Toyota 5603- Manuals

Page 2 - Before Starting Installation; Engine Compartment; kit; Inside Cab; Prepare to Install Kit; Measurements

2 ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603 Before Starting Installation 1. Carefully read all warnings and instructions com-pletely before beginning. 2. Verify all parts have been received in this kit bychecking the parts list at the end of this document. 3. Only install this kit on the vehicle for ...

Page 3 - Front of Vehicle

3 ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603 Front of Vehicle 1. Front bumper a. Remove wiring harnesses from fog lights, ifequipped. b. Remove two pop-up clips, two bolts and grillefrom core support. c. Remove seven pop-up clips from front bumper. WiringHarness Fog Light Bolts Pop-upClips Grille Pop-...

Page 8 - Inside of Vehicle

8 ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603 Inside of Vehicle 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. ShifterConsole CenterConsole Shift Lev...

Page 10 - Underside of Vehicle; Repeat above step for passenger side.; Driver Side; Crossmember

10 ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603 c. Remove bolt and pop-clips from passenger siderear panel and cab. d. Remove driver and passenger body mount boltaccess covers. Underside of Vehicle 1. Remove all clips and two driver side engine guardsfrom driver side wheel well. 2. Repeat above step for...

Page 11 - Rear of Vehicle

11 ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603 5. Remove two nuts and fuel line brackets from driverside body. 6. Remove bolt and brake line bracket from driver sideframe. Front Rear Fuel Lines Bracket Nut Nut Fuel Lines Frame Brake LineBracket Bolt Rear of Vehicle 1. Fuel filler a. Remove fuel filler ...

Page 12 - Install Kit; Cab; Cab Mount

12 ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603 2. Rear bumper a. Remove rear bumper wire harness from driverand passenger frame. b. Remove two license plate lights from rearbumper. c. Without O.E. Trailer Hitch: Remove six bolts and rear bumper from frame. WireHarness Front Frame Bed RearBumper License...

Page 15 - Bed; Bolt; bolts

15 ‘05-‘09 Tacoma (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 bolts , factory captive wash- ers, factory lower washers and factory nuts.Tighten kit bolts to 55 ft. lbs. Bed 1. Lift bed a. Loosen, but D...

Page 17 - Apply a small amount of; Loctite; ® onto; bracket; Repeat above step for driver side.; Bracket; Bumper; Plate

17 ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603 a. Mark and cut driver and passenger O.E. trailerhitch brackets along white lines as shown below. Mark& CutHere BEFORE Mark& CutHere BEFORE AFTER b. Apply a small amount of kit Loctite ® onto threads of two factory bolts and install kit bracket (re...

Page 19 - brackets; tie; Kit; Tie

19 ‘05-‘09 Tacoma (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 frame, if possi-ble. 5...

Page 24 - extension; Extension

24 ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603 e. Install driver and passenger door sill plates. 4. Manual transmission a. Remove plastic cap from end of shift lever. b. Mark alignment and cut lines on shifter leverbelow bend. c. Cut shifter lever along marked cut line. Door SillPlate Shift Lever Plast...

Page 27 - ties

27 ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603 3. Install wire harness and clips to alternator bracketand driver side body bracket. Adjust clips if neces-sary. 4. Install vent hoses to driver side body bracket with kit tie (zip). Battery BodyBracket WireHarness AlternatorBracket Kit Tie (Zip) Bracket V...

Page 31 - After Completing Installation

31 ‘05-‘09 Tacoma (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 clips, two bolts and grille tocore support. g. Install wiring harnesses to fog lights, if equipped. h. Adjust bumper and tighten all hardware. ...

Page 32 - Miscellaneous; Apply; label; of all vehicle occupants.; Dynamic Vehicle Check; Accessories; The following accessories are also available:

32 ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603 Miscellaneous 1. Apply kit label (warning) to dashboard in plain sight of all vehicle occupants. 2. Check all fasteners to ensure they are tight. 3. Ensure all wires, hoses, cables, etc. are properlyconnected and there is ample slack. 4. Fill and check pow...

Page 33 - Kit Parts List; Description; , 1” x 6” rubber hose; Performance Automotive Group

33 ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603 Kit Parts List Qty. Description 8 Block , 2” x 3” spacer 4 Block , 3” x 3” spacer 7 Bolt , 1/4”-20 x 1” 6 Bolt , 3/8”-16 x 1” 2 Bolt , 3/8”-16 x 8” 1 Bolt , 3/8"-24 x 1-1/4", socket head 4 Bolt , M12-1.25 x 160mm 2 Bolt , M12-1.25 x 180mm 2 Bolt , ...