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Removal [11/2018 - ]: Procedure

  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  2. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 2

  3. REMOVE COLUMN HOLE COVER SILENCER SHEET 

    Refer to PROCEDURE - Step 6

  4. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 7

  5. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  6. REMOVE FRONT WHEEL 

    Refer to PROCEDURE - Step 1

  7. REMOVE FRONT BUMPER LOWER ABSORBER 
    1. Remove the 8 bolts, 4 screws and 3 clips.
      GTY594185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Push
    2. Using a screwdriver, disengage the 2 claws to remove the front bumper lower absorber as shown in the illustration.
  8. REMOVE NO. 1 MOTOR UNDER COVER 
    1. Remove the 3 bolts, 9 clips and No. 1 motor under cover from the vehicle.
      GTY542094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 2 MOTOR UNDER COVER 
    1. Remove the 4 screws, 4 clips and No. 2 motor under cover from the vehicle.
      GTY566234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE REAR MOTOR UNDER COVER LH 
    1. Remove the 5 clips and rear motor under cover LH from the vehicle.
      GTY542095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE REAR MOTOR UNDER COVER RH 
    1. Remove the 4 clips and rear motor under cover RH from the vehicle.
      GTY598298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FRONT FLOOR COVER RH 

    Refer to PROCEDURE - Step 3

  13. REMOVE FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 2

  14. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH 
    1. Remove the nut and separate the front stabilizer link assembly LH from the front stabilizer bar.
      GTY547721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the boot of the ball joint.

      HINT: 

      If the ball joint turns together with the nut, use a 6 mm hexagon socket wrench to hold the stud bolt.

  15. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Use the same procedure for the RH side and LH side.

  16. SEPARATE TIE ROD END SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 16

  17. SEPARATE TIE ROD END SUB-ASSEMBLY RH 

    HINT: 

    Use the same procedure for the RH side and LH side.

  18. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 10

  19. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT: 

    Use the same procedure for the RH side and LH side.

  20. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH 
    1. Remove the 4 bolts and rear side rail reinforcement sub-assembly LH.
      GTY583960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH 
    1. Remove the clips and separate the front fender splash shield sub-assembly RH.
      GTY607675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts and rear side rail reinforcement sub-assembly RH.
      GTY583967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. SUPPORT FCV TRANSAXLE WITH MOTOR ASSEMBLY 
    1. Using a transmission jack and wooden blocks, support the FCV transaxle with motor assembly.
      GTY598242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Wooden Block
      WARNING:
      • Do not remove the support before installing the front crossmember sub-assembly and front suspension crossmember sub-assembly.
        GTY596060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • If the support is removed, the FCV transaxle with motor assembly could fall.
  23. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY 
    1. Remove the 3 bolts and separate the front motor mounting insulator from the front crossmember sub-assembly
      GTY599536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts and front crossmember sub-assembly from the vehicle.
      GTY547714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH 
    1. Remove the 2 bolts and front suspension member rear brace LH.
      GTY547715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH 

    HINT: 

    Use the same procedure for the RH side and LH side.

  26. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Remove the 2 bolts and 2 nuts and separate the rear motor mounting insulator from the front suspension crossmember sub-assembly.
      GTY599535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Support the front suspension crossmember sub-assembly with an engine lifter using 4 attachments or equivalent tools as shown in the illustration.
      GTY550166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Engine Lifter
      *b Attachment
      Attachment placement location
      WARNING:
      • The front suspension crossmember sub-assembly is a very heavy component. Make sure that it is supported securely.
        GTY596075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • If the front suspension crossmember sub-assembly is not securely supported, it may drop, resulting in serious injury.
      NOTE:

      Use attachments to keep the front suspension crossmember sub-assembly level.

    3. Remove the 2 bolts and front suspension crossmember sub-assembly with steering gear assembly.
      GTY547716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Slowly lower the front suspension crossmember sub-assembly.
      NOTE:

      When lowering the front suspension crossmember sub-assembly, be careful not to damage the vehicle body or other components installed to the vehicle.

  27. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH 

    See step  4

  28. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT: 

    Use the same procedure for the RH side and LH side.

  29. REMOVE FRONT SUSPENSION MEMBER BRACE 

    See step  7

  30. REMOVE FRONT STABILIZER BAR 
    1. Remove the front stabilizer bar with front stabilizer bar bush LH and front stabilizer bar bush RH from the front suspension crossmember sub-assembly.
      GTY599538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE STEERING LINK ASSEMBLY 

    Refer to PROCEDURE - Step 28

  32. REMOVE REAR CAB MOUNTING LOWER SPACER 
    1. Remove the 4 rear lower cab mounting spacers from the front suspension crossmember sub-assembly.
  33. REMOVE REAR CAB MOUNTING CUSHION 
    1. Remove the 4 rear cab mounting cushions from the front suspension crossmember sub-assembly.
  34. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING FRONT STOPPER 
    1. Remove the 2 front suspension member body mounting rear stoppers from the front suspension crossmember sub-assembly.
      GTY547731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR STOPPER 
    1. Remove the 2 front suspension member body mounting rear stoppers from the front suspension member rear brace LH and front suspension member rear brace RH.
      GTY547732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE FRONT UPPER BODY MOUNTING CUSHION 
    1. Using a chisel and hammer, kink the flange of the front upper body mounting cushion as shown in the illustration.
      GTY547728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply lubricant to the contact surfaces of the front upper body mounting cushion.
    3. Position and firmly secure SST as shown in the illustration.
      • SST: 09950-00020 
      • SST: 09950-00030 
      • SST: 09950-40011 
        1. 09957-04010
      • SST: 09950-60010 
        1. 09951-00300
      GTY610279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
    4. While applying lubricant to the contact surfaces between the front upper body mounting cushion and front suspension crossmember sub-assembly, gradually remove the front upper body mounting cushion.
      NOTE:
      • Be careful when removing the front upper body mounting cushion because it may unexpectedly pop out.
      • Do not reuse the front upper body mounting cushion.
  37. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION 
    1. Apply lubricant to the contact surface of the front suspension member body mounting rear cushion.
    2. Position and firmly secure SST as shown in the illustration.
      • SST: 09710-28031 
        1. 09711-02030
        2. 09711-02040
        3. 94622-51200
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09954-04010
        4. 09955-04031
      • SST: 09950-60010 
        1. 09951-00320
      GTY565500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
    3. While applying lubricant to the contact surfaces between the front suspension member body mounting rear cushion and front suspension crossmember sub-assembly, gradually remove the front suspension member body mounting rear cushion.
      NOTE:
      • Be careful when removing the cushion because it may unexpectedly pop out.
      • Do not reuse the front suspension member body mounting rear cushion.
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