BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

SECTION

BRM

BODY REPAIR

A

B

C

D

E

CONTENTS
KING CAB
VEHICLE INFORMATION ............................. 6
BODY EXTERIOR PAINT COLOR ..................... 6

FOR AUSTRALIA ......................................................40
FOR AUSTRALIA : Undercoating ............................41
FOR AUSTRALIA : Stone Guard Coat ....................41
FOR AUSTRALIA : Body Sealing ............................43

Body Exterior Paint Color ....................................... 6

BODY CONSTRUCTION .................................. 49

PRECAUTION ............................................... 8

FOR THAILAND .........................................................49
FOR THAILAND : Body Construction ......................49

PRECAUTIONS ................................................... 8
Precautions for Removing Battery Terminal ............. 8

REPAIRING HIGH STRENGTH STEEL .............. 9
High Strength Steel (HSS) ........................................ 9

PREPARATION ........................................... 13
REPAIRING MATERIAL ....................................13
Foam Repair ........................................................... 13

BODY COMPONENT PARTS ............................15
FOR THAILAND ........................................................ 15
FOR THAILAND : Underbody Component Parts .... 15
FOR THAILAND : Body Component Parts .............. 16
FOR THAILAND : Rear Body Component Parts .... 18
FOR THAILAND : Frame Component Parts ........... 20
FOR AUSTRALIA ...................................................... 23
FOR AUSTRALIA : Underbody Component Parts.... 23
FOR AUSTRALIA : Body Component Parts ........... 24
FOR AUSTRALIA : Rear Body Component Parts.... 26
FOR AUSTRALIA : Frame Component Parts ......... 28

REMOVAL AND INSTALLATION ............... 32
CORROSION PROTECTION .............................32

Description .............................................................. 32
FOR THAILAND ........................................................ 32
FOR THAILAND : Undercoating ............................. 32
FOR THAILAND : Stone Guard Coat ...................... 33
FOR THAILAND : Body Sealing .............................. 35

Revision: 2014 December

FOR AUSTRALIA ......................................................50
FOR AUSTRALIA : Body Construction ....................51

F

G

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REPLACEMENT OPERATIONS ....................... 53
Description ...............................................................53
FOR THAILAND .........................................................54
FOR THAILAND : Radiator Core Support ...............55
FOR THAILAND : Hoodledge ..................................55
FOR THAILAND : Hoodledge (Partial Replacement) .......................................................................56
FOR THAILAND : Front Pillar ..................................57
FOR THAILAND : Outer Sill (Partial Replacement)
....61
FOR THAILAND : Outer Sill ....................................62
FOR THAILAND : Rear Cab Pillar ...........................62

FOR THAILAND : Back Panel .................................65
FOR THAILAND : Rear Body Fender ......................66
FOR THAILAND : Rear Crossmember ....................67
FOR THAILAND : Crush Horn .................................68
FOR THAILAND : Roof ............................................70
FOR AUSTRALIA ......................................................70
FOR AUSTRALIA : Radiator Core Support .............71
FOR AUSTRALIA : Hoodledge ................................71
FOR AUSTRALIA : Hoodledge (Partial Replacement) .......................................................................72
FOR AUSTRALIA : Front Pillar ................................73
FOR AUSTRALIA : Outer Sill (Partial Replacement) .......................................................................77
FOR AUSTRALIA : Outer Sill .................................78
FOR AUSTRALIA : Rear Cab Pillar .........................78

BRM-1

D23

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FOR AUSTRALIA : Back Panel .............................. 81
FOR AUSTRALIA : Rear Body Fender ................... 82
FOR AUSTRALIA : Rear Crossmember ................. 83
FOR AUSTRALIA : Crush Horn .............................. 84
FOR AUSTRALIA : Roof ........................................ 86

SERVICE DATA AND SPECIFICATIONS
(SDS) ........................................................... 87
BODY ALIGNMENT ........................................... 87
FOR THAILAND ........................................................ 87
FOR THAILAND : Body Center Marks .................... 87
FOR THAILAND : Description ................................ 88
FOR THAILAND : Engine Compartment ................ 88
FOR THAILAND : Underbody ................................. 90
FOR THAILAND : Passenger Compartment
(Windshield and Door Opening) ............................. 93
FOR THAILAND : Passenger Compartment (Rear
Window Opening) ................................................... 94
FOR THAILAND : Rear Body ................................. 96
FOR AUSTRALIA ..................................................... 98
FOR AUSTRALIA : Body Center Marks ................. 98
FOR AUSTRALIA : Description .............................. 99
FOR AUSTRALIA : Engine Compartment .............100
FOR AUSTRALIA : Underbody .............................101
FOR AUSTRALIA : Passenger Compartment
(Windshield and Door Opening) ............................104
FOR AUSTRALIA : Passenger Compartment

(Rear Window Opening) ........................................105
FOR AUSTRALIA : Rear Body ..............................107

LHD : Frame Component Parts ............................ 127
FOR THAILAND ...................................................... 132
FOR THAILAND : Underbody Component Parts . 132
FOR THAILAND : Body Component Parts ........... 134
FOR THAILAND : Rear Body Component Parts ... 136
FOR THAILAND : Frame Component Parts ......... 138
EXCEPT FOR THAILAND (RHD) ........................... 141
EXCEPT FOR THAILAND (RHD) : Underbody
Component Parts .................................................. 141
EXCEPT FOR THAILAND (RHD) : Body Component Parts .............................................................. 142
EXCEPT FOR THAILAND (RHD) : Rear Body
Component Parts .................................................. 144
EXCEPT FOR THAILAND (RHD) : Frame Component Parts .............................................................. 146

REMOVAL AND INSTALLATION ............. 152
CORROSION PROTECTION ........................... 152
Description ............................................................ 152
LHD .......................................................................... 152
LHD : Undercoating .............................................. 152
LHD : Stone Guard Coat ....................................... 153
LHD : Body Sealing ............................................... 155
FOR THAILAND ...................................................... 160
FOR THAILAND : Undercoating ........................... 161
FOR THAILAND : Stone Guard Coat .................... 161
FOR THAILAND : Body Sealing ........................... 163

DOUBLE CAB


EXCEPT FOR THAILAND (RHD) ........................... 168
EXCEPT FOR THAILAND (RHD) : Undercoating . 169
EXCEPT FOR THAILAND (RHD) : Stone Guard
Coat ...................................................................... 169
EXCEPT FOR THAILAND (RHD) : Body Sealing . 171

VEHICLE INFORMATION .......................... 113

BODY CONSTRUCTION .................................. 177

BODY EXTERIOR PAINT COLOR .................. 113

LHD .......................................................................... 177
LHD : Body Construction ...................................... 177

LOCATION OF PLASTIC PARTS ................... 110
Precautions for Plastics .........................................110
Location of Plastic Parts ........................................111

Body Exterior Paint Color ....................................113

PRECAUTION ............................................ 115
PRECAUTIONS ............................................... 115
Precautions for Removing Battery Terminal ..........115

REPAIRING HIGH STRENGTH STEEL .......... 116
High Strength Steel (HSS) .....................................116

PREPARATION .......................................... 120

REPAIRING MATERIAL .................................. 120
Foam Repair ..........................................................120

BODY COMPONENT PARTS ......................... 122
LHD ..........................................................................122
LHD : Underbody Component Parts ......................122
LHD : Body Component Parts ...............................123
LHD : Rear Body Component Parts ......................125

Revision: 2014 December

FOR THAILAND ...................................................... 178
FOR THAILAND : Body Construction ................... 179
FOR AUSTRALIA .................................................... 180
FOR AUSTRALIA : Body Construction ................. 181
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) ....................................................................... 182
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Body Construction ................................... 183

REPLACEMENT OPERATIONS ...................... 185
Description ............................................................ 185
LHD .......................................................................... 186
LHD : Radiator Core Support ................................ 187
LHD : Hoodledge .................................................. 187
LHD : Hoodledge (Partial Replacement) ............... 188
LHD : Front Pillar .................................................. 189

BRM-2


D23


LHD : Center Pillar ................................................ 193
LHD : Outer Sill (Partial Replacement) ................. 195
LHD : Outer Sill .................................................... 196
LHD : Rear Cab Pillar ............................................ 197
LHD : Back Panel .................................................. 200
LHD : Rear Body Fender ....................................... 201
LHD : Rear Crossmember ..................................... 202
LHD : Crush Horn .................................................. 203
LHD : Roof (Normal Roof Models) ........................ 205
FOR THAILAND ...................................................... 206
FOR THAILAND : Radiator Core Support ............. 206
FOR THAILAND : Hoodledge ............................... 207
FOR THAILAND : Hoodledge (Partial Replacement) ..................................................................... 208
FOR THAILAND : Front Pillar ............................... 208
FOR THAILAND : Center Pillar ............................. 212
FOR THAILAND : Outer Sill (Partial Replacement)
.. 214
FOR THAILAND : Outer Sill ................................. 215
FOR THAILAND : Rear Cab Pillar ........................ 216
FOR THAILAND : Back Panel ............................... 219
FOR THAILAND : Rear Body Fender ................... 220
FOR THAILAND : Rear Crossmember ................. 221
FOR THAILAND : Crush Horn .............................. 222
FOR THAILAND : Roof (Normal Roof Models) ..... 224
FOR AUSTRALIA .................................................... 225
FOR AUSTRALIA : Radiator Core Support ........... 225
FOR AUSTRALIA : Hoodledge ............................. 226

FOR AUSTRALIA : Hoodledge (Partial Replacement) ..................................................................... 227
FOR AUSTRALIA : Front Pillar ............................. 227
FOR AUSTRALIA : Center Pillar ........................... 231
FOR AUSTRALIA : Outer Sill (Partial Replacement) ..................................................................... 233
FOR AUSTRALIA : Outer Sill ............................... 234
FOR AUSTRALIA : Rear Cab Pillar ...................... 235
FOR AUSTRALIA : Back Panel ............................ 238
FOR AUSTRALIA : Rear Body Fender ................. 239
FOR AUSTRALIA : Rear Crossmember ............... 240
FOR AUSTRALIA : Crush Horn ............................ 241
FOR AUSTRALIA : Roof (Normal Roof Models) .. 243
FOR AUSTRALIA : Roof (Sunroof Models) .......... 244
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) ....................................................................... 244
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Radiator Core Support ............................. 245
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Hoodledge ................................................ 245
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Hoodledge (Partial Replacement) ............ 246
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Front Pillar ................................................ 247
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Center Pillar ............................................. 251
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Outer Sill (Partial Replacement) .............. 253

Revision: 2014 December

EXCEPT FOR THAILAND AND AUSTRALIA

(RHD) : Outer Sill .................................................. 254
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Rear Cab Pillar ......................................... 255
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Back Panel ............................................... 258
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Rear Body Fender .................................... 259
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Rear Crossmember .................................. 260
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Crush Horn ............................................... 261
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Roof (Normal Roof Models) ...................... 263

A

B

C

D

SERVICE DATA AND SPECIFICATIONS
(SDS) .......................................................... 264

E

BODY ALIGNMENT ........................................ 264

F


LHD .......................................................................... 264
LHD : Body Center Marks ...................................... 264
LHD : Description .................................................. 265
LHD : Engine Compartment .................................. 265
LHD : Underbody ................................................... 267
LHD : Passenger Compartment (Windshield and
Door Opening) ....................................................... 269
LHD : Passenger Compartment (Rear Window
Opening) ................................................................ 273
LHD : Rear Body ................................................... 274
RHD .......................................................................... 276
RHD : Body Center Marks ..................................... 276
RHD : Description .................................................. 277
RHD : Engine Compartment .................................. 278
RHD : Underbody .................................................. 279
RHD : Passenger Compartment (Windshield and
Door Opening) ....................................................... 281
RHD : Passenger Compartment (Rear Window
Opening) ................................................................ 285
RHD : Rear Body ................................................... 286

LOCATION OF PLASTIC PARTS .................. 289

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Precautions for Plastics ......................................... 289
LHD .......................................................................... 289
LHD : Location of Plastic Parts .............................. 290
RHD .......................................................................... 291
RHD : Location of Plastic Parts ............................. 292

SINGLE CAB
VEHICLE INFORMATION ......................... 294
BODY EXTERIOR PAINT COLOR ................. 294
Body Exterior Paint Color .................................... 294

PRECAUTION ............................................ 296
PRECAUTIONS ............................................... 296
Precautions for Removing Battery Terminal .......... 296

BRM-3

D23

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REPAIRING HIGH STRENGTH STEEL .......... 297
High Strength Steel (HSS) .....................................297

PREPARATION .......................................... 301
REPAIRING MATERIAL .................................. 301
Foam Repair ..........................................................301

BODY COMPONENT PARTS ......................... 303
FOR THAILAND .......................................................303
FOR THAILAND : Underbody Component Parts ..303
FOR THAILAND : Body Component Parts ............304
FOR THAILAND : Rear Body Component Parts ..306
FOR THAILAND : Frame Component Parts ..........308
EXCEPT FOR THAILAND .......................................311
EXCEPT FOR THAILAND : Underbody Component Parts ..............................................................311
EXCEPT FOR THAILAND : Body Component
Parts ......................................................................312
EXCEPT FOR THAILAND : Rear Body Component Parts ..............................................................314
EXCEPT FOR THAILAND : Frame Component
Parts ......................................................................316

REMOVAL AND INSTALLATION .............. 320
CORROSION PROTECTION ........................... 320
Description .............................................................320
FOR THAILAND .......................................................320
FOR THAILAND : Undercoating ............................320

FOR THAILAND : Stone Guard Coat ....................321
FOR THAILAND : Body Sealing ............................323
EXCEPT FOR THAILAND .......................................328
EXCEPT FOR THAILAND : Undercoating .............329
EXCEPT FOR THAILAND : Stone Guard Coat .....329
EXCEPT FOR THAILAND : Body Sealing .............331

BODY CONSTRUCTION ................................. 337
FOR THAILAND .......................................................337
FOR THAILAND : Body Construction ....................337
EXCEPT FOR THAILAND .......................................338
EXCEPT FOR THAILAND : Body Construction .....339

REPLACEMENT OPERATIONS ..................... 341
Description .............................................................341
FOR THAILAND .......................................................342
FOR THAILAND : Radiator Core Support .............343
FOR THAILAND : Hoodledge ................................343
FOR THAILAND : Hoodledge (Partial Replacement) .....................................................................344
FOR THAILAND : Front Pillar ................................345
FOR THAILAND : Outer Sill (Partial Replacement)
..349
FOR THAILAND : Outer Sill ..................................350
FOR THAILAND : Rear Cab Pillar .........................351
FOR THAILAND : Back Panel ...............................354

Revision: 2014 December

FOR THAILAND : Rear Body Fender ................... 355
FOR THAILAND : Rear Crossmember ................. 357

FOR THAILAND : Crush Horn .............................. 358
FOR THAILAND : Roof ......................................... 359
FOR AUSTRALIA .................................................... 360
FOR AUSTRALIA : Radiator Core Support .......... 360
FOR AUSTRALIA : Hoodledge ............................. 361
FOR AUSTRALIA : Hoodledge (Partial Replacement) ..................................................................... 362
FOR AUSTRALIA : Front Pillar ............................. 362
FOR AUSTRALIA : Outer Sill (Partial Replacement) ..................................................................... 366
FOR AUSTRALIA : Outer Sill ............................... 367
FOR AUSTRALIA : Rear Cab Pillar ...................... 368
FOR AUSTRALIA : Back Panel ............................ 371
FOR AUSTRALIA : Rear Body Fender ................. 372
FOR AUSTRALIA : Rear Crossmember ............... 374
FOR AUSTRALIA : Crush Horn ............................ 375
FOR AUSTRALIA : Roof ....................................... 376
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) ....................................................................... 377
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Radiator Core Support ............................. 377
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Hoodledge ............................................... 378
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Hoodledge (Partial Replacement) ............ 379
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Front Pillar ............................................... 380
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Outer Sill (Partial Replacement) .............. 383
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Outer Sill ................................................. 384
EXCEPT FOR THAILAND AND AUSTRALIA

(RHD) : Rear Cab Pillar ........................................ 385
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Back Panel ............................................... 388
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Rear Body Fender ................................... 389
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Rear Crossmember ................................. 391
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Crush Horn .............................................. 392
EXCEPT FOR THAILAND AND AUSTRALIA
(RHD) : Roof ......................................................... 393

SERVICE DATA AND SPECIFICATIONS
(SDS) ......................................................... 395
BODY ALIGNMENT ......................................... 395
Body Center Marks ............................................... 395
Description ............................................................ 396
Engine Compartment ............................................ 396
Underbody ............................................................ 398
Passenger Compartment (Windshield and Door
Opening) ............................................................... 400
Passenger Compartment (Rear Window Opening)
. 402

BRM-4

D23


Rear Body ............................................................. 404


LOCATION OF PLASTIC PARTS .................... 407

Precautions for Plastics ......................................... 407
Location of Plastic Parts ........................................ 408

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Revision: 2014 December

BRM-5

D23


BODY EXTERIOR PAINT COLOR
[KING CAB]

< VEHICLE INFORMATION >

VEHICLE INFORMATION
BODY EXTERIOR PAINT COLOR
Body Exterior Paint Color

INFOID:0000000011680921

FOR THAILAND

JSKIA5724ZZ


Component

Door mirror

Front grille

Color code

BCAQ

BEAU

BG42

BK21

BK23

BQX1

BRAA

BQM1

Description

Dark
Brown

Orange


Black

Gray

Silver

White

Dark
Blue

White

2PM

2PM

2S

2FPM

2M

3P

2P

S


Standard
clear coat

×

×

×

×

×

×

×

–

Chromium
plate

Cr

Cr

Cr

Cr


Cr

Cr

Cr

Cr

Material color

–

–

–

–

–

–

–

–

Chromium
plate

Cr


Cr

Cr

Cr

Cr

Cr

Cr

Cr

K23

K23

K23

K23

K23

K23

K23

K23


BCAQ

BEAU

BG42

BK21

BK23

BQX1

BRAA

BQM1

Paint type note

Silver
Front bumper fascia

Body color

Tail gate handle

Material color

–


–

–

–

–

–

–

–

Door outside handle

Chromium
plate

Cr

Cr

Cr

Cr

Cr

Cr


Cr

Cr

Material color

–

–

–

–

–

–

–

–

Upper and
Lower finisher

Material color

–


–

–

–

–

–

–

–

Rear
bumper
reinforcement

Chromium
plate

Cr

Cr

Cr

Cr

Cr


Cr

Cr

Cr

Rear
bumper

NOTE:
• S: 1-Coat solid
• 2M: 2-Coat Metallic
• 2P: 2-Coat pearl
• 2S: 2-Coat solid
• 3P: 3-Coat pearl

Revision: 2014 December

BRM-6

D23


BODY EXTERIOR PAINT COLOR
[KING CAB]

< VEHICLE INFORMATION >
• 2PM: 2-Coat Pearl metallic


A

• 2FPM: 2-Coat Iron pearl metallic

FOR AUSTRALIA
B

C

D

E

F
JSKIA5724ZZ

Component

Door mirror

Front grille

Color code

BAX6

BCAQ

BEAU


BG42

BK21

BK23

BQX1

BRAA

BQM1

Description

Red

Dark
Brown

Orange

Black

Gray

Silver

White

Dark

Blue

White

2S

2PM

2PM

2S

2FPM

2M

3P

2P

S

Standard
clear coat

×

×

×


×

×

×

×

×

–

Chromium
plate

Cr

Cr

Cr

Cr

Cr

Cr

Cr


Cr

Cr

Material color

–

–

–

–

–

–

–

–

–

Chromium
plate

Cr

Cr


Cr

Cr

Cr

Cr

Cr

Cr

Cr

K23

K23

K23

K23

K23

K23

K23

K23


K23

BAX6

BCAQ

BEAU

BG42

BK21

BK23

BQX1

BRAA

BQM1

Paint type note

Silver

H

I

Front bumper fascia


Body color

Tail gate handle

Material color

–

–

–

–

–

–

–

–

–

Door outside handle

Chromium
plate


Cr

Cr

Cr

Cr

Cr

Cr

Cr

Cr

Cr

Rear
bumper

G

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L

Material color


–

–

–

–

–

–

–

–

–

Upper and
Lower finisher

Material color

–

–

–


–

–

–

–

–

–

Rear
bumper
reinforcement

Chromium
plate

M

N
Cr

Cr

Cr

Cr


Cr

Cr

Cr

Cr

Cr

O

NOTE:
• S: 1-Coat solid
• 2M: 2-Coat Metallic

P

• 2P: 2-Coat pearl
• 2S: 2-Coat solid
• 3P: 3-Coat pearl
• 2PM: 2-Coat Pearl metallic
• 2FPM: 2-Coat Iron pearl metallic

Revision: 2014 December

BRM-7

D23



PRECAUTIONS
[KING CAB]

< PRECAUTION >

PRECAUTION
PRECAUTIONS
Precautions for Removing Battery Terminal

INFOID:0000000011667139

• With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key
or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time.
• When disconnecting the 12V battery terminal, turn off the ACC
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.
• For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON the ignition switch.
NOTE:
SEF289H
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:

The removal of 12V battery may cause a DTC detection error.

HOW TO DISCONNECT 12V BATTERY TERMINAL
Disconnect 12V battery terminal according to instruction described below.
1. Open the hood.
2. Turn ignition switch to the ON position.
3. Turn ignition switch to the OFF position with the driver side door opened.
4. Get out of the vehicle and close the driver side door.
5. Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.

6.

D4D engine

: 20 minutes

HRA2DDT

: 12 minutes

K9K engine

: 4 minutes

M9R engine

: 4 minutes

R9M engine


: 4 minutes

V9X engine

: 4 minutes

CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
Remove 12V battery terminal.
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.

Revision: 2014 December

BRM-8

D23


REPAIRING HIGH STRENGTH STEEL
[KING CAB]

< PRECAUTION >

REPAIRING HIGH STRENGTH STEEL

A


High Strength Steel (HSS)

INFOID:0000000011667140

High strength steel is used for body panels in order to reduce vehicle weight.
Accordingly, precautions in repairing automotive bodies made of high strength steel are described below:
Tensile strength

440 - 780 MPa

Revision: 2014 December

B

Major applicable parts

C

• 4th cab mounting crossmember
(Rear floor assembly component part)
• Rear floor side reinforcement
(Rear floor assembly component part)
• Inner sill wheelhouse
(Inner sill extension assembly component part)
• Front seat mounting rear crossmember
(Front floor assembly component part)
• Center pillar crossmember
(Front floor assembly component part)
• Side member outrigger
(Front floor assembly component part)

• 2nd body mounting member
(Front floor assembly component part)
• Inner sill
(Inner front sill assembly component part)
• Lower dash reinforcement
(Lower dash complete component part)
• Upper hoodledge
(Hoodledge assembly component part)
• Lower hoodledge
(Lower hoodledge component part)
• Hoodledge reinforcement extension
(Lower hoodledge component part)
• Lower battery support bracket
(Lower hoodledge component part)
• Lower battery bracket
(Lower hoodledge component part)
• Side radiator core stay
(Side radiator core support component part)
• Front roof rail
(Front roof rail component part)
• Upper inner front pillar
• Inner lock pillar assembly
• Upper front pillar hinge brace
(Outer front pillar reinforcement component part)
• Outer sill reinforcement
• Outer side roof rail reinforcement
• Outer lock pillar reinforcement
• Lower rear panel reinforcement
(Back panel assembly component part)
• Upper front door hinge reinforcement

(Front door assembly component part)
• Lower front door hinge reinforcement
(Front door assembly component part)
• Outer rear door seat belt reinforcement
(Rear door assembly component part)
• 4th floor bolster
(4th floor bolster assembly component part)
• 3rd floor bolster
(3rd floor bolster assembly component part)

BRM-9

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D23


REPAIRING HIGH STRENGTH STEEL
[KING CAB]

< PRECAUTION >
Tensile strength

Major applicable parts

440 - 780 MPa

• Inner front side member
(Frame assembly component part)
• Outer front side member
(Frame assembly component part)
• Outer rear side member
(Frame assembly component part)
• Inner center side member
(Frame assembly component part)
• Front bumper crossmember assembly

• Front suspension rear crossmember assembly
• 4th crossmember
• Diagonal member complete
• Upper rear engine mounting crossmember
(Rear engine mounting crossmember complete component part)
• Rear fuel tank crossmember
(7th crossmember component part)
• Spare wheel cross reinforcement
(Spare wheel crossmember assembly component part)
• Outer front side member extension
(Front side member extension assembly component part)
• Inner front side member extension
(Front side member extension assembly component part)

Read the following precautions when repairing HSS:
1. Additional points to consider
• The repair of reinforcements (such as side members) by heating is not recommended, because it may weaken the component. When heating is unavoidable, never heat HSS parts
above 550°C (1,022°F).
Verify heating temperature with a thermometer.
(Crayon-type and other similar type thermometer are appropriate.)

PIIA0115E

• When straightening body panels, use caution in pulling any HSS panel. Because HSS is very strong,
pulling may cause deformation in adjacent sections of the body. In this case, increase the number of
measuring points, and carefully pull the HSS panel.
• When cutting HSS panels, avoid gas (torch) cutting if possible.
Instead, use a saw to avoid weakening surrounding areas due
to heat. If gas (torch) cutting is unavoidable, allow a minimum
margin of 50 mm (1.97 in).


PIIA0117E

Revision: 2014 December

BRM-10

D23


REPAIRING HIGH STRENGTH STEEL
< PRECAUTION >
• When welding HSS panels, use spot welding whenever possible in order to minimize weakening surrounding areas due to
heat.
If spot welding is impossible, use MIG. welding. Do not use
gas (torch) for welding because it is inferior in welding
strength.

[KING CAB]
A

B

C
PIIA0144E

D

• Spot welding on HSS panels is harder than that of an ordinary
steel panel.

Therefore, when cutting spot welds on a HSS panel, use a low
speed high torque drill (1,000 to 1,200 rpm) to increase drill bit
durability and facilitate the operation.

E

F

G
PIIA0145E

2.

Precautions in spot welding HSS
This work should be performed under standard working conditions. Always note the following when spot welding HSS:
• The electrode tip diameter must be sized properly according to
the metal thickness.

H

I

J

BRM

PIIA0146E

• The panel surfaces must fit flush to each other, leaving no
gaps.


L

M

N
PIIA0147E

O

P

Revision: 2014 December

BRM-11

D23


REPAIRING HIGH STRENGTH STEEL
< PRECAUTION >
• Follow the specifications for the proper welding pitch.

[KING CAB]

Unit: mm (in)

Thickness (T)

Minimum pitch (L)


0.6 (0.024)
0.8 (0.031)
1.0 (0.039)
1.2 (0.047)
1.6 (0.063)
1.8 (0.071)

10 (0.39) or more
12 (0.47) or more
18 (0.71) or more
20 (0.79) or more
27 (1.06) or more
31 (1.22) or more
JSKIA0781ZZ

Revision: 2014 December

BRM-12

D23


REPAIRING MATERIAL
[KING CAB]

< PREPARATION >

PREPARATION


A

REPAIRING MATERIAL
Foam Repair

INFOID:0000000011667141

During factory body assembly, foam insulators are installed in certain body panels and locations around the
vehicle. Use the following procedure(s) to replace any factory-installed foam insulators.

URETHANE FOAM APPLICATIONS

B

C

Use commercially available Urethane foam for sealant (foam material) repair of material used on vehicle.
<Urethane foam for foaming agent>

3M™ Automix™ Flexible Foam 08463 or equivalent

Read instructions on product for fill procedures.

D

E

Example of foaming agent filling operation procedure

1.

a.
b.
c.
d.

Fill procedures after installation of service part.
Eliminate foam material remaining on vehicle side.
Clean area after eliminating form insulator and foam material.
Install service part.
Insert nozzle into hole near fill area and fill foam material or fill enough to close gap with the service part.

F

G

H

I

J

BRM

L
JSKIA0129GB

Urethane foam

M


Nozzle insert hole
: Vehicle front

2.
a.
b.
c.

N

Fill procedures before installation of service part.
Eliminate foam material remaining on vehicle side.
Clean area after eliminating foam insulator and foam material.
Fill foam material on wheelhouse outer side.

O

P

Revision: 2014 December

BRM-13

D23


REPAIRING MATERIAL
[KING CAB]

< PREPARATION >


Urethane foam
Fill while avoiding flange area
: Vehicle front

d.

NOTE:
Fill enough to close gap with service part while avoiding flange
area.
Install service part.
NOTE:
Refer to label for information on working times.

Revision: 2014 December

BRM-14

JSKIA0130GB

D23


BODY COMPONENT PARTS
[KING CAB]

< PREPARATION >

BODY COMPONENT PARTS


A

FOR THAILAND
FOR THAILAND : Underbody Component Parts

INFOID:0000000011667143

B

Refer to parts catalogue for the replacement parts.
C

D

E

F

G

H

I

J

BRM

L


M

N

O

P

JSKIA5725ZZ

Revision: 2014 December

BRM-15

D23


BODY COMPONENT PARTS
[KING CAB]

< PREPARATION >
AT models

MT models

: Both sided anti-corrosive precoated steel sections
: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections

Tensile strength

(MPa)

Both sided
anti-corrosive
precoated
steel sections

Rear floor assembly

440

—

Inner sill extension assembly (RH & LH)

440

×

Front floor assembly

590

—

Inner front sill assembly (RH & LH)

590

×


Cowl top assembly

Under 440

×

Upper dash assembly

Under 440

×

Side dash (RH & LH)

under 440

—

Lower dash complete

440

—

Upper rear hoodledge (RH & LH)

Under 440

×


Hoodledge assembly (RH & LH)

440

×

Lower hoodledge (RH & LH)

440

ì

Side radiator core support (RH & LH)

440

ì

No.

Parts name

NOTE:
ã For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.
• Tensile strength column shows the largest strength value of a part in the component part.

FOR THAILAND : Body Component Parts

INFOID:0000000011667144


Refer to parts catalogue for the replacement parts.

Revision: 2014 December

BRM-16

D23


BODY COMPONENT PARTS
[KING CAB]

< PREPARATION >

A

B

C

D

E

F

G

H


I

J

BRM

L

M

N

O
JSKIA5726ZZ

P
: Both sided anti-corrosive precoated steel sections
: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections

Revision: 2014 December

BRM-17

D23


BODY COMPONENT PARTS
[KING CAB]


< PREPARATION >

Tensile strength
(MPa)

Both sided
anti-corrosive
precoated
steel sections

Under 440

—

590

—

Roof bow No.1

Under 440

—

Roof bow No.2

Under 440

—


Rear roof rail

Under 440

—

Hood

Under 440

×

Front fender (RH & LH)

Under 440

×

Upper inner front pillar (RH & LH)

590

—

Inner lock pillar assembly (RH & LH)

440

—


Outer front pillar reinforcement (RH & LH)

590

—

Outer sill reinforcement (RH & LH)

590

×

Under 440

×

Outer side roof rail reinforcement (RH & LH)

590

—

Outer lock pillar reinforcement (RH & LH)

590

—

Outer front side body (RH & LH)


Under 440

×

Back panel assembly

Under 440

×

590

×

Under 440

×

590

×

Under 440

×

No.

Parts name


Roof
Front roof rail

Front fender bracket assembly (RH & LH)

Front door assembly (RH & LH)
Outer front door panel (RH & LH)
Rear door assembly (RH & LH)
Outer rear door panel (RH & LH)
NOTE:

• For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.
• Tensile strength column shows the largest strength value of a part in the component part.

FOR THAILAND : Rear Body Component Parts

INFOID:0000000011848201

Refer to parts catalogue for the replacement parts.

Revision: 2014 December

BRM-18

D23


BODY COMPONENT PARTS
[KING CAB]


< PREPARATION >

A

B

C

D

E

F

G

H

I

J

BRM

L

M

N


O
JSKIA5727ZZ

P
: Both sided anti-corrosive precoated steel sections
: Both sided anti-corrosive steel and HSS sections

Revision: 2014 December

BRM-19

D23


BODY COMPONENT PARTS
[KING CAB]

< PREPARATION >

Tensile strength
(MPa)

Both sided
anti-corrosive
precoated
steel sections

Rear gate assembly


Under 440

×

Fuel filler lid assembly

Under 440

×

No.

Parts name

Rear body assembly

Refer to No.

−

Center floor panel

Under 440

×

Side panel assembly (RH & LH)

Under 440


×

Rear body tail floor bolster assembly

Under 440

×

4th floor bolster assembly

440

×

3rd floor bolster assembly

440

×

Floor bolster assembly

Under 440

×

1st floor bolster assembly

Under 440


×

Header panel frame assembly

Under 440

ì

Header panel assembly

Under 440

ì

NOTE:
ã For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.
• Tensile strength column shows the largest strength value of a part in the component part.

FOR THAILAND : Frame Component Parts

INFOID:0000000011680922

Refer to parts catalogue for the replacement parts.

Revision: 2014 December

BRM-20

D23



BODY COMPONENT PARTS
[KING CAB]

< PREPARATION >

A

B

C

D

E

F

G

H

I

J

BRM

L


M

N

O
JSKIA5728ZZ

4WD models

P

2WD models

: High strength steel (HSS) sections

Revision: 2014 December

BRM-21

D23


BODY COMPONENT PARTS
[KING CAB]

< PREPARATION >

No.

Tensile strength

(MPa)

Parts name

Both sided
anti-corrosive
precoated
steel sections
−

Frame assembly

Refer to No.

Front bumper crossmember assembly

540

—

Under 440

—

Front suspension rear crossmember assembly

440

—


4th crossmember

540

—

Diagonal member complete

540

—

Rear engine mounting crossmember complete

440

—

Fuel tank crossmember assembly

Under 440

—

Fuel tank cover bracket assembly (RH)

Under 440

—


Fuel tank cover bracket assembly (LH)

Under 440

—

440

—

Under 440

—

Spare wheel crossmember assembly

440

—

Front side member extension assembly (RH & LH)

540

—

1st cab mounting bracket (RH & LH)

Under 440


—

Front suspension cross reinforcement (RH & LH)

Under 440

—

Front suspension bracket assembly (RH & LH)

Under 440

—

Front brake hose bracket (RH & LH)

Under 440

—

Front bound bumper bracket assembly (RH & LH)

Under 440

—

2nd cab mounting bracket (RH & LH)

Under 440


—

Lower front link mounting bracket assembly (RH & LH)

Under 440

—

Engine mounting bracket assembly (RH & LH)

Under 440

—

4th crossmember gusset (RH & LH)

Under 440

—

Rear spring front bracket assembly (RH & LH)

Under 440

—

3rd cab mounting bracket (RH & LH)

Under 440


—

1st rear body mounting bracket (RH & LH)

Under 440

—

2nd rear body mounting bracket (RH & LH)

Under 440

—

Rear bound bumper bracket assembly (RH & LH)

Under 440

—

Rear shock absorber bracket assembly (RH & LH)

Under 440

—

ABS sensor bracket (RH & LH)

Under 440


—

Crossmember collar (RH & LH)

Under 440

—

Rear spring rear bracket assembly (RH & LH)

Under 440

—

Rear brake hose bracket

Under 440

—

4th rear body mounting bracket (RH & LH)

Under 440

—

Crossmember gusset (RH & LH)

Under 440


—

5th rear body mounting bracket (RH & LH)

Under 440

—

2nd crossmember

7th crossmember
Torsion crossmember assembly

NOTE:

Revision: 2014 December

BRM-22

D23


BODY COMPONENT PARTS
[KING CAB]

< PREPARATION >

• For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.

A


• Tensile strength column shows the largest strength value of a part in the component part.

FOR AUSTRALIA
FOR AUSTRALIA : Underbody Component Parts

INFOID:0000000011853122

B

Refer to parts catalogue for the replacement parts.
C

D

E

F

G

H

I

J

BRM

L


M

N

O

P

JSKIA5729ZZ

Revision: 2014 December

BRM-23

D23


BODY COMPONENT PARTS
[KING CAB]

< PREPARATION >
AT models

MT models

: Both sided anti-corrosive precoated steel sections
: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections


Tensile strength
(MPa)

Both sided
anti-corrosive
precoated
steel sections

Rear floor assembly

440

—

Inner sill extension assembly (RH & LH)

440

×

Front floor assembly

590

—

Inner front sill assembly (RH & LH)

590


×

Cowl top assembly

Under 440

×

Upper dash assembly

Under 440

×

Side dash (RH & LH)

under 440

—

Lower dash complete

440

—

Upper rear hoodledge (RH & LH)

Under 440


×

Hoodledge assembly (RH & LH)

440

×

Lower hoodledge (RH & LH)

440

ì

Side radiator core support (RH & LH)

440

ì

No.

Parts name

NOTE:
ã For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.
• Tensile strength column shows the largest strength value of a part in the component part.

FOR AUSTRALIA : Body Component Parts


INFOID:0000000011853123

Refer to parts catalogue for the replacement parts.

Revision: 2014 December

BRM-24

D23


BODY COMPONENT PARTS
[KING CAB]

< PREPARATION >

A

B

C

D

E

F

G


H

I

J

BRM

L

M

N

O
JSKIA5730ZZ

P
: Both sided anti-corrosive precoated steel sections
: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections

Revision: 2014 December

BRM-25

D23