Instruction/ maintenance manual of the product 5603 Toyota
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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, W/O O.E. TRAILER HITCH) 3” BODY LIFT INST ALLA TION INSTRUCTIONS 2005-2006 KIT# 5603* *VEHICLES EQUIPPED WI TH O.
2 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 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 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 Front of V ehicle 1. Front bumper a. Remove wiring harnesses from fog lights, if equipped. b. Remove two pop-up clips, two b olts and grille from core support. c. Remove seven pop-up clips from front bumper .
4 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 g. Remove six nuts and two front bumper brackets from frame ra ils . 2. Automatic T ransmission Cooler: (if equipped) a. Remove four bolts and allow automa tic trans- mission cooler to hang loose from core support.
5 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 3. 6 cyl. models: Remove pow er steering reservoir , three bolts and bracket from fender . DO NOT DIS- CONNECT power steering lin es. 4. 4 cyl. models: Loosen two engine intake clamps and remove e ngine intake hose.
6 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 9. Remove heater hoses from clip on backside o f engine. 10. Remove wir e ha r n ess clip from fi re w al l and bracket . Heater Hoses Clip Clip Wire Harness Bracket 11 . Re move ABS wire harnesses from driver and pas- senger side brackets.
7 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 13. Radiator a. Remove nine pop-up clips and radiator cover from core support. b. Remove four bolts and radiator from core sup- port. Allow radiator to hang on core support by tab s. NOTE Lower the radiator onto the frame prior to the lifting pro- cedures.
8 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 Inside of V ehicle 1. Manual transmission a. Remove center console and shifter console inte- rior panels. b. Remove shift lever from vehicle. 2. Front interior trim panels a. Remove driver and passenger door sill plates.
9 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 3. Extended cab models: Rear interior trim panels a. Fold down rear seats. b. Open floor storage tra y and remove jack. c. Remove pop-up clips and storage tray from vehicle. d. Pull carpet up to expose driver and passenger body mount access plates.
10 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 c. Remove bolt and pop-clips from passenger side rear panel and cab. d. Remove driver and passenger body mount b olt access covers. Underside of V e hicle 1. Remove all clips and two driver side engine guards from driver side wh eel well.
1 1 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 5. Remove two nuts and fuel line brackets from driver side body . 6. Remove bolt and brake line bracket fr om driver side frame. Front Rear Fuel Lines Bracket Nut Nut Fuel Lines Frame Brake Line Bracket Bolt Rear of V ehicle 1.
12 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 2. Rear bumper a. Remove rear bumper wire harness from driver and passenger frame. b. Remove two license plate lights from rear bumper . c. Without O.E. T railer Hitch: Remove six bolts and rear bumper from frame .
13 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 b. Remove bolt, nut, and lower washer from each cab mount on passenger side. 2. Cab passenger side a. Remove captive washers from each factory cab mount bolt. W ARNING Use extreme caution w hen lifting body from frame.
14 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 f. Install factory front captive washer and a kit bolt (3/8” x 8”) on core su pport cab mount. DO NOT TIGHTEN. g. Install factory mid captive washer and kit bolt (M12-1.75 x 200mm) on cab mount. DO NOT TIGHTEN.
15 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 e. Remove rear cab mount kit bolts (M12-1.25 x 210mm) and apply a few drops of kit Loctite ® to threads. Install kit bolt s , factory capti ve wash- ers, factory lower wash ers and factory nu ts. T ighten kit bolts to 55 ft.
16 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 c. Install kit blocks (2” dia.) on frame mounts. d. Lower bed onto kit blocks . e. At front and mid bed mounts, install kit bolt s (M12-1.25 x 160mm) and factory cap tive wash- ers. DO NOT TIGHTEN. Kit Block (2” Dia .
17 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 a. Mark and cut driver and passenger O.E. trailer hitch brackets along white lines as shown below . Mark & Cut Here BEFORE Mark & Cut Here BEFORE AFTER b.
18 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 e. Apply a small amount of kit Loctite ® onto threads of eight factory bolts and install rear bumper and kit brackets (rear bumper) onto O.E. trailer hitch with eight fa ctory bolts. DO NOT TIGHTEN. f.
19 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 d. Apply a small amount of kit Loctite ® to threads of four factory bolts and install rear bumper to kit brackets (rear bumper). DO NOT TIGHTEN. 3. Install license plate lights on rear bumper . 4. Install rear bumper wiring harness on fra me, if possi- ble.
20 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 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).
21 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 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).
22 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 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.
23 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 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.
24 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 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.
25 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 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 .
26 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 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).
27 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 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.
28 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 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 .
29 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 9. 4 cyl. models: Power steering requires no modifica- tion. 10. 6 cyl. models: AC L ine 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.
30 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 c. Install two kit extension (sleeve), two kit bolt s (8mm x 50mm), two kit washers (8mm flat), and automatic transmission cooler lines to lower core support. d. Install automatic transmi ssion cooler onto core support with four bolts.
31 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 d. Install two pop-up clips to fender wells. e. Install five pop-up clips to front bumper . f. Install two pop-up clip s, two bolt s and grille to core support. g. Install wiring harnesses to fog lights, if equipped.
32 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 Miscellaneous 1. Apply kit label (warning) to dashb oard in plain sigh t of all vehicle occupants. 2. Check all fasteners to ensure they are tight. 3. Ensure all wires, hoses, cables, etc. are p roperly connected and there is ample slack.
33 ‘05-‘06 T acoma (W/O Hitch) - 3” Kit 5603 Kit Part s List Qty . Description 8 Block , 2” x 3” spacer 4 Block , 3” x 3” spacer 7 Bolt , 1/4”-2 0 x 1” 6 Bolt , 3/8”-1 6 x 1” 2 Bolt , 3/8”-1 6 x 8” 1 Bolt , 3/8"-24 x 1-1/4", socket head 4 Bolt , M12-1.
An important point after buying a device Toyota 5603 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Toyota 5603 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Toyota 5603 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Toyota 5603 you will learn all the available features of the product, as well as information on its operation. The information that you get Toyota 5603 will certainly help you make a decision on the purchase.
If you already are a holder of Toyota 5603, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Toyota 5603.
However, one of the most important roles played by the user manual is to help in solving problems with Toyota 5603. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Toyota 5603 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
