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Tools Needed:
- ⅜” & ½” Ratchets
- ⅜” Allen sockets, 17mm, 19mm, 21mm Sockets
- 10mm, 11mm, 12mm, 14mm, 17mm Wrenches
- Hammer
- Floor Jack and Jack Stands
- Torque Wrench
- Press
- Bearing Puller
- Seal Puller
- Brake Fluid (DOT 3)
Installation Notes:
- 1. Read all instructions completely and carefully before you begin.
2. Check to make sure the kit is complete and that no parts are missing. If anything is missing, please contact Trail-Gear at (559) 252-4950.
3. Park vehicle on a clean, dry, at, level surface and block the tires so the vehicle can not roll in either direction.
Installation Instructions:
1. Remove the wheels and drums from your vehicle.
2. Disconnect the brake lines (10mm) and the e-brake cables.
3. Remove the 4 nuts holding bearing pocket in place on
each side.
4. Slide the axle assemblies out of the housing. A small
amount of gear oil may leak from the housing, so have a
oil pan ready to catch the fluid.
5. Remove ABS sensor so that bracket will clear and install
the provided freeze plug into the ABS sensor hole.
6. If you are installing new Trail-Gear chromoly axles,
bearing pockets and bearings, skip to step 8. If you are
reusing your axle shafts, bearings, and bearing pockets,
remove the bearing retaining ring from the axle.
7. The drum brake assembly and backing plate
should be removed with a press and a bearing
puller according to your Toyota owners manual.
If you do not have the correct tools or mechanical
experience to complete this step we advise
that you find a qualified automotive shop or an
authorized Trail-Gear installer to complete this
step for you in a safe and professional manner. If
you have any questions about this step, please
call Trail-Gear tech support at (559)252-4950.
8. Press out the 4 studs holding the bearing pocket to the backing plate. Remove the old bearing and seal from the bearing pocket if you plan on installing new ones.
8. Press out the 4 studs holding the bearing pocket to the backing plate. Remove the old bearing and seal from the bearing pocket if you plan on installing new ones.
9. Install new seal and bearing in the bearing pocket and
using a press, install the assembly on the axle. Install
the bearing spacer and the snap ring on axle.
10. Install c-clip securely into groove. Take care to ensure
that c-clip is completely seated in the groove.
10. Continued
11. If you are installing new seals (recommended),
remove the old o-ring from the axle housing and
install new o-ring seal and oil seal.
12. Install axle assembly into the axle housing.
13. Using 3-M10x40mm bolts (per side), install the brake
caliper bracket on the back side of the axle flange. The
bracket needs to be clocked to the 2 o’clock position, or
above the axle to the rear of the vehicle. The brake line
enters the caliper from the bottom and the bleeder is on
the top on both sides of the vehicle.
14. Install one M10x35mm bolt in the remaining hole on each
side. Torque all M10 bolts to 45-50 ft-lbs.
15. Place rotors over the wheel studs and install the calipers
with the special fasteners that are supplied with the
caliper. There is a right hand and a left hand caliper. The
left side is shown, brake line on the bottom, bleeder on
the top. Torque caliper bolts to 30-35 ft-lbs.
16. Install brake lines in calipers using the banjo bolt and 2
copper washers (1 per side) that were supplied with the
caliper. The bend in the fitting needs to be facing
up(away from the bolt head) so that the brake line can be
routed over the leaf spring and on top of the axle.
16 Continued - NOTE: If installing this kit with leaf springs, we recommend
routing the brake line over the leaf spring pack
and then covering the brake line with a piece of hose or
flexible tubing to keep the brake like from chafing.
17. Install brake lines in the factory “T” mounted on the axle
and secure the lines to the axle.
17. Continued - NOTE: When installing disc brake conversion kit brake
lines onto a factory Tacoma “Y”, the brake lines are
exposed and could be damaged by rocks as shown in
step 17. We recommend cutting the factory bracket off
of the axle housing and rotating it back toward the front
of the axle tube so that the brake lines are moved out of
harms way. An example is shown below.
18. Install wheels and torque lug nuts.
19. Completely bleed brakes so that all air is removed from the system and test for leaks.
19. Completely bleed brakes so that all air is removed from the system and test for leaks.
