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Performance Accessories 5603 Installation Instructions Manual

Toyota tacoma (auto. & manual trans., 2 & 4wd, ext. & crew cab, w/o o.e. trailer hitch) 3” body lift
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3651 N Highway 89 • Chino Valley, AZ 86323
(928) 636-7080 • www.p-a-g.net
TOYOTA TACOMA
(AUTO. & MANUAL TRANS., 2 &
4WD, EXT. & CREW CAB, W/O
O.E. TRAILER HITCH)
3" BODY LIFT
INSTALLATION INSTRUCTIONS
2005-2011
*VEHICLES EQUIPPED WITH O.E. TRAILER
HITCH REQUIRE KIT# 5903
WARNING
Installation of a Performance Automotive Group body
lift kit will change the vehicle's center of gravity and
handling characteristics both on- and off-road. You
must drive the vehicle safely! Extreme care must be
taken to prevent vehicle rollover or loss of control,
which could result in serious injury or death. Avoid sud-
den sharp turns or abrupt maneuvers and always make
sure all vehicle occupants have their seat belts fas-
tened.
WARNING
Before you install this kit, read and understand all
instructions, warnings, cautions, and notes in this
instruction sheet and in the vehicle owner's manual.
CAUTION
Proper installation of this kit requires knowledge of the
factory recommended procedures for removal and
installation of original equipment components. We rec-
ommend that the factory shop manual and any special
tools needed to service your vehicle be on hand during
the installation. Installation of this kit without proper
knowledge of the factory recommended procedures
may affect the performance of these components and
the safety of the vehicle. We strongly recommend that
a certified mechanic familiar with the installation of sim-
ilar components install this kit.
WARNING
DO NOT combine suspension, body, or other lift
devices. Use of vehicle with combined lifts may result
in unsafe and/or unexpected handling characteristics.
This kit should only be installed on a vehicle that is in
good working condition. Before you install the kit, thor-
oughly inspect the vehicle for corrosion or deformation
of the sheet metal around the factory body mounts. If
the vehicle is suspected to have been in a collision or
misused, do not install this kit. Off-road use of your
vehicle with this kit installed may increase the stress
applied to the factory body mounts. We do not recom-
KIT# 5603*
mend that any vehicle with a body lift kit installed be
involved in any extreme off-road maneuvers such as
jumping. Failure to observe this warning may result in
serious personal injury and/or severe damage to your
vehicle.
Many states and municipalities have laws restricting
bumper heights and vehicle lifts. Consult state and
local laws to determine if the changes you intend to
make to the vehicle comply with the law.
The installation of larger tires may reduce the effective-
ness of the braking system.
Always wear eye protection when operating power
tools.
Before you install this kit, block the vehicle tires to pre-
vent the vehicle from rolling.
Accidental deployment of the air bag can result in seri-
ous personal injury or death. To avoid accidental
deployment during installation of the kit, the Supple-
mental Restraint System (SRS, or airbag) must remain
deactivated. Do not allow anyone near the airbag dur-
ing installation. Refer to the factory service manual or
owner's manual for the recommended procedure to
disable the SRS. After you install the kit, reactivate the
SRS before driving the vehicle.
NOTE
Performance Automotive Group recommends using
the Loctite® supplied in the kit on the threads of all kit
nuts and bolts unless specified otherwise in these
instructions.
1
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
'05-'11 Tacoma (W/O Hitch) - 3" Kit 5603

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Table of Contents
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  Summary of Contents for Performance Accessories 5603

  • Page 1 SRS before driving the vehicle. NOTE Performance Automotive Group recommends using the Loctite® supplied in the kit on the threads of all kit nuts and bolts unless specified otherwise in these instructions. ‘05-‘11 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 2: Before Starting Installation

    Measurements 1. Measure and record distance between rear bumper and bed Driver Side ________ Passenger Side _________ 2. Measure and record distance between cab and bed. Driver Side ________ Passenger Side _________ ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 3 Use caution when removing front bumper fascia from vehicle. Carefully pull outward from fenders on the sides of front bumper cover to loosen. Remove six nuts and front bumper from vehicle. Front Bumper Nuts ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 4 Remove bolt and AC line bracket from body. AC Line Bolt AC Line Bracket b. Remove two nuts, clamp and rubber isolator from AC line and bracket. Nuts Clamp AC Line AC Line Bracket ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 5 7. 4 cyl. models: Remove lower AC line from two clips and passenger side body. Passenger Side Body Clip AC Line 8. Remove vent tubes from driver side body bracket. Vent Tubes Bracket Battery ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 6 Driver Side ABS Wire Harnesses Passenger Side 12. Remove wire harness and two clips from alternator bracket and driver side body bracket. Alternator Bracket Wire Harness Body Bracket Battery ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 7 Remove coupler bolts, slide coupler up onto upper steering shaft and disconnect steering shaft. d. Slide coupler down and off of upper steering shaft. e. Position steering coupler onto lower steering shaft. ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 8 Remove driver and passenger body mount bolt access cover. Carpet Body Mount Bolt Access Cover NOTE Procedures may vary depending on cab model for access to rear body mount bolt access covers. ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 9 4. Crew cab models: Rear interior trim panels a. Remove three headrests from seatbacks and fold seatbacks down. b. Remove three bolts and pop-clips from driver side rear panel and cab. Driver Side Rear Panel Bolts ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 10 Side Bolt & Brake Line Passenger Side 4. Remove two bolts and parking brake cable brackets from crossmember. Driver Side Parking Brake Cable Crossmember Bolt & Bracket Parking Brake Cable Passenger Side ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 11 Fuel Filler Body Fuel Filler b. Loosen two hose clamps and disconnect vent hose connector. Vent Hose Clamp Fuel Tank Front c. Remove bolt and fuel filler from vehicle. Fuel Filler Bolt Frame ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 12 Cab Mount (Core Support) Cab Mount (Mid Cab) Cab Mount (Rear Cab) NOTE The number of cab mounting bolts may vary with the length of the cab. ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603 Loosen Bolts At These Mounts...
  • Page 13 Slowly lift cab just enough to install a kit block on top of factory upper bushing. front core support cab mount. Front Cab Mount each remaining cab mount. Mid Cab Mount ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 14 (12mm Nylock). Tighten kit bolts to 55 ft. lbs. Mid Cab Mount Kit Bolt (M12-1.75 x 200mm), Kit Nut (12mm Nylock), Factory Captive Washer & Lower Washer ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 15 The factory captive washers will be used with kit bolts. b. Using a hydraulic jack and a wood block, slowly lift passenger side of bed a little more than 3”. Remove Bolts At These Mounts ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 16 Tow- ing after the bumper has been lifted should be accom- plished using a rated Class III receiver type hitch. NOTE Rear bumper installation requires kit# 5903. ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 17 Factory Bolts Kit Bracket (Rear Bumper, Passenger) c. Repeat above step for driver side. d. Remove eight factory bolts from O.E. trailer hitch and frame rails. Factory AFTER Bolts O.E. Trailer Hitch ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 18 (rear bumper, passenger) to passenger side frame. DO NOT TIGHTEN. Factory Bolts Kit Bracket (Rear Bumper, Passenger) Frame c. Repeat above step for driver side. ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 19 Mark fuel filler tubes with cut and alignment lines. Fuel Filler Alignment Lines Cut Lines b. Cut fuel filler on cut lines. Fuel Filler Alignment Lines c. Deburr edges of cut tubes. ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 20 Install factory bolt onto frame and fuel filler. Fuel Filler Bolt Frame Adjust fuel filler and/or kit extensions (hose) to body. Fuel Filler Body Extensions TIGHTEN all hardware. k. Install fuel filler cap. Fuel Filler Body Fuel Filler ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 21 Install fuel line bracket to kit bracket (3” Z- shaped) with kit bolt (1/4” x 1”), two kit washers (1/4” SAE) and kit nut (1/4” Nylock). ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603 Driver Side Looking Back Driver Side...
  • Page 22 Lay carpet down to cover driver and passenger body mount access plates. d. Install storage tray and pop-up clips to vehicle. Storage Tray Pop-up Clips Rear Seat e. Install jack into storage tray. Storage Tray Jack Rear Seat ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 23 Access Cover b. Lay carpet down to cover driver and passenger body mount access covers. c. Install driver and passenger kick panels. Kick Panel d. Install dead pedal. Kick Panel Dead Pedal ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 24 Welding should be performed by a certified welder. Grind off any excess welds. g. Install plastic cap to end of shift lever. h. Install shifter lever. Shift Lever Plastic Cap Install shift and center consoles. Shifter Console Center Console ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 25 Cut off tabs on upper radiator mounts. Upper Radiator Mount Radiator Core Support b. Install four kit brackets (3” radiator) to radiator mounts with four factory bolts. DO NOT TIGHTEN. Radiator Kit Bracket (3” Radiator) Factory Bolt ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 26 (push) and four kit wash- ers (1/4” SAE). Radiator Cover Kit Clip (Push), Kit Washer (1/4” SAE) h. Adjust radiator and ensure fan does not contact fan shroud. TIGHTEN all hardware. ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 27 (zip). Bracket Kit Tie (Zip) Wire Harness 6. Install wire harness clip to firewall bracket. Clip Bracket Wire Harness 7. Install heater hoses on clip and backside of engine. Heater Hoses Clip ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 28 (5/8” OD x 5” L) Kit Clamps (#10 Hose) h. Install power steering reservoir, lines, clamps, and three bolts onto vehicle. Power Steering Reservoir Bolts Adjust hoses and tighten all hardware. ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603 Power Steering Lines Clamps...
  • Page 29 Cut short trans cooler line as shown. Radiator Cut Hose Here b. Insert kit extension (tube 7/16”) into cut trans- mission cooler line with two kit clamps (#6 hose). TIGHTEN two kit clamps (#6 hose). ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 30 Bumper) Kit Bolts (3/8” x 1”), Kit Washers (3/8” USS), Kit Nuts (3/8” Nylock) Front Bumper c. Install front bumper cover to vehicle with six fac- tory screws. Front Bumper Fascia Screws ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 31 1. Install airbag fuse and fuse block cover. Airbag Fuse Fuse Location May Vary Fuse Cover Engine Compartment 1. Connect both battery cables. Connect positive cable first, then negative cable. Positive Cable (Red) Negative Cable (Black) ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 32 Consult an experienced local off road shop to find what wheel and tire combinations work best with your vehicle. Accessories The following accessories are also available: Kit# 6337 - Gap Guards ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603...
  • Page 33: Kit Parts List

    NOTE Depending on the vehicle configuration (automatic or manual transmission, 2WD or 4WD, cab length, bed length, etc.), some parts may not be used. Performance Automotive Group ‘05-‘09 Tacoma (W/O Hitch) - 3” Kit 5603 Rev. 03, Copyright 06/06 www.p-a-g.net...