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Toyota 5613 manual

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  • Page 1

    3651 N Highway 89 • Chino V alley , AZ 86323 (928) 636-7080 • www .p-a-g .net T O Y O TA TA C O M A (AUT O. & MANUAL TRANS., 2 & 4WD, EXT . & CREW CAB, WITH O.E. TRAILER HITCH) 3” BODY LIFT INST ALLA TION INSTRUCTIONS 2005-2006 KIT# 5613 W ARNING Installation of a Performance Automotive Group body lift kit will change the vehicle?[...]

  • Page 2

    2 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Before S t arting Inst allation 1. Carefully read all warning s and instructions com- pletely before beginning. 2. V erify all parts have been received in this kit by checking the part s list at th e end of this docume nt. 3. Only install this kit on the vehicle for which it is specified. If a[...]

  • Page 3

    3 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Front of V ehicle 1. Front bumper a. Remove wiring harnesses from fog lights, if equipped. b. Remove two pop-up clips, two bolts and grill from core support. c. Remove seven pop-up clips from front bumper . Wiring Harness Fog Light Bolts Pop-up Clips Grill Pop-up Clips Front Bumper Fascia d. R[...]

  • Page 4

    4 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 g. Remove six nuts and two front bumper brackets from frame ra ils . Engine Comp artment 1. 6 cyl. models: Loosen airb ox clamp, two clip s and remove airbox cover from engine. 2. 6 cyl. models: AC Line a. Remove bolt and AC line bracket from body . Nuts Front Bumper Brackets Clamp Clips Airbo[...]

  • Page 5

    5 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 6. 4 cyl. models: Remove nut a nd AC line from pas- senger side AC line bracket. 7. 4 cyl. models: Remove lower AC line from two clip s and passenger side body . 8. Remove vent tubes from driver side body bracket. AC Line Bracket Nut AC Line Clip Passenger Side Body AC Line Bracket Vent Tubes [...]

  • Page 6

    6 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 11 . Remove ABS wire harnesses from driver and p as- senger side brackets. 12. Remove wire harness and two clips from alternator bracket and driver side b ody bracket. ABS Wire Harnesse s Driver Side Passenger Side Battery Body Bracket Wire Harness Alternator Bracket 13. Radiator a. Remove nin[...]

  • Page 7

    7 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 14. S teer ing Shaft a. S trap steer ing wheel to prevent accidental movement. b. Mark upper steering shaft in relation to cou pler and lower steering shaft. c. Remove coupler bolts, slide coupler up onto upper steering sha ft and disconnect steering shaft. d. Slide coupler down and off of upp[...]

  • Page 8

    8 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 b. Remove dead pedal. c. Remove driver and passenger kick p anels. d. Pull driver and passenger carpet back from cor- ner and expose body mount bolt access cover . e. Remove driver and passenger body mount b olt access cover . NOTE Procedures may vary de pending on cab model for access to rear[...]

  • Page 9

    9 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 e. Remove four bolts, and driver and passenger body mount access plates. f. Remove driver and passenger body mount b olt access covers. 4. Crew cab models: Rear interior trim panels a. Remove three headrests from seatbacks and fold seatbacks down. b. Remove three bolts and pop-clips from drive[...]

  • Page 10

    10 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 3. Remove two bolts and brake line brackets from driver and passenger side frame rails. 4. Remove two bolts and parking brake cable brackets from crossmember . Driver Side Bolt & Brake Line Passenger Side Driver Side Passenger Side Parking Brake Cable Bolt & Bracket Parking Brake Cabl[...]

  • Page 11

    1 1 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Rear of V eh icle 1. Fuel filler a. Remove fuel filler cap. b. Loosen two hose clamps and disconnect vent hose connector . c. Remove bolt and fuel filler from vehicle. W ARNING Use extreme caution when working nea r the fuel lines and the fuel tank. Clean up spilled fuel immediately . A spar[...]

  • Page 12

    12 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Inst all Kit Cab 1. Lift cab a. Loosen, but DO NOT REMOVE, cab mounting bolts on driver side. b. Remove bolt, nut, and lower washer from each cab mount on passenger side. NOTE The number of ca b mounting bo lts may va ry with the length of the cab. Cab Mount (Core Support) Cab Mount (Mid Cab)[...]

  • Page 13

    13 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 c. Install kit block (2” dia.) on upper bushings on front core support cab mount. d. Install kit blocks (3” dia.) on upper bu shings on each remaining cab mount. e. Lower cab onto kit blocks . f. Install factory front captive washer and a kit bolt (3/8” x 8”) on core su pport cab moun[...]

  • Page 14

    14 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 3. Cab driver sid e a. Repeat previous steps on driver side of cab. b. Set cab-to-bed spacing according to previo us measurement. c. Remove front core support cab mo unt kit bolts (3/8” x 8”) and app ly a few drops of kit Loctite ® to threads. Install kit bolt s , factory captive wash- e[...]

  • Page 15

    15 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 2. Remove bolt from each bed mount on passenger side. 3. Bed passenger side a. Remove ca ptive washer s from each factory be d mount bolt. b. Using a hydraulic jack and a wood block, slowly lift passenger side of bed a little more than 3”. W ARNING Use extreme caution when lifting the bed f[...]

  • Page 16

    16 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 f. At rear bed mount, install kit bolt (M12-1.25 x 180mm) and factory captive w asher . DO NOT TIGHTEN. g. Repeat previous steps on driver side of bed. h. Set bed-to-cab spacing according to previo us measurement. i. Remove each kit bolt , one at a time, and apply a few drops of kit Loctite ?[...]

  • Page 17

    17 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 b. Apply a small amount of kit Loctite ® onto threads of two factory bolts and install kit bracket (rear bump er , passenger) and kit bracket (bumper , spacer) to passenger side bumper with two factory b olts. DO NOT TIGHTEN. c. Repeat above step for driver side. d. Remove eight factory bolt[...]

  • Page 18

    18 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 h. Install kit bracket (rear bumper , middle) onto O.E. trailer hitch with two ki t bolt s (1/2” x 1” ), four kit washers (1/2” SAE), and two kit nuts (1/ 2” stover). DO NOT TIGHTEN. i. Install license plate lights on rear bumper . j. Install rear bumper wiring har ness on frame, if p[...]

  • Page 19

    19 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 d. Install kit extension (1/4” x 6” hose) b etween cut breather tube on fuel filler with two kit clamp s (#6 hose). DO NOT TIGHTEN. e. Install kit extension (5/8” x 6” hose) b etween cut vent tube on fuel filler with two kit clamp s (#10 hose). DO NOT TIGHTEN. f. Install kit extension[...]

  • Page 20

    20 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Underside of V e hicle 1. Parking brake cable a. Install kit bracket (3” w/ stud) to driver side crossmember with factory bolt. b. Install driver side parking brake cable to kit bracket with kit nut (1/4” Nylock) and kit washer (1/4” SAE). c. Install kit bracket (3” w/ stud) to passen[...]

  • Page 21

    21 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 3. Carefully bend brake lines and in stall bolt and brake line bracket to frame. 4. Brake lines a. Install kit bracket (2” Z-shaped) and factor y bolt to driver side frame. b. Install brake line bracket to kit bracket (2” Z- shaped) with kit bolt (1/4” x 1”), two kit washers (1/4” S[...]

  • Page 22

    22 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 2. Crew cab models: Rear interior trim panels a. Install body mount access covers. b. Install passenger side rear panel onto cab with pop-clips and bolt. c. Install driver side rear panel onto cab with pop- clips and three bolts. d. Return seatbacks to upright positio n and install three head[...]

  • Page 23

    23 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 e. Install driver and p a ss enger door sill plates. 4. Manual transmission a. Remove plastic cap from end of shift lever . b. Mark alignment and cut lines on shifter lever below bend. c. Cut shifter lever along marked cut line. Door Sill Plate Shift Lever Plastic Cap Shift Lever Cut Line Ali[...]

  • Page 24

    24 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Engine Comp artment 1. S teer ing shaft a. Install upper steering sh aft into kit extension (steering), ensurin g marks on upper and lower steering shaft are aligned. b. Position kit extension (steering) into stee ring coupler . Ensu re marks on upper and lower steering shaft are aligned. c. [...]

  • Page 25

    25 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 c. Install radiator and fo ur kit brackets to core sup- port with four kit washers (1/4” SAE) and four kit nut s (1/4” Nylock). DO NOT TIGHTEN. d. Assemble kit plates (radiator block off) with kit bolt (1/4” x 1”), two kit washers (1/4” SAE) and kit nut (1/4” Nylock). DO NOT TIGHT[...]

  • Page 26

    26 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 3. Install wire harness and clips to alternator bracket and driver side body bracket. Adjust clips if neces- sary . 4. Install vent hoses to driver side body bracket with kit tie (zip). Battery Body Bracket Wire Harness Alternator Bracket Kit Tie (Zip) Bracket Vent Hoses 5. Install driver and[...]

  • Page 27

    27 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 8. 6 cyl. models: Power st eering re servoi r a. Remove reservoir cap an d drain contents into drain p an. b. Remove two clamps and power steering lines from reservo ir . c. Mark power st eering lines . d. Cut power steering lines along cut marks. e. Drain any remaining fluid from power steer[...]

  • Page 28

    28 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 9. 4 cyl. models: Power steering requires no modifica- tion. 10. 6 cyl. models: AC Line a. Install rubber isolator to body . b. Install AC line and cla mp onto rubber isolator with nut. 1 1. 4 cyl. models: AC Line a. Install kit brack et (3” Z-shaped) to passenger side AC line bracket with [...]

  • Page 29

    29 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 b. Apply a small amount of kit Loc tite ® to six kit bolts (3/8” x 1”) and install front bumper to kit brackets (front bumper) with twelve kit washers (3/8” USS) and six kit nut s (3/8” Nylock). c. Install front bu mp er c over t o veh icl e wit h six fa c- tory screws. Kit Bolts (3/[...]

  • Page 30

    30 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Af ter Completing Inst allation Inside Cab 1. Install airbag fuse and fu se block cover . Engine Comp artment 1. Connect both battery cables . Connect positive cable first, then negative cable. Fuse Cover Fuse Location May Vary Airbag Fuse Negative Cable (B la ck ) Positive Cable (R e d) Misc[...]

  • Page 31

    31 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Accessories The following accessories are also available: Kit # 6337: Gap Guards[...]

  • Page 32

    32 ‘05 - ‘06 T acoma (W/ O.E. Hitch) - 3” Kit 5613 Kit Part s List Qty . Description NOTE Depending on th e vehicle configuration (auto matic or manual transmission, 2WD or 4W D, cab length, bed length, etc.), some part s may not be used. 8 Block (2" x 3" spac er) 4 Block (3" x 3" spac er) 1 Bracket (f ront bum per, driver[...]