Front Stabilizer (KDSS): Overhaul

1. Loosen the bleeder plug on the stabilizer control w/ accumulator housing assy and drain suspension fluid.

   HINT:

   • Drain suspension fluid when performing the operations related to the hydraulic circuits.
   • Draining suspension fluid decreases suspension fluid pressure.
2. Tighten the bleeder plug.

   Torque: 9.5 N.m (97 kgf.cm, 84 in.lbf) 

   Fig 1: Draining Suspension Fluid

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a socket hexagon wrench (8 mm), remove the 4 bolts and 2 rear stabilizer brackets lower and separate the stabilizer bar rear.

   HINT:

   Separate the stabilizer bar rear so that the air in the rear stabilizer control cylinder can be bled out easily when bleeding the hydraulic circuits.

   Fig 2: Separating Stabilizer Bar Rear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 4 bolts and 2 front stabilizer brackets with the wheels on the ground.
   Fig 3: Removing Front Stabilizer Brackets Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a socket hexagon wrench (10 mm), remove the 4 bolts, 2 front stabilizer lower brackets and stabilizer bar front.
3. Remove the 2 front stabilizer link bushes and front stabilizer lower bracket bushes from the stabilizer bar front.
   Fig 4: Removing Front Stabilizer Lower Brackets & Stabilizer Bar Front

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 7 clips and front apron seal LH.
   Fig 5: Removing Front Apron Seal LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove bolt (A) and tube clamp bracket No. 3.
   Fig 6: Removing Tube Clamp Bracket No. 3

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove bolt (B) and separate the return tube sub-assy.
4. Using SST, separate the front stabilizer control tube No. 1 from the front stabilizer w/ tube cylinder assy.

   SST 09023-12701

   Fig 7: Separating Front Stabilizer Control Tube No. 1

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the bolt.

1. Remove the bolt, nut and front stabilizer w/ tube cylinder assy.
   Fig 8: Removing Front Stabilizer With Tube Cylinder Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Turn the bolt while holding the nut.
   • Do not loosen or remove flare nuts (A) and (B) shown in Fig 9.
   • Do not remove or hold the front stabilizer w/ tube cylinder assy by the cylinder boot.
   Fig 9: Do Not Remove Flare Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bleeder plug caps and bleeder plugs from the front stabilizer w/ tube cylinder assy.

1. Remove the bolt, spacer and front stabilizer link assy.
   Fig 10: Removing Front Stabilizer Link Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the front stabilizer link assy with the spacer by temporarily tightening the bolt. Ensure that the identification mark on the front stabilizer link assy faces inward and to the front of the vehicle.
   Fig 11: Tightening Front Stabilizer Link Assy Temporarily

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 2 bleeder plugs and bleeder plug caps to the front stabilizer cylinder w/ tube cylinder assy.

   Torque: 9.5 N.m (97 kgf.cm, 84 in.lbf) 

2. Install the front stabilizer w/ tube cylinder assy by temporarily tightening the nut and bolt.
   NOTE:

   • Turn the bolt while holding the nut.
   • Do not hold or install the front stabilizer w/ tube cylinder assy by the cylinder boot.

   HINT:

   Pass the tube side of the front stabilizer w/ tube cylinder assy under the return tube sub-assy before installing.

   Fig 12: Installing Front Stabilizer With Tube Cylinder Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the bracket by temporarily tightening the bolt.
2. Connect the front stabilizer control tube No. 1.
   1. Apply suspension fluid to the threads of the flare nuts.
   2. Using SST, connect the front stabilizer control tube No. 1 to the front stabilizer w/ tube cylinder assy and tighten the flare nuts.

      SST 09023-12701

      Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) 

      Fig 13: Connecting Front Stabilizer Control Tube No. 1

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Fully tighten the bolt.

   Torque: 29 N.m (296 kgf.cm, 21 ft.lbf) 

4. Install the tube clamp bracket No. 3 with bolt (A).

   Torque: 29 N.m (296 kgf.cm, 21 ft.lbf) 

   Fig 14: Installing Tube Clamp Bracket No. 3

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the return tube sub-assy with bolt (B).

   Torque: 28 N.m (286 kgf.cm, 21 ft.lbf) 

6. Install the front apron seal LH with the 7 clips.
   Fig 15: Installing Front Apron Seal LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SST 09760-60010

Torque: 112 N.m (1,140 kgf.cm, 83 ft.lbf) 

1. Install the 2 front stabilizer lower bracket bushes to the stabilizer bar front.
   1. Align the protrusions on the bushes with the identification marks on the front stabilizer bar front with the protrusions facing inward.
      Fig 16: Installing Front Stabilizer Lower Bracket Bushes To Stabilizer Front

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Support the stabilizer bar front with the identification marks facing down with a jack. Place a wooden block between the jack and the stabilizer bar front to prevent damage.

   HINT:

   Place the jack under the left side of the vehicle.

   Fig 17: Supporting Stabilizer Bar Front With Jack

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a socket hexagon wrench (10 mm), install the stabilizer bar front with the 4 bolts and 2 front stabilizer lower brackets.

   Torque: 59 N.m (602 kgf.cm, 44 ft.lbf) 

   1. Check that the protrusions on the front stabilizer lower bracket bushes are positioned within 20° of the identification marks.
      Fig 18: Installing Stabilizer Bar Front

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 4 bolts, 2 front stabilizer brackets and 2 front stabilizer link bushes with the wheels on the ground.

   Torque: 75 N.m (765 kgf.cm, 55 ft.lbf) 

   HINT:

   There are stamps on the front stabilizer brackets to distinguish between right and left.

   Fig 19: Installing Front Stabilizer Brackets & Front Stabilizer Link Bushes

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 20: Identifying Stamps On Front Stabilizer Brackets

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Fully tighten the bolt on the front stabilizer w/ tube cylinder assy

   Torque: 135 N.m (1,377 kgf.cm, 100 ft.lbf) 

   NOTE: Tighten the bolt with the wheels on the ground.
   Fig 21: Tightening Front Stabilizer With Tube Cylinder Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Fully tighten the bolt on the front stabilizer link assy.

   Torque: 130 N.m (1,326 kgf.cm, 96 ft.lbf) 

   NOTE: Tighten the bolt with the wheels on the ground.
   Fig 22: Tightening Front Stabilizer Link Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Support the stabilizer bar rear with a jack. Place a wooden block between the jack and the stabilizer bar rear to prevent damage.

   HINT:

   Place the jack under the left side of the vehicle.

   Fig 23: Supporting Stabilizer Bar Rear With Jack

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a socket hexagon wrench (8 mm), connect the stabilizer bar rear with the 4 bolts and 2 rear stabilizer brackets lower.

   Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 

   Fig 24: Connecting Stabilizer Bar Rear & Rear Stabilizer Brackets Lower

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Lower the vehicle.
   1. Place the 4 wheels on the ground with the SST connected.
      NOTE:

      • Pay attention to the SST while lowering the vehicle.
      • Ensure that the jack and lift are completely separated from the vehicle.
2. Set charging pressure to within the specified range.
   1. Charge suspension fluid with the SST.

      Specified charging pressure: 

      • 2.60 to 3.00 MPa at 20°C (68°F) (Fluid temperature) 
      • 2.90 to 3.40 MPa at 35°C (95°F) (Fluid temperature) 
3. Stabilize the vehicle.
   1. Do not perform any operations on the vehicle for 30 seconds or more after charging suspension fluid. The vehicle will stabilize during this time.

1. Check the suspension fluid pressure.

1. Measure the difference in vehicle height between the left and right sides.
   1. For measurement procedures, refer to ON-VEHICLE INSPECTION .
2. Tighten the stabilizer control adapter shutter valves.

   Torque: 14 N.m (140 kgf.cm, 10 ft.lbf) 

   Fig 25: Tightening Stabilizer Control Adapter Shutter Valves

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the SST joints.
   NOTE:

   • Ensure that the stabilizer control adapter shutter valves are completely closed before disconnecting the SST joints.
   • Ensure that no pressure is applied to the SST hoses before disconnecting the SST joints.