Toyota Tacoma 2002-06

Upper Control Arms

Print

Bushing Replacement



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the upper control arm from the vehicle.
  4.  
  5. Position the assembly in a suitable holding fixture.
  6.  
  7. Using a hammer and a chisel, raise the flange of the bushing diagonally.
  8.  
  9. On 2WD vehicles, use tool SST09950-40011 remove the bushings from their mountings.
  10.  
  11. On 4WD and PreRunner, use tools SST09613-26010 and 09710-22021 and a shop press remove the bushings from their mountings.
  12.  
  13. Using the special tools, install new bushings.
  14.  

2wd
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the upper control arm.
  4.  
  5. Cut off the outer edges of the bushing so it is flush with arm tube and the shaft.
  6.  


NOTE
Be careful not to damage the edge of the arm tubes.



Click image to see an enlarged view

Fig. Cut the bushing flush with the upper control arm tube and shaft

  1. Using a shop press with tool 09710-03031, press down the suspension arm tube until it touches tool 09710-03141.
  2.  


NOTE
Do not press the tube excessively.

  1. Temporarily install a 1.8-2.0 in. (45-50mm) bolt to the arm shaft on the other side.
  2.  
  3. Using a shop press with tool 09710-03141, remove the bushing from the arm shaft.
  4.  
  5. Repeat this procedure for the other bushing.
  6.  

To install:

  1. Using a shop press and tool 09710-03101, install the new bushing.
  2.  
  3. Place the arm shaft to the bushing.
  4.  
  5. Using a shop press and tool 09710-03101, install the other new bushing.
  6.  


NOTE
Pass the arm shaft through the bushing to make sure that the shaft turns freely and there is no axial play

  1. Install the upper control arm.
  2.  
  3. Check and/or adjust the alignment.
  4.  


    Click image to see an enlarged view

    Fig. Position the upper control arm bushings with the tools



    Click image to see an enlarged view

    Fig. Positioning the upper control arm tube and bolt



    Click image to see an enlarged view

    Fig. Removing the bushings from the upper control arm



    Click image to see an enlarged view

    Fig. Installing the bushings to the upper control arm


  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the upper control arm.
  4.  
  5. Cut off the outer edges of the bushing so it is flush with arm tube and the shaft.
    NOTE
    Be careful not to damage the edge of the arm tubes.



    Click image to see an enlarged view

    Fig. Cut the bushing flush with the upper control arm tube and shaft-2WD 2001-2004

  6.  
  7. Using a shop press with tool 09710-03031, press down the suspension arm tube until it touches tool 09710-03141.
    NOTE
    Do not press the tube excessively.

  8.  
  9. Temporarily install a 1.8-2.0 in. (45-50mm) bolt to the arm shaft on the other side.
  10.  
  11. Using a shop press with tool 09710-03141, remove the bushing from the arm shaft.
  12.  
  13. Repeat this procedure for the other bushing.
  14.  

To install:

  1. Using a shop press and tool 09710-03101, install the new bushing.
  2.  
  3. Place the arm shaft to the bushing.
  4.  
  5. Using a shop press and tool 09710-03101, install the other new bushing.
    NOTE
    Pass the arm shaft through the bushing to make sure that the shaft turns freely and there is no axial play

  6.  
  7. Install the upper control arm.
  8.  
  9. Check and/or adjust the alignment.

    Click image to see an enlarged view

    Fig. Position the upper control arm bushings with the tools-2WD 2001-2004



    Click image to see an enlarged view

    Fig. Positioning the upper control arm tube and bolt-2WD 2001-2004



    Click image to see an enlarged view

    Fig. Removing the bushings from the upper control arm-2WD 2001-2004



    Click image to see an enlarged view

    Fig. Installing the bushings to the upper control arm-2WD 2001-2004

  10.  

4wd
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the upper control arm from the vehicle.
  4.  
  5. Pry up the bushing flange, using a chisel and a hammer.
  6.  
  7. Using tools 09613-26010, 09613-20060 and 09950-00020 and a shop press, remove the bushing.
  8.  

To install:

  1. Using tools 09223-00010, 09506-35010 and a shop press, press the new bushing into the upper control arm.
  2.  
  3. Install the upper control arm to the chassis.
  4.  
  5. Check and/or adjust the alignment.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the upper control arm from the vehicle.
  4.  
  5. Pry up the bushing flange, using a chisel and a hammer.
  6.  
  7. Using tools 09613-26010, 09613-20060 and 09950-00020 and a shop press, remove the bushing.
  8.  

To install:

  1. Using tools 09223-00010, 09506-35010 and a shop press, press the new bushing into the upper control arm.
  2.  
  3. Install the upper control arm to the chassis.
  4.  
  5. Check and/or adjust the alignment.
  6.  

Removal & Installation





Click image to see an enlarged view

Fig. Upper control arm and related components-4WD and PreRunner 2005-2006

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle safely. Remove the tire and wheel assemblies.
  6.  
  7. Remove the speed sensor connector. Remove the two bolts and separate the skid control sensor wire.
  8.  
  9. On 2WD vehicles, remove the bolt and separate the front flexible hose.
  10.  
  11. Support the front suspension lower control arm using a jack.
  12.  
  13. Remove the clip and nut. Using the tool SST09628-62011, or equivalent separate the upper ball joint from the steering knuckle.
  14.  
  15. On 4WD and PreRunner, remove the bolt and bracket.
  16.  
  17. Remove the two upper control arm retaining bolts.
  18.  
  19. Remove the upper control arm from the vehicle.
  20.  

To install:


NOTE
Always fully tighten rubber bushings when the wheels are in full contact with the ground and the vehicle is at curb height. Bounce the vehicle up and down several times to stabilize the suspension, prior to final tightening of these components.

  1. Position the upper control arm on its mounting in the vehicle.
  2.  
  3. Temporarily tighten the upper control arm mounting bolts.
  4.  
  5. Continue the installation in the reverse order of the removal procedure.
  6.  
  7. Final tightening torque for the upper control arm bushings is 60 ft. lbs. on 2WD vehicles and 85 ft. lbs. on 4WD vehicles and PreRunner.
  8.  
  9. Check and adjust the alignment, as required.
  10.  

2-Wheel Drive
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Anti-lock Brake System (ABS) speed sensor and wire harness
     
    Stabilizer bar link
     
    Steering knuckle from the upper bar joint
     

  4.  
  5. Loosen the 2 bolts; then, remove the front and rear alignment adjusting shims.
  6.  
  7. Make note of the number and thickness of the front and rear shims.
  8.  
  9. Remove or disconnect the following:

    Upper control arm
     
    Upper ball joint from the arm
     

  10.  

To install:

  1. Install or connect the following:

    Upper ball joint to the arm. Tighten the fasteners to 29 ft. lbs. (39 Nm).
     

  2.  


NOTE
Do not lose the camber adjusting shims. Record the position and thickness of the camber shims so that these can be reinstalled to there original locations. Install the equal number and thickness of shims into there locations.



Upper control arm with the shims. Tighten the mounting bolts to 94 ft. lbs. (130 Nm).
 
Steering knuckle to the upper ball joint
 
Stabilizer bar link
 
ABS speed sensor and wire harness
 
Front wheel. Tighten the lug nuts to 83 ft. lbs. (110 Nm).
 

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Anti-lock Brake System (ABS) speed sensor and wire harness
     
    Stabilizer bar link
     
    Steering knuckle from the upper bar joint
     

  4.  
  5. Loosen the 2 bolts; then, remove the front and rear alignment adjusting shims.
  6.  
  7. Make note of the number and thickness of the front and rear shims.
  8.  
  9. Remove or disconnect the following:

    Upper control arm
     
    Upper ball joint from the arm
     

  10.  

To install:

  1. Install or connect the following:
    NOTE
    Do not lose the camber adjusting shims. Record the position and thickness of the camber shims so that these can be reinstalled to there original locations. Install the equal number and thickness of shims into there locations.



    Upper ball joint to the arm. Tighten the fasteners to 29 ft. lbs. (39 Nm).
     



    Upper control arm with the shims. Tighten the mounting bolts to 94 ft. lbs. (130 Nm).
     
    Steering knuckle to the upper ball joint
     
    Stabilizer bar link
     
    ABS speed sensor and wire harness
     
    Front wheel. Tighten the lug nuts to 83 ft. lbs. (110 Nm).
     

  2.  

4-Wheel Drive
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Shock and coil spring assembly
     
    Anti-lock Brake System (ABS) speed sensor wire harness clamp
     

  4.  
  5. Upper ball joint, as follows:

    Cotter pins and loosen the nut
     
    Upper ball joint from the control arm, using a ball joint separator
     
    Support the steering knuckle
     
    Nut
     

  6.  
  7. Detach the control arm, by removing the nut, bolt, washers and lowering the arm.
  8.  


    Click image to see an enlarged view

    Fig. Upper control arm and related parts-4wd and PreRunner


To install:

  1. Install or connect the following:

    Upper control arm with the washer, bolt and nut. Tighten the nut to 87 ft. lbs. (115 Nm).
     
    Upper ball joint to the control arm. Tighten the mounting nut to 80 ft. lbs. (105 Nm).
     
    New cotter pin
     
    ABS speed sensor wire harness clamp. Tighten it to 71 inch lbs. (8 Nm).
     
    Shock and coil spring assembly
     

  2.  
  3. Check and/or adjust the alignment.
  4.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Front wheel
     
    Shock and coil spring assembly
     
    Anti-lock Brake System (ABS) speed sensor wire harness clamp
     

  4.  
  5. Upper ball joint, as follows:

    Cotter pins and loosen the nut
     
    Upper ball joint from the control arm, using a ball joint separator
     
    Support the steering knuckle
     
    Nut
     

  6.  
  7. Detach the control arm, by removing the nut, bolt, washers and lowering the arm.

    Click image to see an enlarged view

    Fig. Upper control arm and related components-4WD and PreRunner 2001-2004

  8.  

To install:

  1. Install or connect the following:

    Upper control arm with the washer, bolt and nut. Tighten the nut to 87 ft. lbs. (115 Nm).
     
    Upper ball joint to the control arm. Tighten the mounting nut to 80 ft. lbs. (105 Nm).
     
    New cotter pin
     
    ABS speed sensor wire harness clamp. Tighten it to 71 inch lbs. (8 Nm).
     
    Shock and coil spring assembly
     

  2.  
  3. Check and/or adjust the alignment.
  4.  

 
label.common.footer.alt.autozoneLogo