Technical Service BULLETIN November 10, 2005 Title: Models: 05 Tacoma SU002-05 SUSPENSION TSB REVISION NOTICE: November 11, 2005: Production Change Production Change Effective VINs have been updated. Warranty OFP has been updated, and a footnote has been added. Previous versions of this TSB should be discarded. Introduction Some customers may experience a squeak and/or slap type noise coming from the rear suspension when traveling over bumps or rough road surfaces. The squeak type noise may be caused by a rubbing condition between the rear suspension leaves. The slap type noise may be caused by contact between the overload spring and the first leaf of the spring assembly. Perform the repair procedures outlined in this TSB to address these concerns. Applicable Vehicles 2005 model year Tacoma vehicles produced BEFORE the Production Change Effective VINs shown below. Production Change MODEL Tacoma PRODUCTION CHANGE EFFECTIVE VIN 5TE**#2N#5Z144240 3TM**#2N#5M002881 Parts PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY 04005 36104 Same Spring Silencer Pad Kit 1 Required Tools & Material TOOLS & MATERIAL Wheel Bearing Grease QUANTITY As Needed Warranty OP CODE DESCRIPTION TIME OFP* T1 T2 SU6001 Spring Silencer Pad Kit 1.0 482#0 ####0 91 14 * For OFP, use the Rear Spring Assembly part number for the vehicle that is being repaired. Applicable Warranty**: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle s in-service date. ** Warranty application is limited to correction of a problem based upon a customer s specific complaint. Toyota Supports ASE Certification Page 1 of 5
NOTE: Perform the following procedures on both the RH and LH sides of the vehicle. Rear Silencer Pad Replacement: 1. Place vehicle on lift. 2. Using a pry bar, separate the two main leaves, allowing access to the BLACK spring silencer pad installed on the lower leaf of the spring pack. CAUTION: Be careful NOT to scratch the spring surface with the pry bar. 3. Use the pry bar as a wedge to hold the leaf springs apart. 4. Use a pick, punch, or screwdriver to push upward on the spring silencer pad from the underside of the spring pack through the access hole. Page 2 of 5
5. Push the spring silencer pad up high enough to be able to remove it from the spring assembly. Applying light pressure to the back of the silencer pad will be enough to pop the pad out of position. 6. Remove and discard the spring silencer pad by sliding the pad out between the leaves of the spring assembly. 7. Apply a thin even layer of standard wheel bearing grease to the contact area of the new WHITE silencer pad. 8. Using a screwdriver or pick, center the silencer pad in the hole of the leaf spring. 9. Install the spring silencer pad in the leaf spring pack carefully. It might be necessary to use another pry bar to seat the silencer pad into the mounting hole on the leaf spring assembly. 10. Wipe off any excess grease from the leaf spring assembly. 11. Perform the Front Silencer Pad Replacement procedure in this TSB. Page 3 of 5
Front Silencer Pad Replacement: 1. Using a pry bar, separate the main two leaves, allowing access to the spring silencer pad installed on the lower leaf of the spring pack. CAUTION: Be careful NOT to scratch the spring surface with the pry bar. 2. Use the pry bar as a wedge to hold the leaf springs apart when removing the black spring silencer pad. 3. Using a pick, punch, or screwdriver, push upward on the spring silencer pad from the underside of the spring pack through the access hole. 4. Remove and discard the original BLACK silencer pad from the leaf spring pack. 5. Apply a thin even layer of standard wheel bearing grease to the contact area of the new WHITE silencer pad. 6. Install the spring silencer pad in the leaf spring pack carefully. It might be necessary to use another pry bar to seat the silencer pad into the mounting hole on the leaf spring assembly. 7. Use a screwdriver or pick to center the silencer pad in the hole of the leaf spring. 8. Wipe off any excess grease from the leaf spring assembly. 9. Perform the Overload Leaf Cushion Installation procedure in this TSB. Page 4 of 5
Overload Leaf Cushion Installation: 1. Clean the top of the overload leaf removing any dirt or debris. Clean the surface with brake cleaner or equivalent. 2. Peel off the paper backing and install the overload leaf cushion on top of the overload leaf, in front of and behind the rear axle. 3. Test drive vehicle to confirm repair. Page 5 of 5