Workshop Manual: TF Series

WORKSHOP MANUAL
TF SERIES
CAB
SECTION 10
CAB 10-1
SECTION 10
CAB
TABLE OF CONTENTS
PAGE
Windshield..........................................................................................................................10- 2
Rear Window Assembly ....................................................................................................10- 7
Front Door Assembly ........................................................................................................10- 10
Rear Door Assembly (Crew Cab)......................................................................................10- 20
Instrument Panel................................................................................................................10- 28
Floor Console.....................................................................................................................10- 34
Console Box (Without Floor Console) .............................................................................10- 38
Headlining ..........................................................................................................................10- 39
Interior Trim Panels ........................................................................................................... 10- 44
Fuel Filler Lid Opener Lever/Cable...................................................................................10- 55
Quarter Glass (Extend Cab) ..............................................................................................10- 70
Font Seat ............................................................................................................................10- 71
Rear Seat (Crew Cab) ........................................................................................................10- 74
Jump Seat (Extend Cab) ...................................................................................................10- 75
Front Seat Belt ...................................................................................................................10- 76
Rear Seat Belt (Crew Cab) ................................................................................................10- 80
Rear Seat Belt (Extend Cab) .............................................................................................10- 84
Front Wheel Extension......................................................................................................10- 87
Rear Wheel Extension .......................................................................................................10- 88
Tail Gate Assembly............................................................................................................10- 89
10-2 CAB
WINDSHIELD
REMOVAL
RTW4A0LF000901
Removal Steps
1. Interior trim panels (Front side)
/Headlining/Instrument panel assembly
2. Wiper arm assembly
▲ 3. Room mirror
4. Side moulding
5. Vent cowl cover
6. Windshield stopper
7. Upper moulding
▲ 8. Windshield glass
9. Engine hood rear seal
CAB 10-3
Important Operations - Removal

3. Room Mirror
Remove the screw and pull the room mirror to upper side.
8. Windshield Glass
Remove the windshield glass, carefully following the steps
listed below:
1) Use a knife to cut through part of the adhesive caulking
material.
2) Secure one end of a piece of steel piano wire (0.02 inches
in diameter) to a piece of wood that can serve as a handle.
3) Use a pair of needle nose pliers to insert the other end of
the piano wire through the adhesive caulking material at the
edge of the windshield glass.
4) Secure the other end of the piano wire to another piece of
wood.
5) With the aid of an assistant, carefully move the piano wire

with a sawing motion to cut through the adhesive caulking
material around the entire circumference of the windshield
glass.
6) Lift the windshield from the body.
7) Clean any remaining adhesive caulking material from the
area of the body which holds the windshield.
8) Use a soft rag and unleaded gasoline to wipe off any
adhesive remaining on the windshield glass.
10-4 CAB
INSTALLATION
RTW4A0LF001201
Installation Steps
▲ 1. Engine hood rear seal
2. Upper moulding
▲ 3. Windshield glass
4. Windshield stopper
5. Vent cowl cover
6. Side moulding
7. Room mirror
▲ 8. Wiper arm assembly
9. Interior trim panels (Front side)
/Headlining/Instrument panel assembly
CAB 10-5
Important Operations - Installation

1. Engine Hood Rear Seal
Install the engine hood rear seal as shown in the illustration.
1 : Seal
2 : Clip
3 : Rear (windshield glass side)
4 : Front
3. Windshield Glass
1) Clean the windshield glass bonding surface.
adhesive remaining on the body.
3) Mount the body window glass as shown in the illustration.
Attach spacers at five locations.
· Always use new spacer.
4) Install the windshield upper molding.
· Peel off the tear-away paper from the windshield upper
RTW3A0SH000201
molding, and start applying it with one end of the glass
and cut away the surplus at the other end of the glass
for length adjustment.
· Always use new upper molding.
5) Temporary install the windshield support.
6) Apply primer 1 Sunstar #435-98 or equivalent to the body

side bonding surface. The primer should extend at least 25
mm (1 in).
Apply primer Sunstar #435-40 or equivalent to the
windshield glass side bonding surface.
The primer should extend 16.5 mm (0.6 in) and 25 mm (1.0
in) from end of the glass.
10-6 CAB
7) Apply the window glass sealing adhesive 2 .

If you are using an air gun, air pressure should be
maintained at 147 - 294 kpa.
After drying primer completely, apply a sealing adhesive
(Sunstar #557 or equivalent) along the edge of the glass so
that the sealing adhesive has a 20 mm (0.79 in) junction at
middle of the vase of the glass.
Note :
Open time (1 min. or more) should be set after application
of the primer.
Bonding shall be done within 5 minutes after the sealing
adhesive has been applied.
8) Adjust the setting of the windshield glass with suction discs.

Set the windshield with sealing adhesive applied to entire
circumference in the body panel. Specifically, adjust
windshield support with the upper molding making contact
with the body panel, press the glass, and tighten the
windshield support.
9) Use unleaded gasoline and a soft cloth to wipe away any

excess adhesive.
Cure the bonding at a temperature of 68° - 86°F (20° -
30°C) for twenty-four hours.
Check that the windshield does not leak water.
8. Wiper Arm Assembly

· Set the wiper arm/blade so that the tips of both blades
are positioned the specified value of A and B from the
upper edge of the cowl cover as shown in the figure.
A 40 mm (1.57 in)
B 52 mm (2.05 in)
· Tighten the wiper arm assembly fixing nuts to the
specified torque.
Torque N×m (kgf×m/lb×ft)
31 (3.1/23)
CAB 10-7
REAR WINDOW ASSEMBLY

REMOVE AND INSTALLATION
Removal Steps Installation Steps

1. Interior trim panels/Headlining ▲ 3. Rear window
2. Rear defogger connector (W/Rear 2. Rear defogger connector (W/Rear
defogger) defogger)
▲ 3. Rear window 1. Interior trim panels/Headlining
10-8 CAB
Important Operation - Removal

3. Rear Window Glass
Remove the glass, carefully following the steps listed below :
1) Use a knife to cut through part of the adhesive caulking
material.
2) Secure one end of a piece of steel piano wire (0.02 inches
in diameter) to a piece of wood that can serve as a handle.
3) Use a pair of needle nose pliers to insert the other end of
the piano wire through the adhesive caulking material at the
edge of the rear window glass.
4) Secure the other end of the piano wire to another piece of
wood.
5) With the aid of an assistant, carefully move the piano wire

with a sawing motion to cut through the adhesive caulking
material around the entire circumference of the rear window
glass.
6) Lift the rear window glass from the body.
7) Clean any remaining adhesive caulking material from the
area of the body which holds the rear window glass.
adhesive remaining on the rear window glass.
Important Operation - Installation

3. Rear Window Glass
1) Clean the rear window glass bonding surface.
adhesive remaining on the body.
3) Install the fastener tape to body panel flange.
4) Apply primer 1 sunster #435-40 or equivalent to the rear

window glass side bonding surface.
The primer should extend 23 mm (0.9 in.) form end of the
glass.
CAB 10-9
5) Apply the rear window glass seling adhesive 2 .

If you are using an air gun, air pressure should be
maintained at 147 – 294 kpa.
After drying primer completely, apply a sealing adhesive
(Sunstar #557 or equivalent) along the edge of the glass so
that the sealing adhesive has a 20 mm (0.79 in.) junction at
left corner of the base of the glass.
Note:
Open time (1 min. or more) should be set after application
of the primer.
Bonding shall be done within 5 minutes after the sealing
adhesive has been applied.
6) Insert the glass supports into the panel and then push the
glass against the panel to affix it in place.
Wipe away any adhesive that oozes out around the edges.
7) Check that the rear window glass does not leak water.
10-10 CAB
FRONT DOOR ASSEMBLY
REMOVAL AND INSTALLATION
This illustration is based on RHD model

▲ 1. Door harness 5. Door assembly
▲ 2. Checker arm screw 4. Upper hinge bolt
▲ 3. Lower hinge bolt ▲ 3. Lower hinge bolt
4. Upper hinge bolt ▲ 2. Check arm screw
5. Door assembly 1. Door harness

1. Door Harness
Remove the harness bracket and disconnect the door
harness connectors.
CAB 10-11
2. Check Arm Screw
3. Lower Hinge Bolt

Position a wood block under the door for protection and
support the door assembly with hands at removal or
installation.
Important Operations – Installation

3. Lower Hinge Bolt; Hinge to Door
34 (3.5/25)
2. Check Arm Screw; Check Arm to Body

24 (2.4/17)
10-12 CAB
DISASSEMBLY

RTW4A0LF000701
Disassembly Steps
▲ 1. Switch bezel/Window regulator handle ▲14. Window regulator/Power window
▲ 2. Power window switch regulator
▲ 3. Bezel ▲ 15. Glass run
▲ 4. Door mirror cover ▲ 16. Glass run rear channel / Glass ran rear
▲ 5. Door trim panel channel with Door lock control or Anti
▲ 6. Tweeter (Required Option) theft (EC)
▲ 7. Door mirror assembly ▲ 17. Door lock assembly/Door lock assembly
▲ 8. Outer waste seal with super lock
▲ 9. Bracket ▲ 18. Outside handle protector (EUROPE)
▲10. Speaker assembly ▲ 19. Outside handle
▲11. Waterproof sheet ▲ 20. Door lock cylinder protector (EUROPE)
▲12. Inside lever ▲ 21. Door lock cylinder / Door lock cylinder
▲13. Window glass with door lock switch (EC)
22. Door harness assembly
23. Anti rattler
CAB 10-13
Important Operations
1. Switch Bezel/Window Regulator Handle
· Remove the 2 screws and disconnect the connectors.
· To remove the regulator handle, remove the clip at the

root of the handle by using wire.
2. Power Window Switch

· Remove the 3 screws.
3. Bezel
· Remove the screw.
4. Door Mirror Cover

· Pull out the upper clip, and then take out the cover
upward.
5. Door Trim Panel
· Pull out the trim panel at the 8 clip positions (Power
window type).
10-14 CAB
· Remove the 2 screws and pull out the trim panel at the 8
clip positions (Window regulator handle type).
6. Tweeter (Required option)

· Disconnect the tweeter harness connector and remove
the 3 screws.
RTW3A0SH000701
7. Door Mirror Assembly

· Remove 3 fixing bolts and then remove the connector.
8. Outer Waste Seal
9. Bracket
10.Speaker Assembly
· Remove the fixing screw and then remove the
connector.
11.Waterproof Sheet
· Take care not to damage the sheet when peeling it off.
12.Inside Lever
· Disconnect the door lock cables.
CAB 10-15
13.Window Glass
· Remove 2 bolts through the access hole and pull out the
window glass upward.
14.Window Regulator/Power Window Regulator
· Remove the 4 fixing bolts and the 2 fixing nuts.
· Disconnect the power window motor connector.
15.Glass Run
· Pull it out from the door frame of the channel.
16.Glass Run Rear Channel
· Remove the bolt.
· Bolt is removed after removing door lock cylinder switch
harness. (Expect EC)
17.Door Lock Assembly

· Disconnect the lock cable from the anti rattler.
· Remove the 3 fixing screws and the bolt.
· Disconnect the linkage at the outside handle and the
lock cylinder.
· Disconnect the harness connector.
18.Outside Handle Protector (EUROPE)

· Remove the fixing bolt from the outside handle.
19.Outside Handle
20.Door Lock Cylinder Protector (EUROPE)
· Remove the fixing bolt from the outside handle.
21.Door Lock Cylinder
· Remove the 2 fixing bolts from the outside handle.
10-16 CAB
REASSEMBLY
RTW4A0LF000801
Reassembly Steps
1. Anti rattler ▲ 11. Window glass
2. Door harness assembly 12. Inside lever
▲ 3. Door lock cylinder / Door lock cylinder 13. Waterproof sheet
with door lock switch (EC) 14. Speaker assembly
▲ 4. Door lock cylinder protector (EUROPE) 15. Bracket
▲ 5. Outside handle 16. Outer waste seal
▲ 6. Outside handle protector (EUROPE) 17. Door mirror assembly
7. Door lock assembly / Door lock 18. Tweeter (Required option)
assembly with super lock 19. Door trim panel
8. Glass run rear channel / Glass ran rear 20. Door mirror cover
channel with Door lock control or Anti 21. Bezel
theft (EC) 22. Power window switch
9. Glass run ▲ 23. Switch bezel / Window regulator handle
10. Window regulator / Power window
regulator
CAB 10-17
3. Door Lock Cylinder
· Tighten the door lock cylinder fixing bolts to the specified
torque.
Torque N×m (kgf×m/lb×in)
9 (0.9/78)
4. Door Lock Cylinder Protector (EUROPE)

· Tighten the door lock cylinder protector fixing bolt to the
specified torque.
9 (0.9/78)
5. Outside Handle
· Tighten the outside handle fixing bolts to the specified
torque.
9 (0.9/78)
6. Outside Handle Protector (EUROPE)

· Tighten the outside handle protector fixing bolt to the
specified torque.
9 (0.9/78)
11.Window Glass
· Insert the window glass into position by tilting it as
necessary, then set it against the channel of the window
regulator.
· Attach the window glass to the window regulator with the

2 bolts.
10-18 CAB
23.Window Regulator Handle

· Install the regulator handle as illustrated when closing
the window glass.
CAB 10-19
ADJUSTMENT (FRONT)
Door Hinge
Door alignment can be obtained by moving door hinges.
Prior to adjustment, remove the fender and set the door
temporarily.
Loosen hinge to door bolts when adjusting steps between the
door and body.
Loosen hinge to body bolts to adjust the clearance between the
door and body.
Door Striker
Loosen the striker screws and adjust the position of the striker
by holding a piece of wood against the striker and tapping it
with a hammer.
To obtain correct adjustment, move the position of the striker
vertically so that the lower face of the dovetail becomes parallel
to the striker.
10-20 CAB
REAR DOOR ASSEMBLY (CREW CAB)

▲ 1. Door harness 5. Door assembly
▲ 2. Checker arm screw 4. Upper hinge bolt
▲ 3. Lower hinge bolt ▲ 3. Lower hinge bolt
4. Upper hinge bolt ▲ 2. Check arm screw
5. Door assembly 1. Door harness

1. Door Harness
Remove the center pillar lower trim cover and disconnect
the door harness connector.
2. Check Arm Screw

CAB 10-21
3. Lower Hinge Bolt

Position a wood block under the door for protection and
support the door assembly with hands at removal or
installation.

3. Lower Hinge Bolt; Hinge to Door
34 (3.5/25)
2. Check Arm Screw; Check Arm to Body

24 (2.4/17)
10-22 CAB
DISASSEMBLY
RTW3A0LF000601
Disassembly Steps
▲ 1. Switch bezel/Window regulator handle ▲ 10. Window regulator/Power window
▲ 2. Power window switch regulator
▲ 3. Bezel ▲ 11. Glass run rear channel
▲ 4. Door trim panel ▲ 12. Door lock assembly
▲ 5. Bracket ▲ 13. Glass run
▲ 6. Speaker assembly ▲ 14. Window glass
▲ 7. Waterproof sheet ▲ 15. Outside handle
▲ 8. Inside lever 16. Door harness assembly
▲ 9. Outer waste seal 17. Anti rattler
CAB 10-23
1. Switch Bezel/Window Regulator Handle
· Remove the 2 screws and disconnect the connector.
RTW3A0SH000401
· To remove the regulator handle, remove the clip at the

root of the handle by using wire.
2. Power Window Switch

· Pry the 4 clip positions.
3. Bezel
· Remove the screw.
4. Door Trim Panel
· Pull out the trim panel at the 7 clip positions (Power
window type).
RTQ3A0SH000501
· Remove the 2 screws and pull out the trim panel at the 7
clip positions (Window regulator handle type).
10-24 CAB
5. Bracket
6. Speaker assembly
· Remove the fixing bolt and then remove the connector.
7. Waterproof Sheet
· Take care not to damage the sheet when peeling it off.
8. Inside Lever
· Disconnect the door lock cables.
9. Outer Waste Seal
10.Window Regulator/Power Window Regulator
· Remove the 2 bolts fixing the window glass through the
access hole.
· Move the window glass upward and hold it with adhesive
tape.
· Remove the 5 bolts fixing the window regulator.
· Disconnect the power window motor connector.
11.Glass Run Rear Channel
· Remove the bolt.
12.Door Lock Assembly
· Disconnect the lock cable from the anti rattler.
· Remove the 3 fixing screws and the bolt.
· Disconnect the linkage and harness connector.
13.Glass Run
· Remove the adhesive tape and move the window glass
downward.
· Pull it out from the door frame of the channel.
14.Window Glass
· Pull out the window glass upward.
15.Outside Handle
· Remove the 2 fixing bolts.
CAB 10-25
REASSEMBLY
RTW3A0LF000701
Reassembly Steps
1. Anti rattler 9. Outer waste seal
2. Door harness assembly 10. Inside lever
▲ 3. Outside handle 11. Waterproof sheet
4. Window glass 12. Speaker assembly
5. Glass run 13. Bracket
6. Door lock assembly 14. Door trim panel
7. Glass run rear channel 15. Bezel
8. Window regulator/Power window 16. Power window switch
regulator ▲ 17. Switch bezel/Window regulator handle
10-26 CAB
3. Outside Handle
· Tighten the outside handle fixing bolts to the specified
torque.
9 (0.9/78)
17.Window Regulator Handle

· Install the regulator handle as illustrated when closing
the window glass.
CAB 10-27
ADJUSTMENT (REAR)
Door Hinge
Door alignment can be obtained by moving door hinges.
Prior to adjustment, set the door temporarily.
Loosen hinge to door bolts when adjusting steps between the
door and body.
Loosen hinge to body bolts to adjust the clearance between the
door and body.
Door Striker
Loosen the striker screws and adjust the position of the striker
by holding a piece of wood against the striker and tapping it
with a hammer.
To obtain correct adjustment, move the position of the striker
vertically so that the lower face of the dovetail becomes parallel
to the striker.
10-28 CAB
INSTRUMENT PANEL
REMOVAL

RTW4A0LF001001
Disassembly Steps ▲ 13. Ashtray case

▲ 1. Front console assembly ▲ 14. Center cluster assembly
▲ 2. Glove box ▲ 15. Control lever assembly
▲ 3. Instrument panel driver lower cover 16. Storage box assembly
assembly ▲ 17. Ashtray bracket
▲ 4. Driver knee bolster assembly 18. Meter assembly
▲ 5. Driver air bag 19. Passenger lower bracket
▲ 6. Steering wheel/ steering cowl 20. Glove box cover
▲ 7. Meter cluster assembly ▲ 21. Passenger air bag (if so equipped)
8. Dash side trim cover ▲ 22. Side ventilation grille
9. Front pillar trim cover ▲ 23. Vent duct assembly/Defroster nozzle
10. Front cover assembly
11. Side cover 24. Instrument harness assembly
▲ 12. Instrument panel & Cross beam ▲ 25. Instrument panel
assembly ▲ 26. Cross beam
CAB 10-29
1. Front Console Assembly
· Refer to Floor Consol in this section.
2. Glove Box
· Remove 2 fixing screws and pulling the handle.
3. Instrument Panel Driver Lower Cover Assembly

1) Remove the engine hood opener 2 fixing screws.
2) Remove the lower cover one fixing screw.
3) Pull out the cover (Stick type parking brake only).
4) Pull out the lower cover assembly.
4. Driver Knee Bolster Assembly

· Remove 4 fixing bolts.
Caution:
For precaution on installation or removal of SRS-air bag
system, refer to section 9 “Supplemental Restraint System
(SRS) - AIR BAG”
5. Driver Air Bag
6. Steering Wheel/Steering Cowl
· Refer to Section 3B “STEERING COLUMN” for steering
lock assembly removal steps.
7. Meter Cluster Assembly

· Pull out the 4 clip positions.
10-30 CAB
12.Instrument Panel & Cross Beam Assembly

1) Remove the two bolts fixing the steering column to the
cross beam and the two bolts fixing the brake pedal
bracket to the cross beam.
2) Remove the two bolts fixing the parking brake bracket to

the cross beam (Stick type parking brake only).
3) Disconnect the control cables at the blower unit and

heater unit.
Remove the front & side cover from the instrument
panel.
4) Remove the fasteners fixing the instrument panel &
cross beam assembly to the body panel.
5) Disconnect the instrument harness connectors.

CAB 10-31
13.Ashtray Case
· Pull out the ashtray case.
14.Center Cluster Assembly
1) Pull out the cluster at the 6 clip positions.
2) Disconnect the cigarette lighter, accessory socket,
hazard switch and clock connectors.
15.Control Lever Assembly
· Remove the 2 fixing screws.
17.Ashtray Bracket
· Remove the 3 fixing screws and illumination connector.
Caution:
For precautions on installation or removal of SRS-air bag
system, refer to section 9 "Supplemental Restraint System
(SRS) - AIR BAG".
21.Passenger Air Bag
· Remove 2 fixing bolts, 2 fixing nuts and connector.
22.Side Ventilation Grille.
· Pull out the grilles and disconnect switch connector
(Driver’s side).
23.Vent Duct Assembly/Defroster Nozzle Assembly
· Refer to section 1 “HVAC” for defroster nozzle and
ventilation duct removal steps.
25.Instrument Panel
· Remove the clip and 6 fixing bolts.
26.Cross Beam
10-32 CAB
INSTALLATION

RTW4A0LF001101
Installation Steps
1. Cross beam 14. Ashtray case
2. Instrument panel ▲ 15. Instrument panel & Cross beam
3. Instrument harness assembly assembly
4. Vent duct assembly/Defroster nozzle 16. Side cover
assembly 17. Front cover
5. Side ventilation grille 18. Front pillar trim cover
6. Passenger air bag 19. Dash side trim cover
7. Glove box cover 20. Meter cluster assembly
8. Passenger lower bracket ▲ 21. Steering wheel/Steering cowl
9. Meter assembly 22. Driver air bag
10. Ashtray bracket 23. Driver knee bolster assembly
11. Storage box assembly 24. Instrument panel driver lower cover
12. Control lever assembly assembly
13. Center cluster assembly 25. Glove box
26. Front console assembly
CAB 10-33
15.Instrument Panel & Crass Beam Assembly
1) Tighten the 4 bolts fixing the cross beam and body panel
to the specified torque.
19 (1.9/14)
2) A Bolt: Steering Column to Cross Beam
20 (2.0/14)
B Bolt: Pedal Bracket to Cross Beam
15 (1.5/11)
3) C Bolt: Parking Brake Bracket to Cross Beam

15 (1.5/11)
21.Steering Wheel/Steering Cowl

· Tighten the steering wheel fixing nut to the specified
truque.
35 (3.6/26)
10-34 CAB
FLOOR CONSOLE
745R300001
A/T Model
▲ 1. Rear floor console (Bucket seat model 3. A/T switch
only) 2. Front floor console
▲ 2. Front floor console 1. Rear floor console (Bucket seat model
3. A/T switch only)
CAB 10-35

1. Rear Floor Console (Bucket Seat Model Only)
1) Open the rear console lid and remove 2 screws.
2) Pull out the front part of rear console at the 2 clip
positions.
2. Front Floor Console
1) Remove the 2 screws.
2) Pull out the rear part of front console at the 2 clip
positions and disconnect the switch connecter.
3) Remove the front console by pull out it rear ward.
10-36 CAB
745r300002
M/T Model
▲ 1. Rear floor console (Bucket seat model 3. Front floor console
only) 2. Shift knob
2. Shift knob 1. Rear floor console (Bucket seat model
▲ 3. Front floor console only)
CAB 10-37

1. Rear Floor Console (Bucket Seat Model Only)
1) Open the rear console lid and remove 2 screws.
2) Pull out the front part of rear console at the 2 clip
positions.
3. Front Floor Console
1) Remove the 2 screws.
2) Pull out the rear part of front console at the 2 clip
positions.
3) Remove the front console by pull out it rear ward.
10-38 CAB
CONSOLE BOX (WITHOUT FLOOR CONSOLE)
RTW4A0MF000201
M/T Model
1. Screw 2. Console box
2. Console box 1. Screw
CAB 10-39
HEADLINING
EXTEND CAB Model

▲ 1. Interior trim panels 8. Headlining
▲ 2. Sunvisor/Sunvisor holder 7. Dome light
▲ 3. Spot light 6. Coat hook
▲ 4. Assist grip 5. Hole cover
5. Hole cover 4. Assist grip
▲ 6. Coat hook 3. Spot light
▲ 7. Dome light 2. Sunvisor/Sunvisor holder
▲ 8. Headlining 1. Interior trim panels
10-40 CAB
RTW3A0LF001101
REGULAR CAB Model

CAB 10-41

RTW3A0LF001001
CREW CAB Model

▲ 3. Spot light 6. Coat hook
▲ 6. Coat hook 3. Spot light
10-42 CAB

1. Interior Trim Panels
· Refer to Interior Trim Panels in this section.
2. Sunvisor/Sunvisor Holder
1) Remove the 2 screws fixing the sunvisor.
2) Remove the screw fixing the sunvisor holder.
3. Spot Light
· Pull out the spot light and disconnect the connector.
4. Assist Grip
· Remove the 2 fixing screw.
6. Coat Hook
· Open the cover and remove the fixing screw.
7. Dome Light
1) Remove the dome light lens and the fixing screws.
2) Disconnect the dome light connector.
CAB 10-43
8. Headlining
· Pull out the headlining with the retainer from roof rear
header panel as direction of shown in the illustration.
Note :
Remove steps (2-7) can be removed from the headlining in
any order.
10-44 CAB
INTERIOR TRIM PANELS
RTW3A0MF001301
EXTEND CAB Model

1. Sill plate 11. Body side rear upper trim cover
2. Dash side trim cover ▲ 10. Torque side seat belt
▲ 3. Front pillar trim cover 9. Door finisher
▲ 4. Rear upper cushion 8. Body side rear lower trim cover
5. Jack cover 7. Rear speaker grille/Rear speaker
▲ 6. Rear end trim cover ▲ 6. Rear end trim cover
▲ 7. Rear speaker grille/Rear speaker 5. Jack cover
▲ 8. Body side rear lower trim cover 4. Rear upper cushion
9. Door finisher 3. Front pillar trim assembly
▲10. Tongue side seat belt 2. Dash side trim cover
▲11. Body side rear upper trim cover 1. Sill plate
CAB 10-45

3. Front Pillar Trim Cover
· Turn up the finisher and pry the trim cover clips free
from the body panel.
Then remove the trim cover by pulling upward at the
lower part of it.
4. Rear Upper Cushion

· Slide the upper cushion upward to remove it.
6. Rear End Trim Cover
· Pry the trim cover clips free from the body panel, and
slide the trim cover upward to remove it.
7. Rear Speaker Grille/Rear Speaker

1) Remove the rear speaker grille (1).
2) Remove the 3 screws fixing the rear speaker (2) and
disconnect the connector (3).
8. Body Side Rear Lower Trim Cover

· Pry the trim cover clips free from the body panel.
10-46 CAB
10. Tongue Side Seat Belt

1) Pull out the adjuster knob.
2) Open the through ring anchor cover and remove the
seat belt upper anchor bolt.
RTW3A0SH000301
11. Body Side Rear Upper Trim Cover

CAB 10-47

· Tighten the seat belt upper anchor bolt to the specified
torque.
40 (4.1/30)

· Insert the hooks on the back upper portion of trim cover
to the body panel.
10-48 CAB
RTW40MF000301
REGULAR CAB Model

1. Sill plate 8. Body side rear upper trim cover
2. Dash side trim cover ▲ 7. Tongue side seat belt
▲ 3. Body side rear lower trim cover ▲ 6. Rear end trim cover
4. Door finisher 5. Front pillar trim cover
▲ 5. Front pillar trim cover 4. Door finisher
▲ 6. Rear end trim cover 3. Body side rear lower trim cover
▲ 7. Tongue side seat belt 2. Dash side trim cover
▲ 8. Body side rear upper trim cover 1. Sill plate
CAB 10-49


Then remove the trim cover by pulling upward at the
lower part of it.


RTW3A0SH000301
10-50 CAB
8. Body Side Rear Upper Trim Cover


torque.
40 (4.1/30)

to the body panel.
CAB 10-51
RTW4A0MF000401
CREW CAB Model

▲ 1. Front sill plate/Rear sill plate 13. Body side rear upper trim cover
2. Dash side trim cover ▲ 12. Rear tongue side seat belt
▲ 3. Front pillar trim cover 11. Center pillar upper trim cover
▲ 4. Center pillar lower trim cover ▲10. Front tongue side seat belt
5. Front door finisher 9 Rear door finisher
6. Cover 8. Body side rear lower trim cover
▲ 7. Rear end trim cover ▲ 7. Rear end trim cover
▲ 8. Body side rear lower trim cover 6. Cover
9. Rear door finisher 5. Front door finisher
▲10. Front tongue side seat belt 4. Center pillar lower trim cover
▲11. Center pillar upper trim cover 3. Front pillar trim cover
12. Rear tongue side seat belt 2. Dash side trim cover
▲ 13. Body side rear upper trim cover 1. Front sill plate/Rear sill plate
10-52 CAB

1. Front Sill Plate/Rear Sill Plate
· Pull out the 4 clip positions (Front).
· Pull out the 2 clip positions (Rear).

Then remove the trim cover by pulling upward a the
lower part of it.
4. Center Pillar Lower Trim Cover

· Pry the trim cover lips free from the body panel.


10.Front Tongue Side Seat Belt

CAB 10-53

RTW3A0SH000301
11.Center Pillar Upper Trim Cover

13.Body Side Rear Upper Trim Cover


12. Rear Tongue Side Seat Belt
torque.
40 (4.1/30)
10-54 CAB
10. Front Tongue Side Seat Belt

torque.
40 (4.1/30)

to the body panel.
CAB 10-55
FUEL FILLER LID OPENER LEVER/CABLE

REMOVAL (REGULAR CAB RHD MODEL)
686R300015
Removal Steps
▲ 1. Front sill plate
▲ 2. Fuel filler lid opener cover
▲ 3. Fuel filler lid opener lever
4. Rear wheel housing extension panel
▲ 5. Fuel filler lid cable assembly
10-56 CAB

REMOVAL (EXTEND CAB RHD MODEL)
686R300016
Removal Steps
CAB 10-57

REMOVAL (REGULAR CAB LHD MODEL)
RTW4A0LF000101
Removal Steps
10-58 CAB

REMOVAL (EXTEND CAB LHD MODEL)
RTW4A0LF000201
Removal Steps
CAB 10-59

1. Front Sill Plate
2. Fuel Filler Lid Opener Cover

3. Fuel Filler Lid Opener Lever

· Remove the 2 opener fixing bolts and disconnect the
cable.
5. Fuel Filler Lid Cable Assembly

· Remove some fixing clips, turn the cable holder on the
side of recess in 90° counterclockwise and remove it
from the recess. Pull out the grommet to frontward of
vehicle and remove the cable assembly.
10-60 CAB

REMOVAL (CREW CAB RHD MODEL)
686R300010
Removal Steps
▲ 2. Rear sill plate
3. Center pillar lower trim cover
CAB 10-61

REMOVAL (CREW CAB LHD MODEL)
RTW4A0LF000301
Removal Steps
▲ 2. Rear sill plate
3. Center pillar lower trim cover
10-62 CAB

1. Front Sill Plate
· Pull out 4 clip positions.
2. Rear Sill Plate
· Pull out 2 clip positions.
4. Fuel Filler Lid Opener Cover

5. Fuel Filler Lid Opener Lever

· Remove the 2 opener fixing bolts and disconnect the
cable.

· Remove some fixing clips, turn the cable holder on the
side of recess in 90° counterclockwise and remove it
from the recess. Pull out the grommet to frontward of
vehicle and remove the cable assembly.
CAB 10-63
INSTALLATION (REGULAR CAB RHD MODEL)
686R300017
Installation Steps
3. Fuel filler lid opener lever
4. Fuel filler lid opener cover
5. Front sill plate
10-64 CAB
INSTALLATION (EXTEND CAB RHD MODEL)
686R300019
Installation Steps
5. Front sill plate
CAB 10-65
INSTALLATION (CREW CAB RHD MODEL)
686R300013
Installation Steps
▲ 1. Fuel filler lid cable assembly 5. Center pillar lower trim cover
2. Rear wheel housing extension panel 6. Rear sill plate
3. Fuel filler lid opener lever 7. Front sill plate
10-66 CAB
INSTALLATION (REGULAR CAB LHD MODEL)
RTW4A0LF000401
Installation Steps
5. Front sill plate
CAB 10-67
INSTALLATION (EXTEND CAB LHD MODEL)
RTW4A0LF000501
Installation Steps
5. Front sill plate
10-68 CAB
INSTALLATION (CREW CAB LHD MODEL)
RTW4A0LF000601
Installation Steps
▲ 1. Fuel filler lid cable assembly 5. Center pillar lower trim cover
2. Rear wheel housing extension panel 6. Rear sill plate
3. Fuel filler lid opener lever 7. Front sill plate
CAB 10-69

· Install the cable holder of cable assembly to the recess
and push the grommet in to the back panel. Fix the clips
to the pointed places.
Note:
To install, follow the removal steps in the reverse order,
noting the following points.
· Do not make extreme curve on the cable.
· Install the cable from inside of the cab.
10-70 CAB
QUARTER GLASS (EXTEND CAB)

RTW4A0MF000101

▲ 1. Body side rear trim covers ▲ 4. Weather strip
2. Hinge/Faster 3. Quarter glass
3. Quarter glass 2. Hinge/Faster
4. Weather strip 1. Body side rear trim covers

1. Body Side Rear Trim Covers
Important Operation – Installation

4. Weather Strip
· Install the weather strip by aligning to corners with white
mark to the upper coners on the body panel.
CAB 10-71
FRONT SEAT
RTW3A0MF000301

▲ 1. Front cover 6. Seat adjuster
2. Rear cover ▲ 5. Side seat belt buckle/Pretensioner seat
3. Bolt belt/Center seat belt
▲ 4. Seat assembly 4. Seat assembly
▲ 5. Side seat belt buckle/Pretensioner seat ▲ 3. Bolt
belt/Center seat belt 2. Rear cover
6. Seat adjuster 1. Front cover
10-72 CAB

1. Front Cover
· While pushing the cover downward, pull it.
4. Seat Assembly
· Disconnect the seat belt warning harness connector
(Driver’s side only).
5. Side Seat Belt Buckle/Pretensioner Seat Belt/Center
Seat Belt
· Remove the seat belt fixing screw and the warning
harness connector clip (Bucket seat model).
· Remove the pretensioner seat belt fixing screw and the

warning harness connector (With pretensioner seat belt
model).
RTW4A0SH000101-X
· Remove the seat belt fixing screws and the warning

harness connector clip (Bench seat model).
24.jpg

5. Buckle Side Seat Belt/Pretensioner Seat Belt/Center
Seat Belt
· Tighten the seat belt fixing screws to the specified
torque.
40 (4.1 / 30)
CAB 10-73
3. Bolt: Seat Assembly to Floor Panel

The fixing procedure of a bolt
(1) Front inboard
(2) Front outboard
(3) Rear inboard
(4) Rear inboard
40 (4.1 / 30)
10-74 CAB
REAR SEAT (CREW CAB)
RTW3A0SF000101

▲ 1. Nut 2. Rear seat assembly
2. Rear seat assembly ▲ 1. Nut

1. Nut
· Pull the strap to release the seat back lock and fold
down the seat back.

1. Nut

40 (4.1 / 30)
CAB 10-75
JUMP SEAT (EXTEND CAB)
RTW3A0MF001201

1. Cover 4. Storage box
2. Bolt 3. Jump seat assembly
3. Jump seat assembly ▲ 2. Bolt
4. Storage box 1. Cover

2. Bolt
Bolt Torque N×m (kg×m/lb×ft)

40 (4.1 / 30)
10-76 CAB
FRONT SEAT BELT

(TONGUE SIDE SEAT BELT)

1. Body side rear lower trim cover ▲ 7. Adjustable shoulder anchor fixing bolts
2. Lower anchor bolt 6. Body side rear upper trim cover
▲ 3. Knob ▲ 5. Retractor fixing bolt
▲ 4. Upper anchor bolt ▲ 4. Upper anchor bolt
5. Retractor fixing bolt 3. Knob
6. Body side rear upper trim cover ▲ 2. Lower anchor bolt
7. Adjustable shoulder anchor fixing bolts 1. Body side rear lower trim cover
CAB 10-77

3. Knob
· Pull out the knob.
4. Upper anchor bolt
· Open the through ring anchor cover and remove the
RTW3A0SH000301

7. Adjustable shoulder anchor fixing bolts
Bolt torque N×m (kgf×m/lb×ft)
40 (4.1 / 30)
5. Retractor fixing bolt
40 (4.1 / 30)
40 (4.1 / 30)
2. Lower anchor bolt
40 (4.1 / 30)
10-78 CAB

(SIDE SEAT BELT BUCKLE/PRETENSIONER SEAT BELT/
CENTER SEAT BELT)
RTW3A0MF000401

▲ 1. Front seat assembly ▲ 2. Side seat belt buckle/Pretensioner seat
▲ 2. Side seat belt buckle/Pretensioner seat belt/Center seat belt
belt/Center seat belt ▲ 1. Front seat assembly
CAB 10-79

1. Front Seat Assembly
· Refer to Front Seat in this section.
2. Side Seat Belt Buckle/Pretensioner Seat Belt/Center

Seat Belt
· Remove the seat belt fixing screw and the warning
harness connector clip (Bucket seat model).
· Remove the pretensioner seat belt fixing screw and the

warning harness connector (With pretensioner seat belt
model).
RTW4A0SH000101-X
· Remove the seat belt fixing screws and the warning

harness connector clip (Bench seat model).
24.jpg

2. Side Seat Belt Buckle/Pretensioner Seat Belt /Center
Seat Belt
· Tighten the seat belt fixing screws to the specified
torque.
40 (4.1 / 30)
1. Front Seat Assembly
· Tighten the seat assembly fixing bolts to the specified
torque.
40 (4.1 / 30)
10-80 CAB
REAR SEAT BELT (CREW CAB)


1. Body side rear lower trim cover ▲ 7. Adjustable shoulder anchor fixing bolts
2. Lower anchor bolt 6. Body side rear upper trim cover
▲ 3. Knob ▲ 5. Retractor fixing bolt
▲ 4. Upper anchor bolt ▲ 4. Upper anchor bolt
5. Retractor fixing bolt 3. Knob
6. Body side rear upper trim cover ▲ 2. Lower anchor bolt
7. Adjustable shoulder anchor fixing bolts 1. Body side rear lower trim cover
CAB 10-81

3. Knob
· Pull out the knob.
RTW3A0SH000301

7. Adjustable shoulder anchor fixing bolts
40 (4.1 / 30)
40 (4.1 / 30)
40 (4.1 / 30)
40 (4.1 / 30)
10-82 CAB

(REAR CENTER SEAT BELT/REAR SEAT BELT BACKLE)
RTW3A0LF000901

1. Nut ▲ 6. Rear center seat belt
2. Rear seat belt buckle ▲ 5. Bolt
▲ 3. Cover 4. Rear end trim cover
▲ 4. Rear end trim cover 3. Cover
5. Bolt 2. Rear seat belt buckle
6. Rear center seat belt ▲ 1. Nut
CAB 10-83

3. Cover
· Pry the lower portion of the cover and remove it.
RTW3A0SH000601

6. Rear center seat belt
· Install the seat belt webbing through the through ring on
the back panel as shown in the illustration.
RTW3A0SH001601
5. Bolt: Rear Center Seat Belt to Floor Panel

40 (4.1 / 30)
1. Nut: Rear Seat Assembly/Rear Seat Belt Buckle to Floor

Panel
40 (4.1 / 30)
10-84 CAB
REAR SEAT BELT (EXTEND CAB)

RTW3A0MF000701

▲ 1. Body side rear lower trim cover ▲ 4. Retractor fixing bolt
2. Lower anchor bolt ▲ 3. Upper anchor bolt
▲ 3. Upper anchor bolt ▲ 2. Lower anchor bolt
4. Retractor fixing bolt 1. Body side rear lower trim cover
CAB 10-85

1. Body side rear lower trim cover
· Refer to Interior Trim Panels in this section..
seat belt upper anchor bolt
RTW3A0SH000301

40 (4.1 / 30)
40 (4.1 / 30)
40 (4.1 / 30)
10-86 CAB

(REAR SEAT BELT BACKLE)
RTW3A0SF000201

▲ 1. Cover 3. Rear seat belt buckle
2. Bolt ▲ 2. Bolt
3. Rear seat belt buckle 1. Cover

1. Cover
· Refer to Jump Seat (Extend Cab) in this section.
2. Bolt: Jump Seat Assembly/Rear Seat Belt Buckle to
Floor Panel
40 (4.1 / 30)
CAB 10-87
FRONT WHEEL EXTENTION


1. Screw 2. Front wheel extension
▲ 2. Front wheel extension 1. Screw

2. Front Wheel Extension
· pull out the 5 clip positions
10-88 CAB
REAR WHEEL EXTENTION

RTW4A0MF000501

1. Screw 2. Rear wheel extension
▲ 2. Rear wheel extension 1. Screw

2. Rear Wheel Extension
· Pull out the 6 clip positions (Extend cab)
· Pull out the 5 clip positions (Crew cab)
CAB 10-89
TAIL GATE ASSEMBLY

CENTER PULL HANDLE MODEL

1. Hole cover plate ▲ 7. Tail gate lock striker
▲ 2. Outside handle assembly ▲ 6. Tail gate hinge
3. Tail gate lock assembly ▲ 5. Tail gate
4. Tail gate link 4. Tail gate link
▲ 5. Tail gate ▲ 3. Tail gate lock assembly
6. Tail gate hinge ▲ 2. Outside handle assembly
7. Tail gate lock striker 1. Hole cover plate
10-90 CAB

2. Outside Handle Assembly
· Disconnect the lock link and remove the 2 fixing bolts.
5. Tail Gate
1) Removing the tailgate assembly may require two people.
2) Remove the tailgate hinge fixing bolts.

7. Tail Gate Lock Striker
· Tighten the lock striker fixing bolts to the specified
torque.
Torque N×m(kgf×m/lb×ft)
15 (1.5 / 11)
6. Tail Gate Hinge

· Tighten the hinge fixing bolts to the specified torque.
C: Bolt
40 (4.1 / 30)
5. Tail Gate
1) A: Bolts
Torque N×m(kgf×m/lb×in)
13 (1.3 / 113)
2) B: Bolt
25 (2.5 / 18)
3) Check the tailgate and rear body.
a. Clearance: 5.0 mm (0.20 in.)
b. Height (Step): Flush
c. Height (Step): Flush
3. Tail Gate Lock Assembly
· Tighten the lock assembly fixing bolts to the specified
torque.
15 (1.5 / 11)
2. Outside Handle Assembly
· Tighten the outside handle assembly fixing bolts to the
specified torque and if remove the key cylinder (if
equipped) tighten it to the specified torque.
9 (0.9 / 78)
No. TFCAB-WE-0431

Workshop Manual: TF Series

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WORKSHOP MANUAL

Important Operations - Removal

5) With the aid of an assistant, carefully move the piano wire

Important Operations - Installation

6) Apply primer 1 Sunstar #435-98 or equivalent to the body

7) Apply the window glass sealing adhesive 2 .

8) Adjust the setting of the windshield glass with suction discs.

9) Use unleaded gasoline and a soft cloth to wipe away any

8. Wiper Arm Assembly

REAR WINDOW ASSEMBLY

Removal Steps Installation Steps

Important Operation - Removal

5) With the aid of an assistant, carefully move the piano wire

Important Operation - Installation

4) Apply primer 1 sunster #435-40 or equivalent to the rear

5) Apply the rear window glass seling adhesive 2 .

FRONT DOOR ASSEMBLY

REMOVAL AND INSTALLATION

This illustration is based on RHD model

Removal Steps Installation Steps

Important Operations - Removal

2. Check Arm Screw

3. Lower Hinge Bolt

Important Operations – Installation

2. Check Arm Screw; Check Arm to Body

This illustration is based on RHD model

· To remove the regulator handle, remove the clip at the

2. Power Window Switch

4. Door Mirror Cover

6. Tweeter (Required option)

7. Door Mirror Assembly

17.Door Lock Assembly

18.Outside Handle Protector (EUROPE)

This illustration is based on RHD model

4. Door Lock Cylinder Protector (EUROPE)

6. Outside Handle Protector (EUROPE)

· Attach the window glass to the window regulator with the

23.Window Regulator Handle

REAR DOOR ASSEMBLY (CREW CAB)

REMOVAL AND INSTALLATION

Removal Steps Installation Steps

Important Operations - Removal

2. Check Arm Screw

3. Lower Hinge Bolt

Important Operations – Installation

2. Check Arm Screw; Check Arm to Body

· To remove the regulator handle, remove the clip at the

2. Power Window Switch

17.Window Regulator Handle

This illustration is based on RHD model

Disassembly Steps ▲ 13. Ashtray case

3. Instrument Panel Driver Lower Cover Assembly

4. Driver Knee Bolster Assembly

7. Meter Cluster Assembly

12.Instrument Panel & Cross Beam Assembly

2) Remove the two bolts fixing the parking brake bracket to

3) Disconnect the control cables at the blower unit and

5) Disconnect the instrument harness connectors.

This illustration is based on RHD model

3) C Bolt: Parking Brake Bracket to Cross Beam

21.Steering Wheel/Steering Cowl

REMOVAL AND INSTALLATION

Important Operations - Removal