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Performance 5613 Installation Instructions Manual

Toyota 2005 tacoma; toyota 2006 tacoma; 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, WITH
O.E. TRAILER HITCH)
3" BODY LIFT
INSTALLATION INSTRUCTIONS
2005-2006
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.
WARNING
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# 5613
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.
WARNING
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.
WARNING
Always wear eye protection when operating power
tools.
WARNING
Before you install this kit, block the vehicle tires to pre-
vent the vehicle from rolling.
WARNING
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
'05 - '06 Tacoma (W/ O.E. Hitch) - 3" Kit 5613

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Summary of Contents for Performance 5613

  • 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 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 2: Before Starting Installation

    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 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • 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 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 4 4. 4 cyl. models: Loosen two engine intake clamps and remove engine intake hose. Clamps Air Hose 5. 4 cyl. models: Remove bolt from passenger side AC line bracket. AC Line Bolt AC Line Bracket ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 5 Tubes Bracket Battery 9. Remove heater hoses from clip on backside of engine. Heater Hoses Clip 10. Remove wire harness clip from firewall and bracket. Clip Bracket Wire Harness ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 6 Remove four bolts and radiator from core sup- port. Allow radiator to hang on core support by tabs. Core Support Radiator Bolts NOTE Lower the radiator onto the frame prior to the lifting pro- cedures. ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 7 Console Center Console b. Remove shift lever from vehicle. Shift Lever Plastic Cap 2. Front interior trim panels a. Remove driver and passenger door sill plates. Door Sill Plate ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 8 Rear Seat c. Remove pop-up clips and storage tray from vehicle. Storage Tray Pop-up Clips Rear Seat d. Pull carpet up to expose driver and passenger body mount access plates. ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 9 1. Remove all clips and two driver side engine guards from driver side wheel well. Driver Side Front Engine Guard Rear Engine Guard 2. Repeat above step for passenger side. ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 10 5. Remove two nuts and fuel line brackets from driver side body. Fuel Lines Bracket Front Fuel Lines Rear 6. Remove bolt and brake line bracket from driver side frame. Frame Brake Line Bracket Bolt ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 11 Remove two license plate lights from rear bumper. Rear Bumper License Plate Light c. Remove four bolts and rear bumper from O.E. trailer hitch brackets. Frame Trailer Hitch Brackets Bolts ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 12 (under the body seam). Slowly lift cab just enough to install a kit block on top of factory upper bushing. ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 13 (M12-1.75 x 200mm) h. Install factory rear captive washer and kit bolt (M12-1.25 x 210mm) on cab mount. DO NOT TIGHTEN. Rear Cab Mount Kit Bolt (M12-1.25 x 210mm) ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 14 Loosen, but DO NOT REMOVE, bed mounting bolts on driver side. Bolts NOTE The number of bed mounting bolts may vary with the length of the bed. ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613 Loosen Bolts At These Mounts...
  • Page 15 (M12-1.25 x 160mm) and factory captive wash- ers. DO NOT TIGHTEN. Install Kit Bolts At These Mounts Front Bed Mount Kit Block (2” Dia.) Mid Bed Mount Rear Bed Mount Kit Bolts (M12-1.25 x 160mm) ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 16 Class III receiver type hitch. a. Mark and cut driver and passenger O.E. trailer hitch brackets along white lines as shown below. Mark & Cut Here Mark & Cut Here ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613 BEFORE BEFORE AFTER...
  • Page 17 (9/16” Stover) g. Install kit bracket (rear bumper, middle) onto rear bumper with two factory bolts and nuts. DO NOT TIGHTEN. Factory Bolts Bumper Kit Bracket (Rear Bumper, Middle) ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 18 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 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 19 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 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 20 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 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613 Driver Side Looking Back...
  • Page 21 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 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 22 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 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 23 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 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 24 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 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 25 (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 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 26 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 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 27 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 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613 Power Steering Lines Clamps...
  • Page 28 Apply a small amount of kit Loctite® to six fac- tory studs and install kit brackets (front bumper) to frame with six factory nuts. Kit Bracket (Front Bumper) Factory Studs & Nuts ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 29 Install two pop-up clips, two bolts and grill to core support. Screws Pop-up Clips Grill g. Install wiring harnesses to fog lights, if equipped. Wiring Harness Fog Light h. Adjust bumper and tighten all hardware. ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 30 Failure to provide the customer with this information can result in damage to the vehicle and severe personal injury. ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 31 Accessories The following accessories are also available: Kit # 6337: Gap Guards ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613...
  • Page 32: Kit Parts List

    Plate (radiator block off, driver) Plate (radiator block off, passenger) Plate (rear bumper) Tie (zip) Washer (1/2" SAE) Washer (1/4" SAE) Washer (3/8" USS) Washer (9/16" SAE) Performance Automotive Group ‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613 Copyright 03/06 www.p-a-g.net...