Section 1: Inspection/Repair Procedure For 21 States

INSPECTION/REPAIR PROCEDURE FOR 21 STATES:

Step 1. Visual Inspection Procedure

Required Tools & Equipment:

Name Part No. Quantity

Punch Tester 00216-00006 1
Wire Brush (Large) 00216-00008 1
Scraper Supplied by Dealer *
Safety Goggles Supplied by Dealer *
Mask Supplied by Dealer *
Paper Clip (Small) Supplied by Dealer *

1.1 Inspection Procedure

1.1.1 Lift the vehicle

Note: All wheels must be free from floor.

1.1.2 Visual check

CAUTION: WEAR SAFETY GOGGLES AND MASK FOR PROTECTION.

Remove the mud, rust scale, etc. adhering to the lower and side surfaces of the rear suspension arms with a wire brush, scraper, rag, etc.

Check the lower and side surfaces of the rear suspension arms visually and determine if there is any rust perforation.

If any perforation exists on either arm, proceed to Step 4 (Suspension Arm Replacement Procedure) and replace both arms. If no perforation is evident, proceed to Step 2 Punch Test Procedure

Step 2. Punch Test Procedure

2.1 Preparation for punch test

Suspension Arm:

2.1.1 Clean any undercoat, rust scale, mud, etc, from around the areas
indicated by "X" in figures 1 and 2. It is necessary to scrape these areas clean in order to position the punch tester flat against the surface.

Punch Test:

1.1.4 Mark the 6 points shown for the punch test - Fig. 3.

CAUTION: WEAR SAFETY GOGGLES AND MASK FOR PROTECTION. Use only the punch tester provided by Toyota.

Punch:

1. Punch
2. Trigger Tube
3. Spring
4. Lock Pin Set Position Groove
5. Lock Pin
6. Trigger Tube Groove

Notes: (1) - Do not store the punch with the lock pin engaged in the set position groove. Not only is it dangerous, but it will weaken the spring causing the performance of the punch to deteriorate.

(2) - Do not release the punch meaninglessly in the air. This could be dangerous and will shorten the life of the punch.
(3) - This punch must be used only for checking AL rear suspension arms.

Trigger Tube:

After sliding the trigger tube toward the punch, Fig. 5, turn the trigger tube clockwise (right) so that the lock pin goes into the groove on the trigger tube. Fig. 6.

Trigger Tube:

C. Pull the trigger tube back Fig. 7, (direction A) against the resisting force of the spring, and after sliding it to the proper lock pin set position, turn it clockwise (right) to engage the lock pin in the groove at that position. Fig. 8.

Punch:

D. Press the end of the punch against the surface of the rear suspension arm in the specified points on the under surface so that it is perpendicular to the surface. Fig. 9.
Caution: If the punch in not held firmly against arm, the punch will "jump" on impact causing inaccurate results. Press the punch firmly against the suspension arm for accurate results.

Punch Trigger:

E. Hold the punch firmly against the arm and turn the trigger tube counterclockwise (left) Fig. 10, to release the lock pin, letting the punch strike the arm surface. Fig. 11.

Punch Tester:

F. Determine if the punch tester punctured the arm by inserting a stiff wire (standard paper clip) to the punched indent. Fig. 12.

G. If the punch tester DID NOT puncture any of the 6 points in either of the suspension arms, proceed to Step 3 - Anti-rust procedure. If the punch tester DID puncture any of the 6 points in either of the suspension proceed to Step 4 - Replace lower arms.