Page 1
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
2005-2006 KIT# 5603*
*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 sudden sharp turns or abrupt maneuvers and always make
sure all vehicle occupants have their seat belts fastened.
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 recommend 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 similar 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, thoroughly 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 recommend 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.
WARNING
The installation of larger tires may reduce the effectiveness of the braking system.
WARNING
Always wear eye protection when operating power
tools.
WARNING
Before you install this kit, block the vehicle tires to prevent the vehicle from rolling.
WARNING
Accidental deployment of the air bag can result in serious personal injury or death. To avoid accidental
deployment during installation of the kit, the Supplemental Restraint System (SRS, or airbag) must remain
deactivated. Do not allow anyone near the airbag during 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 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 2
Before Starting Installation
Inside Cab
NOTE
Kit parts are prefaced by the word kit and appear in
bold print.
1. Carefully read all warnings and instructions com-
pletely before beginning.
2. Verify all parts have been received in this kit by
checking the parts list at the end of this document.
NOTE
If parts are missing from kit, please be prepared to provide the following information:
1. Name of purchase location
2. Bar Code on side of box
3. Date above bar code
4. Date inside box cover
5. Inspector # from inside box cover
3. Only install this kit on the vehicle for which it is
specified. If anytime during the installation you
encounter something different from what is outlined
in the instructions, call technical support at (928)
636-7080.
1. Airbag Fuse
NOTE
The location of the airbag fuse may vary; check the
owner's manual.
a. Remove fuse cover.
b. Remove airbag fuse.
Fuse Cover
Airbag Fuse
4. Special tools needed:
a. Welder or access to a professional welding
shop.
b. Die grinder or similar tool capable of cutting
metal.
5. Park vehicle on a clean, dry, flat, level surface and
block tires so vehicle cannot roll in either direction.
Engine Compartment
1. Disconnect both battery cables. Disconnect nega-
tive cable first, then positive cable.
Positive
Cable (Red)
Negative
Cable (Black)
Fuse Location
May Vary
Prepare to Install Kit
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 _________
2 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 3
Front of Vehicle
d. Remove two pop-up clips from fender wells.
1. Front bumper
a. Remove wiring harnesses from fog lights, if
equipped.
Wiring
Harness
Fog Light
b. Remove two pop-up clips, two bolts and grille
from core support.
Bolts
Pop-up
Clips
Fender Well
Pop-up
Clip
Front
Bumper
e. Remove six screws and front bumper fascia
from vehicle.
Front
Bumper
Fascia
Grille
c. Remove seven pop-up clips from front bumper.
Pop-up
Clips
Front
Bumper
Fascia
Screws
NOTE
Use caution when removing front bumper fascia from
vehicle. Carefully pull outward from fenders on the
sides of front bumper cover to loosen.
f. Remove six nuts and front bumper from vehicle.
Front
Bumper
Nuts
3 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 4
g. Remove six nuts and two front bumper brackets
from frame rails.
Nuts
Front Bumper
Brackets
2. Automatic Transmission Cooler: (if equipped)
Engine Compartment
1. 6 cyl. models: Loosen airbox clamp, two clips and
remove airbox cover from engine.
Airbox Cover
Clamp
Clips
a. Remove four bolts and allow automatic trans-
mission cooler to hang loose from core support.
Bolts
Bolts
b. Remove two bolts and automatic transmission
cooler lines from lower core support.
Bolts
Radiator
Auto
Trans
Lines
Lower Core Support
2. 6 cyl. models: AC Line
a. 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
4 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 5
3. 6 cyl. models: Remove power steering reservoir,
three bolts and bracket from fender. DO NOT DISCONNECT power steering lines.
6. 4 cyl. models: Remove nut and AC line from passenger side AC line bracket.
Power
Steering
Reservoir
Bracket
Bolts
4. 4 cyl. models: Loosen two engine intake clamps
and remove engine intake hose.
Clamps
Air Hose
AC Line
Bracket
Nut
AC Line
7. 4 cyl. models: Remove lower AC line from two cl ips
and passenger side body.
Passenger
Side Body
Clip
5. 4 cyl. models: Remove bolt from passenger side
AC line bracket.
AC Line
Bolt
AC Line
Bracket
AC Line
8. Remove vent tubes from driver side body bracket.
Vent
Tubes
Bracket
Battery
5 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 6
9. Remove heater hoses from clip on backside of
engine.
11. Remove ABS wire harnesses from driver and passenger side brackets.
Heater
Hoses
Clip
10. Remove wire harness clip from fi re wall and bracket.
Clip
Bracket
Driver
Side
ABS Wire
Harnesses
Passenger
Side
12. Remove wire harness and two clips from alternator
bracket and driver side body bracket.
Wire
Harness
Alternator
Bracket
Wire
Harness
Body
Bracket
Battery
6 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 7
13. Radiator
14. Steering Shaft
a. Remove nine pop-up clips and radiator cover
from core support.
Pop-up
Clips
Radiator
Cover
Core
Support
b. Remove four bolts and radiator from core sup-
port. Allow radiator to hang on core support by
tabs.
Core
Support
Radiator
Bolts
WARNING
Accidental deployment of the air bag can result in serious personal injury or death. To avoid accidental
deployment during installation of the lift kit, the Supplemental Restraint System (SRS, or airbag) must remain
deactivated. Do not allow anyone near the airbag during installation. Refer to the factory service manual or
owner's manual for the recommended procedure to
disable the SRS. After kit installation, the SRS must be
reactivated before driving the vehicle.
CAUTION
If the following step is not performed, the airbag clockspring could be damaged. Do not turn the steering
wheel while the steering shaft is disconnected.
a. Strap steering wheel to prevent accidental
movement.
b. Mark upper steering shaft in relation to coupler
and lower steering shaft.
Upper Steering
Shaft
Alignment Mark
Tab
NOTE
Lower the radiator onto the frame prior to the lifting procedures.
Coupler
Bolts
Lower Steering
Shaft
c. 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.
7 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 8
Inside of Vehicle
b. Remove dead pedal.
1. Manual transmission
a. Remove center console and shifter console inte-
rior panels.
Shifter
Console
Center
Console
b. Remove shift lever from vehicle.
Shift Lever
Kick Panel
Dead Pedal
c. Remove driver and passenger kick panels.
Kick Panel
Plastic Cap
2. Front interior trim panels
a. Remove driver and passenger door sill plates.
Door Sill
Plate
d. Pull driver and passenger carpet back from cor-
ner and expose body mount bolt access cover.
e. 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.
8 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 9
3. Extended cab models: Rear interior trim panels
a. Fold down rear seats.
e. Remove four bolts, and driver and passenger
body mount access plates.
Access
Plate
Rear Seat
b. Open floor storage tray and remove jack.
Storage Tray
Jack
Rear Seat
c. Remove pop-up clips and storage tray from
vehicle.
Storage Tray
Bolts
Carpet
Rear
f. Remove driver and passenger body mount bolt
access covers.
Access
Cover
4. Crew cab models: Rear interior trim panels
a. Remove three headrests from seatbacks and
fold seatbacks down.
Pop-up
Clips
Rear Seat
d. Pull carpet up to expose driver and passenger
body mount access plates.
b. Remove three bolts and pop-clips from driver
side rear panel and cab.
Driver Side
Rear Panel
Bolts
9 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 10
c. Remove bolt and pop-clips from passenger side
rear panel and cab.
3. Remove two bolts and brake line brackets from
driver and passenger side frame rails.
Passenger
Side Rear
Panel
Bolt
d. Remove driver and passenger body mount bolt
access covers.
Access
Cover
Driver
Side
Bolt & Brake
Line
Passenger
Side
4. Remove two bolts and parking brake cable brackets
from crossmember.
Driver
Side
Parking
Brake Cable
Underside of Vehicle
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.
Crossmember
Bolt &
Bracket
Parking
Brake Cable
Passenger
Side
10 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 11
5. Remove two nuts and fuel line brackets from driver
side body.
Rear of Vehicle
Fuel Lines
Bracket
Nut
Front
Nut
Fuel Lines
Rear
6. Remove bolt and brake line bracket from driver side
frame.
Frame
WARNING
Use extreme caution when working near the fuel lines
and the fuel tank. Clean up spilled fuel immediately. A
spark could cause an explosion or fire resulting in serious personal injury and property damage.
1. Fuel filler
a. Remove fuel filler cap.
Fuel Filler
Body
Fuel Filler
Cap
b. Loosen two hose clamps and disconnect vent
hose connector.
Vent Hose
Brake Line
Bracket
Bolt
Clamp
Fuel Tank
Front
c. Remove bolt and fuel filler from vehicle.
Fuel Filler
Bolt
Frame
11 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 12
2. Rear bumper
a. Remove rear bumper wire harness from driver
and passenger frame.
d. With O.E. Trailer Hitch: Remove four bolts and
rear bumper from O.E. trailer hitch brackets.
Frame
Bed
Wire
Harness
Frame
Front
b. Remove two license plate lights from rear
bumper.
Rear
Bumper
License Plate
Light
Trailer
Hitch
Brackets
Bolts
Install Kit
Cab
1. Lift cab
a. Loosen, but DO NOT REMOVE, cab mounting
bolts on driver side.
c. Without O.E. Trailer Hitch: Remove six bolts
and rear bumper from frame.
Frame
Bumper
Bracket
Bolts
Cab Mount
(Core Support)
Cab Mount
(Mid Cab)
Cab Mount
(Rear Cab)
Loosen Bolts
At These Mounts
NOTE
The number of cab mounting bolts may vary with the
length of the cab.
12 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 13
b. Remove bolt, nut, and lower washer from each
cab mount on passenger side.
Cab Mount
Remove Bolt
From These Mounts
NOTE
The factory captive washers will be used with kit bolts.
b. Position a hydraulic jack and a wood block
under passenger side of cab (under the body
seam). Slowly lift cab just enough to install a kit
block on top of factory upper bushing.
Bolt
Nut & Lower
Washer
WARNING
Use extreme caution when lifting body from frame. To
prevent serious personal injury, ensure the lifting
device is securely placed. Keep your hands out from
between the body and frame.
CAUTION
Continually check hoses, wires, lines, etc. to be sure
that everything is flexing properly and not binding, or
damage to the vehicle could result. Be especially careful of the a/c hoses at the fire wall, the belt pulley, and
at the core support. Ensure brake lines stretch while
lifting. Bending the lines to gain ample slack may be
necessary. Be extremely careful not to kink the lines.
2. Cab passenger side
WARNING
The kit blocks must be installed in addition to the factory upper and lower bushings. Installing the kit blocks
without the factory upper and lower bushings could
result in damage to the vehicle and/or serious personal
injury.
c. Install kit block (2” dia.) on upper bushin gs on
front core support cab mount.
Front Cab Mount
Kit Block
(2” Dia.)
Upper Bushing
a. Remove captive washers from each factory cab
mount bolt.
Front Bolt &
Washer
Mid Bolt &
Washer
Rear Bolt &
Washer
Front, Mid &
Rear Captive
Washers
d. Install kit blocks (3” dia.) on upper bushings on
each remaining cab mount.
Kit Block
Mid Cab Mount
(3” Dia.)
Upper Bushing
Kit Block
(3” Dia.)
Upper Bushing
Rear Cab Mount
e. Lower cab onto kit blocks.
13 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 14
f. Install factory front captive washer and a kit bolt
(3/8” x 8”) on core support cab mount. DO NOT
TIGHTEN.
3. Cab driver side
a. Repeat previous steps on driver side of cab.
Front Cab Mount
Kit Bolt
(3/8” x 8”)
g. Install factory mid captive washer and kit bolt
(M12-1.75 x 200mm) on cab mount. DO NOT
TIGHTEN.
Mid Cab Mount
b. Set cab-to-bed spacing according to previous
measurement.
c. Remove front core support cab mount kit bolts
(3/8” x 8”) and apply a few drops of kit Loctite®
to threads. Install kit bolt s, factory captive wash-
ers, factory lower washers and kit nuts (3/8”
Nylock). Tighten kit bolts to 55 ft. lbs.
Front Cab Mount
Kit Bolt
(3/8” x 8”),
Kit Nut
(3/8” Nylock),
Factory Captive
Washer & Lower
Washer
Kit Bolt
(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
d. Remove mid cab mount kit bolts (M12-1.75 x
200mm) and apply a few drops of kit Loctite® to
threads. Install kit bolts, factory captive wash-
ers, factory lower washers and kit nuts (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
Kit Bolt
(M12-1.25 x 210mm)
14 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 15
e. Remove rear cab mount kit bolts (M12-1.25 x
210mm) and apply a few drops of kit Loctite® to
threads. Install kit bolts, factory captive wash-
ers, factory lower washers and factory nuts.
Tighten kit bolts to 55 ft. lbs.
Rear Cab Mount
Kit Bolt
(M12-1.25 x 210mm),
Factory Captive
Washer, Lower
Washer & Nut
Bed
1. Lift bed
a. Loosen, but DO NOT REMOVE, bed mounting
bolts on driver side.
Loosen Bolts
At These Mounts
2. Remove bolt from each bed mount on passenger
side.
Remove Bolts
At These Mounts
Bolts
WARNING
Use extreme caution when lifting the bed from the
frame. To prevent serious personal injury, ensure the
lifting device is securely placed. Keep your hands out
from between the bed and frame.
CAUTION
To prevent damage to the vehicle while lifting the bed,
continually check hoses, wires, brake lines, etc. to
ensure everything is flexing properly and not binding.
Ensure clearance between bed and cab is maintained.
Bolts
NOTE
The number of bed mounting bolts may vary with the
length of the bed.
3. Bed passenger side
a. Remove captive washers from each factory bed
mount bolt.
Factory Bed
Mount Bolt
Captive
Washer
NOTE
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”.
15 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 16
c. Install kit blocks (2” dia.) on frame mounts.
Front Bed
Mount
Kit Block
(2” Dia.)
Mid Bed Mount
f. At rear bed mount, install kit bolt (M12-1.25 x
180mm) and factory captive washer. DO NOT
TIGHTEN.
Install Kit Bolt
At This Mount
Kit Bolt
(M12-1.25 x 180mm)
Rear Bed Mount
d. Lower bed onto kit blocks.
e. At front and mid bed mounts, install kit bolts
(M12-1.25 x 160mm) and factory captive washers. DO NOT TIGHTEN.
Install Kit Bolts
At These Mounts
Kit Bolts
(M12-1.25 x 160mm)
g. Repeat previous steps on driver side of bed.
h. Set bed-to-cab spacing according to previous
measurement.
i. Remove each kit bolt, one at a time, and apply a
few drops of kit Loctite® to threads. Install kit
bolt with factory captive washer.
Rear of Vehicle
1. With O.E. Trailer Hitch: Rear bumpe r
WARNING
The following procedure is intended only to enhance
the appearance of the vehicle. The rear bumper will no
longer be rated for towing of any kind. Towing with the
rear bumper after it has been lifted can result in death,
serious personal injury, or damage to the vehicle. Towing after the bumper has been lifted should be accomplished using a rated Class III receiver type hitch.
NOTE
Rear bumper installation requires kit# 5903.
16 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 17
a. Mark and cut driver and passenger O.E. trailer
hitch brackets along white lines as shown below.
BEFORE
Mark
& Cut
Here
BEFORE
b. Apply a small amount of kit Loctite® onto
threads of two factory bolts and install kit
bracket (rear bumper, passenger) and kit
bracket (bumper, spacer) to passenger side
bumper with two factory bolts. DO NOT
TIGHTEN.
Kit Plate
(Rear
Bumper,
Spacer)
Bumper
Factory
Bolts
Mark
& Cut
Here
AFTER
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
Bolts
O.E.
Trailer Hitch
17 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 18
e. Apply a small amount of kit Loctite® onto
threads of eight factory bolts and install rear
bumper and kit brackets (rear bumper) onto
O.E. trailer hitch with eight factory bolts. DO
NOT TIGHTEN.
Kit Bracket
(Rear
Bumper)
Factory
Bolts
O.E.
Trailer
Hitch
f. Install two kit brackets (rear bumper) onto O.E.
trailer hitch with two kit bolts (9/16” x 1-1/2”),
four kit washers (9/16” SAE), and two kit nuts
(9/16” stover). DO NOT TIGHTEN.
Kit Bracket
(Rear
Bumper)
Kit Bolt
(9/16” x
1-1/2”),
Kit Washers
(9/16” SAE),
Kit Nuts
(9/16” Stover)
g. Inst all kit bracket (rear bumper, middle) onto
rear bumper with two factory bolts and nuts. DO
NOT TIGHTEN.
h. Install kit bracket (rear bumper, middle) onto
O.E. trailer hitch with two kit bolts (1/2” x 1”),
four kit washers (1/2” SAE), and two kit nuts (1/
2” stover). DO NOT TIGHTEN.
Kit Bracket
(Rear
Bumper,
Middle)
Kit Bolt
(1/2” x 1”),
Kit Washers
(1/2” SAE),
Kit Nuts
(1/2” Stover)
2. Without O.E. Trailer Hitch: Rear bumper
WARNING
The following procedure is intended only to enhance
the appearance of the vehicle. The rear bumper will no
longer be rated for towing of any kind. Towing with the
rear bumper after it has been lifted can result in death,
serious personal injury, or damage to the vehicle. Towing after the bumper has been lifted should be accomplished using a rated Class III receiver type hitch.
a. Remove four bolts and two bumper brackets
from bumper.
b. Apply a small amount of kit Loctite® to threads
of three factory bolts and install kit bracket (rear
bumper, passenger) to passenger side frame.
DO NOT TIGHTEN.
Factory Bolts
Factory
Bolts
Bumper
Kit Bracket
(Rear
Bumper,
Middle)
Kit Bracket
(Rear
Bumper,
Passenger)
Frame
c. Repeat above step for driver side.
18 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 19
d. Apply a small amount of kit Loctite® to threads
of four factory bolts and install rear bumper to
kit brackets (rear bumper). DO NOT TIGHTEN.
Kit Bracket
(Rear
Bumper)
Factory Bolts
Rear
Bumper
6. Set bumper to previous bed-to-bumper measurements.
7. TIGHTEN all rear bumper hardware.
8. Fuel filler
WARNING
Use extreme caution when working near the fuel lines
and the fuel tank. Clean up spilled fuel immediately. A
spark could cause an explosion or fire resulting in serious personal injury and property damage.
a. Mark fuel filler tubes with cut and alignment
lines.
3. Install license plate lights on rear bumper.
Rear
Bumper
License Plate
Light
4. Install rear bumper wiring harness on frame, if possi-
ble.
Wire
Harness
Frame
Fuel Filler
Alignment
Lines
Cut Lines
b. Cut fuel filler on cut lines.
Fuel Filler
Alignment
Lines
5. Install kit tie (zip) to rear crossmember an d bumper
wiring harness.
Kit Tie
(Zip)
Wire
Harness
Crossmember
c. Deburr edges of cut tubes.
19 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 20
d. Inst all kit extension (1/4” x 6” hose) between cut
breather tube on fuel filler with two kit clamps
(#6 hose). DO NOT TIGHTEN.
Kit Extension
(1/4” x 6”)
Breather
Tube
Kit Clamps
(#6 Hose)
g. Install fuel filler onto fuel tank with two factory
hose clamps and factory clip. DO NOT
TIGHTEN.
Vent Hose
Clamp
h. Install factory bolt onto frame and fuel filler.
e. Install kit extension (5/8” x 6” hose) between cut
vent tube on fuel filler with two kit clamps (#10
hose). DO NOT TIGHTEN.
Kit Extension
(5/8” x 6”)
Vent
Tube
Kit Clamps
(#10 Hose)
f. Install kit extension (1” x 6” hose) between cut
filler tube on fuel filler with two kit clamps (#20
hose). DO NOT TIGHTEN.
Kit Extension
(1” x 6”)
Filler
Tube
Fuel Filler
Bolt
Frame
i. Adjust fuel filler and/or kit extensions (hose) to
body.
Fuel Filler
Body
Kit
Extensions
j. TIGHTEN all hardware.
Kit Clamps
(#20 Hose)
k. Install fuel filler cap.
Fuel Filler
Body
Fuel Filler
Cap
20 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 21
Underside of Vehicle
1. Parking brake cable
d. Install passenger side parking brake cable to kit
bracket with kit nut (1/4” Nylock) and kit
washer (1/4” SAE).
a. Install kit bracket (3” w/ stud) to driver side
crossmember with factory bolt.
Kit Bolt
(1/4” x 1”),
Kit Washer
(1/4” SAE),
Kit Nut
(1/4” Nylock)
Kit Bracket
(3” W/ Stud)
Parking Brake
Cable
Factory Bolt
Crossmember
2. Fuel lines
a. Install kit bracket (2” stand off) to driver side
stud with factory nut.
Stud &
Factory Nut
Kit Bracket
(2” Stand Off)
Fuel Lines
Kit Bolt
(1/4” x 1”),
Kit Washer
(1/4” SAE),
Kit Nut
(1/4” Nylock)
b. Install fuel line bracket to kit bracket (2” stand
off) with kit bolt (1/4” x 1”), two kit washers (1/4”
SAE) and kit nut (1/4” Nylock).
Driver Side
Looking Back
b. Install driver side parking brake cable to kit
bracket with kit nut (1/4” Nylock) and kit
washer (1/4” SAE).
c. Install kit bracket (3” w/ stud) to passenger side
crossmember with factory bolt.
Kit Bolt
(1/4” x 1”),
Kit Washer
(1/4” SAE),
Kit Nut
(1/4” Nylock)
Parking Brake
Cable
Kit Bracket
(3” W/ Stud)
Factory Bolt
c. Install kit bracket (3” Z-shaped) to driver side
stud with factory nut.
Stud &
Factory Nut
Kit Bracket
(3” Z-Shaped)
Kit Bolt
(1/4” x 1”),
Kit Washer
(1/4” SAE),
Kit Nut
(1/4” Nylock)
Fuel Lines
Driver Side
Looking Back
d. 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).
Crossmember
21 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 22
3. Carefully bend brake lines and install bolt and brake
line bracket to frame.
b. Install driver and passenger body mount access
plates and bolts.
Frame
Brake Line
Bracket
Bolt
4. Brake lines
a. Install kit bracket (2” Z-shaped) and factory bolt
to driver side frame.
Brake Line
Bracket
Kit Bolt
(1/4” x 1”),
Kit Washers
(1/4” SAE),
Kit Nut
(1/4” Nylock)
Access
Plate
Bolts
Carpet
Rear
c. 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
Kit Bracket
(2” Z-Shaped)
Factory Bolt
b. Install brake line bracket to kit bracket (2” Z-
shaped) with kit bolt (1/4” x 1”), two kit washers
(1/4” SAE) and kit nut (1/4” Nylock).
c. Repeat above steps for passenger side.
Inside of Vehicle
1. Extended cab models: Rear interior trim panels
a. Install body mount access covers.
Access
Cover
Rear Seat
e. Install jack into storage tray.
Storage Tray
Jack
Rear Seat
22 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 23
2. Crew cab models: Rear interior trim panels
3. Front interior trim panels
a. Install body mount access covers.
Access
Cover
b. Install passenger side rear panel onto cab with
pop-clips and bolt.
Passenger
Side Rear
Panel
a. Install driver and passenger body mount bolt
access cover.
Carpet
Body Mount
Bolt
Access
Cover
b. Lay carpet down to cover driver and passen ger
body mount access covers.
c. Install driver and passenger kick panels.
Kick Panel
Bolt
c. Install driver side rear panel onto cab with pop-
clips and three bolts.
Driver Side
Rear Panel
Bolts
d. Return seatbacks to upright position and install
three headrests onto seatbacks.
d. Install dead pedal.
Kick Panel
Dead Pedal
23 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 24
e. Install driver and passenger door sill plates.
Door Sill
Plate
d. Position kit extension (manual shifter) between
two cut pieces of shifter lever. Ensure alignment
marks on each cut shifter lever piece are aligned
and rubber boot is on shift lever.
Shift Lever
Kit Extension
(Manual
Shifter)
Alignment
Mark
e. Weld kit extension (manual shifter) in place.
4. Manual transmission
a. Remove plastic cap from end of shift lever.
Shift Lever
Plastic Cap
b. Mark alignment and cut lines on shifter lever
below bend.
Shift Lever
WARNING
Welding should be performed by a certified welder.
f. Grind off any excess welds.
g. Install plastic cap to end of shift lever.
h. Install shifter lever.
Shift Lever
Plastic Cap
i. Install shift and center consoles.
Shifter
Console
Cut Line
Alignment
Line
c. Cut shifter lever along marked cut line.
Center
Console
24 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 25
Engine Compartment
2. Radiator
1. Steering shaft
Kit Extension
(Steering)
WARNING
Verify the steering extension is securely installed as
specified in the instructions. Failure to do so may
cause steering malfunction, resulting in property damage or serious personal injury.
a. Install upper steering shaft into kit extension
(steering), ensuring marks on upper and lower
steering shaft are aligned.
a. Cut off tabs on upper radiator mounts.
Upper
Radiator
Mount
Radiator
Core
Support
Tab
b. Install four kit brackets (3” radiator) to radiator
mounts with four factory bolts. DO NOT
TIGHTEN.
Alignment
Mark
Upper Steering
Shaft
Kit Bolt
(3/8” x 1-1/4”)
Kit Extension
(Steering)
Steering Coupler
& Bolts
Lower Steering
Shaft
b. Position kit extension (steering) into steering
coupler. Ensure marks on upper and lower
steering shaft are aligned.
c. Apply a few drops of kit Loctite® to factory bolts
and kit bolt (3/8” x 1-1/4”).
Alignment
Mark
Radiator
Kit Bracket
(3” Radiator)
Factory
Bolt
d. Install bolts and tighten to 33 lb.-ft.
25 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 26
c. Install radiator and four kit brackets to core sup-
port with four kit washers (1/4” SAE) and four kit
nuts (1/4” Nylock). DO NOT TIGHTEN.
Kit Washer
(1/4” SAE),
Kit Nut
(1/4” Nylock)
Kit Bracket
(3” Radiator)
f. Install radiator cover to core support with five
factory pop-up clips.
Factory
Pop-up Clips
Core
Support
Radiator
Cover
g. Install radiator cover to kit plates (radiator blo ck
off) with four kit clips (push) and four kit wash-
ers (1/4” SAE).
d. Assemble kit plates (radiator block off) with kit
bolt (1/4” x 1”), two kit washers (1/4” SAE) and
kit nut (1/4” Nylock). DO NOT TIGHTEN.
Kit Plates
(Radiator
Block Off)
Kit Bolt
(1/4” x 1”),
Kit Washer
(1/4” SAE),
Kit Nut
(1/4” Nylock)
e. Install kit plates (radiator block off) to radiator
with four factory pop-up clips.
Kit Plates
(Radiator
Block Off)
Radiator
Cover
Kit Clip
(Push),
Kit Washer
(1/4” SAE)
h. Adjust radiator and ensure fan does not contact
fan shroud.
i. TIGHTEN all hardware.
Factory
Pop-up Clips
26 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 27
3. Install wire harness and clips to alternator bracket
and driver side body bracket. Adjust clips if necessary.
5. Install driver and passenger brake line wire harnesses to brackets with two kit ties (zip).
Bracket
Alternator
Bracket
Wire
Harness
Body
Bracket
Battery
4. Install vent hoses to driver side body bracket with kit
tie (zip).
Kit Tie
(Zip)
Wire
Harness
6. Install wire harness clip to firewall bracket.
Clip
Bracket
Wire
Harness
Bracket
Vent
Hoses
Kit Tie
(Zip)
7. Install heater hoses on clip and backside of engine.
Heater
Hoses
Clip
27 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 28
8. 6 cyl. models: Power steering reservoir
a. Remove reservoir cap and drain contents into
drain pan.
b. Remove two clamps and power steering lines
from reservoir.
Power
Steering
Reservoir
Power
Steering
Lines
Clamps
f. Install kit extension (7/16” OD x 5” L) between
cut power steering lines with two kit clamps (#6
hose). DO NOT TIGHTEN.
Kit Extension
(7/16” OD x 5” L)
Kit Clamps
(#6 Hose)
c. Mark power steering lines.
Cut Marks
Power
Steering
Lines
Front
Cut Marks
Front
g. Install kit extension (5/8” OD x 5” L) between
cut power steering lines with two kit clamps
(#10 hose). DO NOT TIGHTEN.
Kit Extension
(5/8” OD x 5” L)
Kit Clamps
(#10 Hose)
h. Install power steering reservoir, lines, clamps,
and three bolts onto vehicle.
Power
Steering Lines
d. Cut power steering lines along cut marks.
e. Drain any remaining fluid from power steering
lines into drain pan.
Power
Steering
Reservoir
Bolts
Clamps
i. Adjust hoses and tighten all hardware.
28 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 29
9. 4 cyl. models: Power steering requires no modification.
d. Install AC line to kit bracket (3” w/ stud ) with kit
washer (1/4” SAE) and kit nut (1/4” Nylock).
10. 6 cyl. models: AC Line
a. Install rubber isolator to body.
AC Line
Clamp
Nut
Rubber
Isolator
b. Install AC line and clamp onto rubber isolator
with nut.
11. 4 cyl. models: AC Line
a. Install kit bracket (3” Z-shaped) to passenger
side AC line bracket with bolt.
Install
Kit Bracket
(3” ZShaped)
Here
12. 6 cyl. models: Install airbox cover to engine with
two clips. Tighten clamp.
Airbox Cover
Clamp
Clips
13. 4 cyl. models: Install air hose to engine with two
clamps.
Clamps
Air Hose
AC Line
Bracket
b. Install AC line to bottom of kit bracket (3” Z-
shaped) with kit bolt (1/4” x 1”), two kit washers
(1/4” SAE) and kit nut (1/4” Nylock).
c. Install kit bracket (3” w/ stud) to rubber isolator
and passenger side AC line bracket with nut.
AC Line
Bracket
Rubber
Isolator
Install Kit Bracket
(3” W/ Stud) Here
Nut
AC Line
Front of Vehicle
1. Automatic Transmission Cooler: (if equipped)
NOTE
Parts to perform the automatic transmission modification are included in Kit# 5903. The automatic transmission cooler is a factory option with the tow package.
a. 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).
29 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 30
c. Install two kit extension (sleeve), two kit bolts
(8mm x 50mm), two kit washers (8mm flat), and
automatic transmission cooler lines to lower
core support.
b. Apply a small amount of kit Loctite® to six kit
bolts (3/8” x 1”) and install front bumper to kit
brackets (front bumper) with twelve kit washers
(3/8” USS) and six kit nuts (3/8” Nylock).
Kit Bolts
(10mm x
50mm),
Kit Washer
(10mm Flat)
Lower
Core
Support
Auto Trans Lines
d. Install automatic transmission cooler onto core
support with four bolts.
Bolts
Bolts
Kit Bracket
(Front
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.
2. Front bumper
a. 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
Front
Bumper
Fascia
Screws
30 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 31
d. Install two pop-up clips to fender wells.
After Completing Installation
Fender Well
Pop-up
Clip
Front
Bumper
e. Install five pop-up clips to front bumper.
Pop-up
Clips
Front
Bumper
Inside Cab
1. Install airbag fuse and fuse block cover.
Airbag Fuse
Fuse Location
May Vary
Fuse Cover
f. Install two pop-up clips, two bolts and grille to
core support.
Screws
Pop-up
Clips
Grille
g. Inst all wiring harnesses to fog lights, if equipped.
Wiring
Harness
Fog Light
Engine Compartment
1. Connect both battery cables. Connect positive cable
first, then negative cable.
Positive
Cable (Red)
Negative
Cable (Black)
h. Adjust bumper and tighten all hardware.
31 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 32
Miscellaneous
Accessories
1. Apply kit label (warning) to dashboard in p lain sight
of all vehicle occupants.
2. Check all fasteners to ensure they are tight.
3. Ensure all wires, hoses, cables, etc. are properly
connected and there is ample slack.
4. Fill and check power steering reservoir with fresh
power steering fluid. Start engine and turn wheel
several times in either direction. Shut off engine and
recheck power steering reservoir. Add fluid, if necessary.
Dynamic Vehicle Check
1. Check steering in both directions to ensure that
there is no bind. Check operation of clutch, brake
system, and parking brake. Check operation of
transmission and transfer case. Ensure there is full
engagement in all gears and 4WD ranges. Check
battery connections and electrical component operations. Test-drive vehicle..
The following accessories are also available:
Kit# 6337 - Gap Guards
WARNING
Retorque all fasteners after 500 miles and after off road
use. All body lift components should be visually
inspected and fasteners retorqued during routine vehicle servicing.
CAUTION
Performance Automotive Group does not recommend
any particular wheel and tire combinations for use with
its body lifts and cannot assume responsibility for the
customer’s choice of wheels and tires. Refer to your
owner's manual for recommended tire sizes and warnings related to the use of oversized tires. Larger wheel
and tire combinations increase stress and wear on
steering and suspension components, which leads to
increased maintenance and higher risk for component
failure. Larger wheel and tire combinations also alter
speedometer calibration, braking effectiveness, center
of gravity, and handling characteristics. Consult an
experienced local off road shop to find what wheel and
tire combinations work best with your vehicle.
32 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Page 33
Kit Parts List
Qty. Description
8 Block, 2” x 3” spacer
4 Block, 3” x 3” spacer
7 Bolt, 1/4”-20 x 1”
6 Bolt, 3/8”-16 x 1”
2 Bolt, 3/8”-16 x 8”
1 Bolt, 3/8"-24 x 1-1/4", socket head
4 Bolt, M12-1.25 x 160mm
2 Bolt, M12-1.25 x 180mm
2 Bolt, M12-1.25 x 210mm
2 Bolt, M12-1.75 x 200mm
1 Bracket, 2” stand off
2 Bracket, 2” Z-shaped
7 Bracket, 3” radiator w/ stud
2 Bracket, 3” Z-shaped
1 Bracket, front bumper, driver
1 Bracket, front bumper, passenger
1 Bracket, rear bumper, driver
1 Bracket, rear bumper, passenger
4 Clamp, #10 hose
2 Clamp, #20 hose
4 Clamp, #6 hose
4 Clip, push
1 Extension, 1” x 6” rubber hose
1 Extension, 1/4” x 6” rubber hose
1 Extension, 5/8” OD x 5” L metal
1 Extension, 5/8” x 3” manual shifter
1 Extension, 5/8” x 6” rubber hose
1 Extension, 7/16” OD x 5” L metal
1 Extension, steering
1 Instruction sheet
1 Label, logo
1 Label, warning
1 Loctite®, 6mL tube
13 Nut
2 Nut, 12mm Nylock
8 Nut, 3/8”-16 Nylock
1 Plate, radiator block off, driver
1 Plate, radiator block off, passenger
4 Tie, zip
24 Washer, 1/4” SAE
12 Washer, 3/8” USS
, 1/4”-20 Nylock
NOTE
Depending on the vehicle configuration (automatic or
manual transmission, 2WD or 4WD, cab length, bed
length, etc.), some parts may not be used.
Rev. 03, Copyright 06/06
Performance Automotive Group
www.p-a-g.net
33 ‘05-‘06 Tacoma (W/O Hitch) - 3” Kit 5603
Loading...