal and installation of rubber hangers. 3. Installation of TRD Exhaust System (I4 & V6) (a) Connect the TRD B & C pipes using the supplied exhaust gasket, and the two 14mm bolts. (Fig. 2-5) (b) Install the new center (B&C) pipe assembly onto the 2 OE hangers, and connect front flange using the OE hardware. (Fig. 2-6) (1) NOTE: FOR PPO ONLY: Ensure that the original gasket remains on converter assembly flange. (Fig. 2-2)

download
2. Preparing Vehicle for Tow Hitch Installation. (a) Protect exhaust pipe with a shop towel. (b) Remove lower LH cover. Set aside cover and fastening hardware for later use. (Fig. 2-1) (c) Remove the tie down hook. Discard tie down hook and 2 bolts. (Fig. 2-1) (d) Remove lower RH cover. Set aside cover and fastening hardware for later use. (Fig. 2-2) (e) Remove the tie down hook. Discard tie down hook and 2 bolts. (Fig. 2-2) 3. Remove the factory lower fascia cover (a) Remove push pins (1 per side) and save for later use. (Fig. 3-1) (b) Using diagonal cutters, cut the tab on the fascia cover in order to access the plastic clip. Remove clips (1 per side) and save for later use. (Fig. 3-2) Do not damage the clip while cutting the tab. (If damage occurs, the clip p/n is: 52535-28020). (c) Remove lower fascia cover by pulling cover away from vehicle and disengaging latches. (Fig. 3-3) (d) Remove rubber drain plugs from bottom and outside of the frame on both sides (LH/RH). (Fig. 3-4)

download
1. Assemble Jack Handle and Lower Spare Tire. (a) Remove the tool bag from the storage location (Fig. 3-1 on page 3) (b) Assemble the jack handle (3) and extensions rods (1 & 2) (Fig. 1-1). (c) Insert the square end of the extension rod through the access hole in the bumper and into the lowering screw (Fig. 1-2). (d) Turn counterclockwise making sure the jack handle remains firmly fitted to the extension rods. (e) Lower the tire partially from the vehicle to a suitable height allowing access to the lowering screw. (1) Ensure the wheel is safely supported in that position to prevent the spare tire from swaying during the spare tire lock installation. 2. Spare Tire Lock Installation. (a) Install the spare tire lock assembly into the lowering screw (Fig. 2-1). (1) Line up the cross pin on the spare tire lock with the slot on the lowering screw. Press the spare tire lock in place until fully seated into the bottom of the lowering screw. (b) Assemble the key assembly onto the hooked extension rod (Fig. 2-2). (c) Insert the extension rod with key through the access hole in the rear bumper (Fig. 2-3). (d) Rotate key in the lock assembly until the lock and key patterns engage. (e) Turn the jack handle clockwise making sure that the jack handle remains firmly fitted to the extension rod raising the tire until it is stowed in its original position. 3. Installation Completion (a) Disassemble the extension rod and key. (b) Place the key into the tool bag and stow with jack in the vehicle storage area (Fig. 3-1). (c) Place the ID card, order form, customer notice card and instruction sheet in the McGard envelope. (d) Place the envelope into the glove compartment.

download
NOTE: BALL JOINT CHECKING NOTE: See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT. Ball joint must be removed for the following checking procedure. See LOWER CONTROL ARM and BALL JOINTS under REMOVAL & INSTALLATION. Remove ball joint and place in vise, with ball joint stud pointing upward. Flip stud back and forth about 5 times. Reinstall the ball joint nut. Place torque wrench on ball joint nut and turn nut continuously 1 turn every 2 to 4 seconds. Read torque measurement on 5th turn. See BALL JOINT TURNING TORQUE SPECIFICATIONS table. If torque is not within specification, replace ball joint. WHEEL BEARING CHECKING NOTE: Wheel bearings are not adjustable. Whenever bearings are removed, replace with NEW bearings, races and oil seals. 1. Remove front wheel. Remove brake caliper and disc. Support caliper out of way. Using dial indicator placed near center of axle hub, check backlash by moving hub in bearing shaft direction. If backlash exceeds .002″ (.05 mm), replace bearing. 2. Check deviation at axle hub surface, outside of hub bolt by moving hub with twisting motion. If deviation is more than .002″ (.05 mm), replace bearing. Reinstall disc, brake caliper and front wheel. See Fig. 1 and Fig. 2 .

download
DTC P0500: VEHICLE SPEED SENSOR (VSS) MALFUNCTION (ES 300 & HIGHLANDER) CAUTION: If ECM replacement is instructed in following testing, always ensure ECM harness connector and ground circuit are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. If ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION. NOTE: For circuit reference, see CONNECTOR IDENTIFICATION and/or WIRING DIAGRAMS . Circuit Description Anti-Lock Brake System (ABS) wheel speed sensors detect wheel speed and sends signals to ABS ECU. The ABS ECU converts signals into a 4-pulse signal and outputs signal to instrument cluster. Instrument cluster converts signal to a more precise waveform and outputs signal to ECM. ECM determines vehicle speed based on frequency of these pulse signals. DTC is set when ECM does not detect any VSS signal while vehicle is in motion. Possible causes are: Faulty wheel speed sensors. Open or short in VSS circuit. Faulty instrument cluster. Faulty ECM. l l l l Diagnosis & Repair eg

download
Removal 1. Raise and support vehicle. Remove front wheel. Remove shock absorber. See LOWER CONTROL ARM & BALL JOINT . Remove hub grease cap. Remove ABS speed sensor and wire harness clamp from steering knuckle. Remove brakeline bracket from steering knuckle. Remove the bolt and separate the brake tube bracket from the steering knuckle. Using Special Tool (09023-00100), disconnect the brake tube from the front disc brake caliper assembly. Remove the bolt and separate the brake tube bracket from the steering knuckle. Remove the 2 bolts and front disc brake caliper assembly. Remove rotor. 2. On 4WD models, using a screwdriver and a hammer, remove the front axle hub grease cap. Remove the cotter pin and a lock cap. Remove the front axle hub nut. On all models, remove the nut and separate the stabilizer link assembly from the steering knuckle. Remove the cotter pin. Using Special Tool (09628- 62011), separate the tie rod end sub-assembly from the steering knuckle. 3. Remove 2 lower ball joint bolts, and disconnect lower ball joint. Remove upper ball joint, cotter pin and retaining nut. Using ball joint separator, separate upper ball joint from knuckle. On 4WD models, using a plastic hammer, separate the front axle hub from the front drive shaft. Remove the front axle hub sub- assembly. On all models, remove steering knuckle with hub. Installation To install, reverse removal procedure. Clean bolt threads. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Depress brake pedal several times. Check front wheel alignment. Ensure ABS speed sensor has a good signal.