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10-47405 Instructions

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1. SUSPENSION 8 19 08 2005 08 TOYOTA TACOMA 4WD amp PRE RUNNER 4 SUSPENSION SYSTEM P N 10 47405 INSTALLATION INSTRUCTIONS NOTE Each lift kit and options to lift kits are packaged separately Therefore installation procedures are covered in separate instructions Familiarize yourself with each specific set of instructions before beginning www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 1 16 47405 Part List Item Box 1 of 5 20 57405 1 20 57405 2 Box 2 of 5 20 57405 5D 20 57405 6P Box 3 of 5 20 57405 14 20 51099 22 20 71097 15 11148 20 830918 20 71110 13 30034 Z 13 10038 Z 13 20069 Z 13 10514 13 21703 Z Box 4 of 5 20 57405 3 20 57405 4 20 57405 8 20 57405 9 20 57405 10 20 830658 13 90126 20 68188 13 30330 13 10423 www racecardynamics com Description Front Crossmember Rear Crossmember Spindle Drvr Spindle Pass Lateral Compression Strut Bracket Rear Strut Mount Hardware Pack Bushings Bushing Red Large Sleeve 75 OD x 095w x 2 75 Hardware Pack Compression Strut Washer 1 2 SAE Flat Nut 1 2 13 Nylon Insert Lock Hex Bolt 1 2 13 x 4 Nut 1 2 13 Top Lock Gr C Hex Bolt 1 2 13 x 3 Diff Mount Drvr Diff Mount Pass Skidplate Bumpstop Drop Drvr Bumpstop Drop Pass Rear Tapered Block 4 U Bolt 9 16 18x2 1 2 x10 Hardware Pack U Bolt Washer 9 16 Flat Nut 9 16 18 Fine H
2. Sleeve 3 4 x 095 x 2 25 Lg Hex Bolt 1 2 13 x 3 1 2 Hardware Pack Bumpstop Drop Washer 10mm Flat Washer 10mm Split Lock Nut 10mm x 1 25 Top Lock Hex Bolt 10mm x 1 25 x 20mm Washer 3 8 Flat Hardened Washer 3 8 Split Lock Hex Bolt 3 8 16 x 1 1 4 Nut 3 4 16 Top Lock Hardware Pack Sway Drop Sway Bar Relocating Pack Allen Bolt 10mm 1 25 x 20mm Hex Bolt 10mm 1 25 x 20mm Washer 10mm Flat RCD Suspension 619 588 4723 Page 3 16 47405 NONAA NNAWWW NB AR MNNNABANMNDND NNMAND 13 13 13 13 13 13 13 12 12 12 21 21 21 14 14 11 11 14 20 20 20 20 20 20 20 20 16 16 16 16 info racecardynamics com 20 71123 13 10155 Z 13 21157 Z 13 30187 Z 20 57405 16 20 71136 20 57405 17 13 30187 Z 13 21157 Z 13 10155 Z 20 71149 20 57405 12 13 30187 Z 13 21157 Z 13 10155 Z 20 69891 13 23367 Z 13 30629 13 30577 Z 20 833479 Box 5 of 5 Hardware Pack Park Brake Nut 5 16 18 Nylon Insert Lock Hex Bolt 5 16 18 x 3 4 Washer 5 16 SAE Flat Park Brake Cable Bracket Hardware Pack Rear Brakeline Rear Brakeline Bracket Washer 5 16 SAE Flat Hex Bolt 5 16 18 x 3 4 Nut 5 16 18 Nylon Insert Lock Hardware Pack Front Brakeline Front Brakeline Drop Washer 5 16 SAE Flat Hex Bolt 5 16 18 x 3 4 Nut 5 16 18 Nylon Insert Lock Hardware Pack Carrier Bearing Spacers Hex B
3. 57405 8 using 3 8 hard 3 8 x 1 1 4 Bolt ware provided 10mm Washer 13 22938 Z 13 30642 Z Illustration 21 E 3 8 Washer 2 13 30408 Z 48 Install Red Bushings 15 11148 and Sleeves 20 830918 into both ends of the Lateral Compression Struts Bumpstop Bracket 20 57405 9 3 8 Lock Washer 13 30151 Z 3 8 Toplock Nut 20 57405 14 Attach Lateral 13 10553 Z Compression Strut to Strut l im teplodk Nut Mount bracket located on rear 13 10865 Z crossmember using hardware provided A kaa Illustration 22 10mm 20mm Bolt 13 23744 Z y Do not tighten at this Nee N time Bumpstop www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 15 16 47405 Illustration 21 Front Crossmember Rear Crossmember 20 57405 1 20 57405 2 p _ 3 8 Washer 13 30408 Z 3 8 Lock Washer 13 30151 Z Skid Plate 3 8 x 1 1 4 Bolt em Illustration 22 1 2 Toplock Nut Ld Ed 13 10514 Z Rear Crossmember 20 57405 2 Strut Mount Bracket 1 2 Washer 20 51099 22 13 30034 Z 1 2 x4 Bolt 13 20069 Z 1 2 Nylock Nut 1 2 x 3 Bolt 13 10038 Z 13 21703 Z Bushing Red 15 11148 Compression Strut 20 57405 14 20 830918 www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 16 16 47405 Note that the struts have a slight offset to them This offset should go to the inside 49 Attach
4. RCD Strut Mount Bracket 20 51099 22 to opposite end of the compression strut Rotate the compression strut assembly upward until bracket contacts the bottom of the transmission crossmember Use the bracket as a guide to mark and then center punch the mounting hole locations Drill 1 2 hole at each of the marked locations Install using the 1 2 hardware provided Torque the nuts to 65 ft Ibs Illustration 22 50 Install the wheels and tires and lower the vehicle to the ground Torque lug nuts to 83 ft Ibs 51 When the vehicle is at ride height torque the lower control arm to front and rear crossmember cam bolts to 100 ft Ibs www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 17 16 47405 Rear Installation Instructions 1 Raise the vehicle If working without a shop hoist support vehicle with suitable safety stands To do this put vehicle in gear block front wheels both in front and behind tires then disengage emergency brake Place floor jack underneath rear axle and raise vehicle Place safety jack stands under frame to support vehicle and lower vehicle onto safety stands Remove rear tire wheel assemblies Illustration 23 2 Disconnect parking brake ca bles at the leaf spring hanger and also at the leaf spring Illustration 23 Disconnect Here 3 Disconnect bracket where brake hoses attach to rear ane LES i gt gt 4 Loosen ABS bracket at frame and rotat
5. These tools can be purchased from your Toyota Dealer Ball Joint Tool 09628 62011 Spring Compressor 09727 30021 www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 6 16 47405 Front Installation Instructions 1 Raise the vehicle If working without a shop hoist support vehicle with suitable safety jack stands Put vehicle in gear set emergency brake and block rear wheels both in front and behind tires Loosen front wheel lug nuts Place floor jack under the lower control arm s front crossmember and raise vehicle Place safety jack stands under frame rails behind front wheel wells and lower the frame onto the stands Once securely on jack stands remove floor jack Remove front wheels Illustration 1 2 Remove the skid plate and skid plate brackets Illustration 1 3 Beginning with the drivers side unclip the ABS sensor line and disconnect at the knuckle Remove the screw attach ing the brakeline to the knuckle Illustration 2 4 Remove the bolts holding the Caliper Anchor Bracket to the Steering Knuckle Illustration 2 Pull the Bracket and Caliper assembly away from the Brake Rotor and hang out of the way with a length of wire careful not to damage the brake lines DO NOT let the Caliper hang from the brake line 5 Remove the Brake Rotor from the Hub and set aside Illustration 2 6 Remove Axle Hub Grease Cap Illustration 2 7 Remove the axle to wheel hub nut Illus
6. 0 57405 17 using original bolt at axle and Spring Hanger 5 16 hardware provided at brake line Original Bolt 12 Attach RCD Park Brake Cable Re location Brackets 20 57405 16 at Park Brake Bracket front leaf spring hangers using 20 57405 16 original hardware Attach Park Brake Cables to Brackets US 5 16 x 3 4 Bolt ing 5 16 hardware provided 13 21157 Z Illustration 25 5 16 Washer R 5 16 Nut 13 30187 Z a 7 www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 19 16 47405 13 Install rear tire wheel assemblies and lower the vehicle Torque lug nuts to 83 ft lbs 14 vehicle is equipped with a 2 piece driveshaft Illustration 26 using a Carrier bearing in the center support drive shaft remove two bolts clamping the car rier bearing to the crossmember Illustration 26 Place 1 OD x 1 2 x 1 LG round spacers RCD 20 833479 between car rier bearing mount and crossmember and re mount carrier bearing using 10mm x 60mm Hex Bolts with 10mm Flat and Lock Washers www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 20 16 47405 Some Final Notes After installation is complete double check that all nuts and bolts are tight Refer to the torque specifications chart on the last page If new tires are installed that are more then 10 taller than original tires the speedometer must be recalibrated for the Anti Lock B
7. 4 ft Ibs Anti lock Brake Sensor Bolt 73 in Ibs www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 22 16 47405
8. Nut 1 2 x 3 1 2 Bolt 13 22249 Z 13 10514 Z AD Rear Crossmember Front Crossmember___ __ SS 2 ts qe 20 57405 2 20 57405 1 30 Align marks made on the front drive shaft U joint and differential yoke and reconnect the front drive shaft to the differen tial Illustration 15 31 Connect the differential vent hose and electrical connector Existing Hardware Lower Control Arm www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 12 16 47405 32 Install lower control arms into the front and rear crossmembers using existing hardware previously removed Do not tighten at this time Illustration 15 33 Using an external coil compressor compress the coil on the stock shock The spring is under EXTREME PRESSURE make sure you use a proper spring compressor and fully understand how to oper ate it See page 6 for Toyota s ex ternal coil compressor part num ber Once tension is removed off end plate loosen and remove nut on end of shock shaft Slowly release tension on coil compressor until the coil is completely free Illustration 16 Illustration 16 34 Make sure coil seat is securely resting on snap ring of new front Bil stein Shock 50 BE5 E122 T0 provided and place original coil onto the new shock The end of the coil should sit in a pocket shaped especially for it on the new coil seat Use the coil compressor and compress the coil enough to put the existing top sea
9. aft rearward to disengage Illustration 7 17 Disconnect the electrical connector and vent hose from differential assembly Illustration 8 18 Support front differential assembly with a floorjack Remove the two bolts 6696 at bottom of front crossmember and E pe LA the socket head nut at the rear Slowly ANY remove the differential assembly from vehicle and lower it to the floor Illustration 8 19 Temporarily install Rear Crossmember RCD 20 57405 2 for reference when marking the frame for the differential cutout Mark the frame just inside the lower control arm pocket weld on the drivers side and in line with the top plate of the RCD Crossmember Also mark the three 13 32 holes to be drilled at the rear edge of the Crossmember Illustration 9 20 Remove the Crossmember to cut the frame 21 Using a suitable cutting tool cut out the section of the frame as marked Rear Crossmember Drill Here 20 57405 2 www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 10 16 47405 22 Drill the three 13 32 holes as previously marked Paint all bare metal surfaces Illustration 10 23 Remove the two front mounting brackets from the Differential Illustration 10 24 Insert the Bushings 15 11148 and sleeves 20 832725 into the Diff Brackets RCD 20 57405 3 20 57405 4 Illustration 11 25 Install the two brackets RCD 20 57405 3 20 57405 4 using the original
10. e so that the wires point down 5 Use a floor jack to raise the rear axle just enough to relieve tension from the shock absorbers and remove them 6 Remove rear U bolts attaching rear axle to driver side leaf spring Care fully lower rear axle CAUTION Do not allow axle to hang by any hoses or cables 7 Insert new riser Block RCD 20 830658 on axle pad Make sure the pin in the block indexes into the hole of the axle housing spring pad The short end of the block goes toward the front of the vehicle Carefully www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 18 16 47405 raise rear axle until block makes contact with leaf spring Make sure center bolt is aligned with the hole in the block Illustration 24 Illustration 24 8 Re mount axle to spring using the new RCD U eee bolts 13 90126 Wash ers 13 30330 and High r Nuts 13 10423 with ex isting spring plates Da Torque U bolts nuts to 85 100 ft Ibs Rear Block 20 830658 gt 9 Repeat steps 3 through 10 on passenger side 9 16 Flat Washer 10 Install new longer Shock 13 30330 Absorbers BE5 B110 T5 Using the existing hardware attach the shock to the lower axle mount Attach shock to the upper frame mount and torque the nuts to specifications listed on page 21 9 16 High Nut 13 10423 11 Reform brakeline so that hoses point Illustration 25 up Attach to axle with 2
11. g to the areas they will be used Placing the hardware with brackets before you begin will save installation time This kit is supplied as a bolt on assembly Do not weld anything to the components and do not weld the components to the vehicle All components in this kit come with a protective coating Do not plate i e chrome cadmium zinc etc or otherwise alter the finish in any way This could decrease the structural strength of the components Secure and properly block vehicle prior to beginning installation Always wear safety glasses when using power tools Foot Pound torque readings are listed on the Torque Specifications chart at the end of the instructions unless specifically stated in an instruction DO NOT USE AN IMPACT WRENCH TO TIGHTEN ANY OF THE BOLTs www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 5 16 47405 PLEASE NOTE WARNING DO NOT USE WHEEL SPACERS Front end realignment is necessary Speedometer recalibration is necessary if larger tires 10 more than stock diameter are installed System is designed to accommodate up to a 33 x 12 50 or metric equivalent tire on a wheel size of 17 x 8 with a maximum of 4 5 backspacing System is designed to work with factory VSC systems VSC systems may be more sensitive than stock under certain driving conditions Special tools are required for safe removal and installation of the ball joints and tie rods
12. hardware Torque to 120 ft Ibs Illustration 11 Illustration 11 Sleeve 20 832725 Bushing Red A oja 1511148 Diff Mount Pass lt 20 57405 4 Existing mee 26 Raise Differential assembly into posi Illustration 12 tion 3 4 x 4 1 4 Bolt 13 21859 Diff Mount Drvr 20 57405 3 27 Install Front Crossmember RCD 20 57405 1 into existing front lower con trol arm mounting pockets using 3 4 3 4 Teplock Nut hardware and Centering Washers pro 2 13 10644 Z vided Do not tighten at 111 this time Centering Washer Ss Illustration 12 EL a E 20 57405 1 www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 11 16 47405 28 Install Rear Crossmember RCD 20 Illustration 13 57405 2 into existing rear lower control arm pockets using 9 16 Nut Strip Centering Washer 20 57405 13 20 57405 11 hardware and Centering Washer 9 16 Nut provided Do not tighten at this 13 19397 Z time Illustration 13 A fe 9 16 x 5 Bolt 29 Insert the two 1 2 bolts attaching als the Differential to the Front lt lt EF Washer Crossmember and the original 13 30408 Z nut at the rear of the Differen ici 4 tial Torque the 1 2 bolts to 90 13 30151 Z Ra ft Ibs and the socket head nut 20 57405 2 to 64 ft Ibs Illustration 14 13 21534 Z Illustration 14 Differential with Brackets 1 2 Washer 13 30382 Z 55 55 1 2
13. igh s N NNA A gt 2 a 2 00 RCD Suspension 619 588 4723 Page 2 16 47405 Illus 12 14 9 13 14 17 22 22 22 22 22 22 22 22 22 11 11 21 20 24 24 24 24 info racecardynamics com 20 68305 13 20447 Z 15 10966 15 11395 15 11447 15 11460 20 71019 20 57405 13 13 30408 Z 13 30151 Z 13 21534 Z 20 57405 11 13 23731 Z 13 10397 Z 20 71032 20 832283 13 21859 Z 13 10644 Z 20 71045 13 30408 Z 13 30151 Z 13 22938 Z 20 71058 13 30382 Z 13 10514 Z 15 11148 20 832725 13 22249 Z 20 71071 13 30642 13 30577 Z 13 10865 Z 13 23744 Z 13 30408 Z 13 30151 Z 13 22938 Z 13 10553 2 20 71084 20 57405 7 13 23757 13 23744 13 30642 www racecardynamics com Hardware Pack Universal Hex Bolt 10 x 1 2 Unslot Clamp 3 8 x 3 8 x 203 Plastic Tie 6 Plastic Tie 8 Plastic Tie 11 Hardware Pack Rear Crossmember Nut Strip Rear Crossmember Washer 3 8 Flat Hardened Washer 3 8 Split Lock Hex Bolt 3 8 16 x 1 Washer Centering Tab Hex Bolt 9 16 12 x 5 Nut 9 16 12 Top Lock Hardware Pack Front Crossmember Washer Centering Tab Hex Bolt 3 4 10 x 4 1 4 Nut 3 4 10 Top Lock Hardware Pack Skid Plate Washer 3 8 Flat Hardened Washer 3 8 Split Lock Hex Bolt 3 8 16 x 1 1 4 Hardware Pack Diff Mount Washer 1 2 Flat Hardened Nut 1 2 13 Top Lock Bushing Red Large
14. olt 10mm x 60mm Washer 10mm Flat Washer 10mm Lock Spacer Carrier Bearing F4 BE5 E122 T0 Front Shock F4 BE5 B110 T5 Rear Shock www racecardynamics com Page 4 16 47405 RCD Suspension 619 588 4723 NANN NNAN 25 25 25 25 19 19 19 19 info racecardynamics com INTRODUCTION Installation by a professional mechanic is recommended Use of the appropriate tools a Toyota service manual and a shop hoist can greatly reduce installation time Prior to installation carefully inspect the vehicle s steering and drive train systems paying close attention to the tie rod ends rack amp pinion unit ball joints and wheel bearing preload Also check steering to frame and suspension to frame attachment points for stress cracks The overall vehicle must be in excellent working condition repair or replace worn parts Read instructions carefully and study illustrations before attempting installation RCD Suspension is not responsible for damage failure or injury resulting from improper installation or parts substitution of this kit Check parts and hardware against the parts list to assure that your kit is complete Re port any shortages to RCD Suspension at 1 619 588 4723 The parts and hard ware supplied are of high grade material and must not be replaced by inferior parts or failure may result Do not begin installation if parts are missing Separate parts accordin
15. rake System to function properly Contact an Authorized Toyota dealer for details on recalibration With vehicle on the floor cycle the steering lock to lock and inspect steering Suspension and driveline systems for proper operation tight ness and adequate clearance Recheck brake hose fitting for leaks Be sure all hoses are long enough Have headlights readjusted to proper setting Realign front end to factory specifications Be sure vehicle is at desired ride height prior to realignment www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 21 16 47405 Torque Specifications General Torque Specifications 5 16 20 ft Ibs 9 ft Ibs 35 ft Ibs 23 ft Ibs 7 16 60 ft Ibs 45 ft Ibs Existing Hardware Torque Specifications Wheel Hub to Knuckle Bolts 59 ft Ibs Front Differential Mounting Socket Head Nut 64 ft Ibs Front Driveshaft Front Differential Pinion Flange Bolts 65 ft Ibs Lower Control Arm Mounting Bolts 100 ft Ibs Sway Bar Link Nuts 52 ft Ibs Lower Ball Joint Bracket to Knuckle Bolts 118 ft Ibs Axle Nut 173 ft Ibs Upper Ball Joint Nut 81 ft Ibs Tie Rod Nut 67 ft Ibs Caliper Mount to Steering Knuckle Bolts 91 ft Ibs Front Shock Upper Mount Nuts 47 ft Ibs Front Shock Lower Mount Bolt 61 ft Ibs Wheel Lug Nuts 83 ft Ibs Rear Shock Upper Mount Nuts 15 ft Ibs Rear Shock Lower Mount Bolt to Nut T
16. t for the coil and new hardware on to shock shaft Use the 12mm x 1 25 pitch Nyloc Nut provided with the new shock to secure all top hardware Once tightened slowly re move coil compressor 35 Position new shock assembly back into original location Make sure once the top three bolts are in position that the bottom eyelet is oriented so that it will fit into the lower control arm and the bolt will fit Install ex isting nuts onto top studs on shock mount and torque to 47 ft lbs Raise lower control arm into position and install existing lower shock bolt Torque to 101 ft Ibs 36 Remove the splash shield hub and bearing assembly from existing front spindles Reinstall the splash shield hub and bearing assembly to new Front Spindles 20 57405 5D Drvr and 20 57405 6P Pass Illustration 17 www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 13 16 47405 NOTE Make sure that hub and bearing assemblies are reinstalled on the same side they were removed from Apply Loctite com pound to existing hardware Torque bolts to 59 ft Ibs Illustration 17 37 Connect driver side front spin dle assembly to the upper and lower control arm ball joints Torque upper ball joint nut to 81 ft lbs Torque lower ball joint bracket bolts to 118 ft Ibs Drvr Knuckle 1 20 57405 5D Shield O Ring Dust Seal 38 Rotate tie rod so that stud is pointing down and attach the tie rod to
17. the front spindle Beare ny Torque nut to 67 ft Ibs Illustration 18 39 Torque axle hub to 173 ft Ibs Sway Bar Drop Bracket 20 57405 7 40 Install Anti sway bar to frame us a ing Sway Bar Drops RCD 20 ki 1323757 a rO a 57405 7 and hardware pro vided Illustration 18 pr 41 Attach Sway Bar End Links to i knuckles using original hardware Bolt Torque to 52 ft Ibs 13 23744 10mm Washer 13 30642 Z 42 Disconnect Front brakeline mounting bracket at frame and install Front Brakeline Drop RCD 20 57405 12 to frame using original hardware Re bend brakeline to line up with hole in Drop Bracket Attach with hardware provided Illustration 19 www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 14 16 47405 43 Install brake rotor Reattach the front Illustration 19 caliper with existing hardware Torque caliper mounting bracket hex bolts to F 5 16 Washer spindle to 91 ft Ibs re kai 44 Repeat steps 32 thru 42 on opposite side 5 16 Nut 13 10155 Z 5 16 x 3 4 Bolt 13 21157 Z 45 Unscrew all bumpstops from stock location Install in hole on both New RCD Bumpstop Extensions 20 Brakeline Bracket 57405 9 20 57405 10 Use 10mm Top 20 57405 12 Lock Nut and washer provided Illustration 20 46 Install RCD Bumpstop Brackets to frame using 3 8 hardware provided Illustration 20 Illustration 20 47 nstall RCD Skid Plate 20
18. tration 2 www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 7 16 47405 Illustration 2 Brake Caliper Axle Nut Steering Knuckle Dust Seal Dust Cap O Ring Dust Shiel Bearing Assembl www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 8 16 47405 8 Disconnect and remove Sway Bar with Links from vehicle Illustration 3 9 Remove the nut from the steering Tie Rod Separate the Tie Rod from the Steering Knuckle Illustration 2 Illustration 4 10 Remove the nut from the Upper Ball Joint Separate the Upper Ball Joint from the Steer ing Knuckle Illustration 2 11 Remove the two bolts attaching the Knuckle to Lower Ball Joint Bracket Illustration 4 Illustration 5 12 Remove Steering Knuckle and set aside e VANI Wek 13 Disconnect Front Strut from Lower Control M Arm at bottom and from Frame at top and re NASA move Illustration 5 14 Remove the lower control arm pivot bolts and A remove lower control arm TT KARA DIH EFR 15 Repeat steps 3 thru 14 on opposite side www racecardynamics com RCD Suspension 619 588 4723 info racecardynamics com Page 9 16 47405 16 Locate the front drive shaft U joint to Illustration 7 differential yoke Place an index mark for installation reference on both the drive shaft U joint and differential yoke Remove the hardware from the yoke and slide the sh

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