Performance 5613 Installation Instructions Manual Download Page 25

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‘05 - ‘06 Tacoma (W/ O.E. Hitch) - 3” Kit 5613

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.

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.

Install kit

plates

(radiator block off) to radiator

with four factory pop-up clips.

Kit

Washer

(1/4” SAE),
Kit

Nut

(1/4” Nylock)

Kit

Bracket

(3” Radiator)

Kit

Plates

(Radiator
Block Off)

Kit

Bolt

(1/4” x 1”),
Kit

Washer

(1/4” SAE),
Kit

Nut

(1/4” Nylock)

Kit

Plates

(Radiator
Block Off)

Factory
Pop-up Clips

Install radiator cover to core support with five
factory pop-up clips.

Install radiator cover to kit

plates

(radiator block

off) with four kit

clips

(push) and four kit

wash-

ers

(1/4” SAE).

Adjust radiator and ensure fan does not contact
fan shroud.

TIGHTEN all hardware.

Radiator
Cover

Factory
Pop-up Clips

Core
Support

Kit

Clip

(Push),
Kit

Washer

(1/4” SAE)

Radiator
Cover

Summary of Contents for 5613

Page 1: ... installed on a vehicle that is in good working condition Before you install the kit thor oughly 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 W...

Page 2: ... in either direction Engine Compartment 1 Disconnect both battery cables Disconnect nega tive cable first then positive cable NOTE Kit parts are prefaced by the word kit and appear in bold print NOTE If parts are missing from kit please be prepared to pro vide 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 f...

Page 3: ...ess Fog Light Bolts Pop up Clips Grill Pop up Clips Front Bumper Fascia d Remove two pop up clips from fender wells e Remove six screws and front bumper fascia from vehicle f Remove six nuts and front bumper from vehicle NOTE Use caution when removing front bumper fascia from vehicle Carefully pull outward from fenders on the sides of front bumper cover to loosen Fender Well Front Bumper Pop up Cl...

Page 4: ...mp Clips Airbox Cover AC Line Bolt AC Line Bracket b Remove two nuts clamp and rubber isolator from AC line and bracket 3 6 cyl models Remove power steering reservoir three bolts and bracket from fender DO NOT DIS CONNECT power steering lines 4 4 cyl models Loosen two engine intake clamps and remove engine intake hose 5 4 cyl models Remove bolt from passenger side AC line bracket Clamp Nuts AC Lin...

Page 5: ...er AC line from two clips and passenger side body 8 Remove vent tubes from driver side body bracket AC Line Bracket Nut AC Line Clip Passenger Side Body AC Line Bracket Vent Tubes Battery 9 Remove heater hoses from clip on backside of engine 10 Remove wire harness clip from firewall and bracket Heater Hoses Clip Clip Wire Harness Bracket ...

Page 6: ...Harnesses Driver Side Passenger Side Battery Body Bracket Wire Harness Alternator Bracket 13 Radiator a Remove nine pop up clips and radiator cover from core support b Remove four bolts and radiator from core sup port Allow radiator to hang on core support by tabs NOTE Lower the radiator onto the frame prior to the lifting pro cedures Pop up Clips Radiator Cover Core Support Radiator Bolts Core Su...

Page 7: ...RS or airbag must remain deactivated Do not allow anyone near the airbag dur ing 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 clock spring could be damaged Do not turn the steering wheel while ...

Page 8: ...res may vary depending on cab model for access to rear body mount bolt access covers Dead Pedal Kick Panel Kick Panel Carpet Body Mount Bolt Access Cover 3 Extended cab models Rear interior trim panels a Fold down rear seats b Open floor storage tray and remove jack c Remove pop up clips and storage tray from vehicle d Pull carpet up to expose driver and passenger body mount access plates Rear Sea...

Page 9: ...e bolts and pop clips from driver side rear panel and cab Access Plate Carpet Bolts Rear Access Cover Driver Side Rear Panel Bolts c Remove bolt and pop clips from passenger side rear panel and cab d Remove driver and passenger body mount bolt access covers Underside of Vehicle 1 Remove all clips and two driver side engine guards from driver side wheel well 2 Repeat above step for passenger side P...

Page 10: ...ble brackets from crossmember Driver Side Bolt Brake Line Passenger Side Driver Side Passenger Side Parking Brake Cable Bolt Bracket Parking Brake Cable Crossmember 5 Remove two nuts and fuel line brackets from driver side body 6 Remove bolt and brake line bracket from driver side frame Front Rear Fuel Lines Bracket Nut Nut Fuel Lines Frame Brake Line Bracket Bolt ...

Page 11: ...el immediately A spark could cause an explosion or fire resulting in seri ous personal injury and property damage Fuel Filler Cap Body Fuel Filler Vent Hose Clamp Front Fuel Tank Fuel Filler Bolt Frame 2 Rear bumper a Remove rear bumper wire harness from driver and passenger frame b Remove two license plate lights from rear bumper c Remove four bolts and rear bumper from O E trailer hitch brackets...

Page 12: ...ifting 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 care ful of the a c hoses at the fire wall the belt pulley and at the core support...

Page 13: ...on core support cab mount DO NOT TIGHTEN Kit Block 2 Dia Upper Bushing Front Cab Mount Kit Block 3 Dia Upper Bushing Mid Cab Mount Rear Cab Mount Kit Block 3 Dia Upper Bushing Kit Bolt 3 8 x 8 Front Cab Mount g Install factory mid captive washer and kit bolt M12 1 75 x 200mm on cab mount DO NOT TIGHTEN h Install factory rear captive washer and kit bolt M12 1 25 x 210mm on cab mount DO NOT TIGHTEN ...

Page 14: ...ry lower washers and kit nuts 12mm Nylock Tighten kit bolts to 55 ft lbs Kit Bolt 3 8 x 8 Kit Nut 3 8 Nylock Factory Captive Washer Lower Washer Front Cab Mount Mid Cab Mount Kit Bolt M12 1 75 x 200mm Kit Nut 12mm Nylock Factory Captive Washer Lower Washer 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 f...

Page 15: ...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 NOTE The factory captive washers will be used with kit bolts Remove Bolts At These Mounts Bolts Factory Bed Mount Bolt Captive Washer c Install kit blocks 2 dia on frame mounts ...

Page 16: ...r 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 Tow ing after the bumper has been lifted should be accom plished using a rated Class III receiver type hitch Install...

Page 17: ...er Hitch 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 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 g Install kit bracket rear bumper mid...

Page 18: ...ht Wire Harness Frame k Install kit tie zip to rear crossmember and bumper wiring harness l Set bumper to previous bed to bumper mea surements m TIGHTEN all rear bumper hardware 2 Fuel filler a Mark fuel filler tubes with cut and alignment lines b Cut fuel filler on cut lines c Deburr edges of cut tubes WARNING Use extreme caution when working near the fuel lines and the fuel tank Clean up spilled...

Page 19: ...th two kit clamps 20 hose DO NOT TIGHTEN Kit Extension 1 4 x 6 Kit Clamps 6 Hose Breather Tube Kit Extension 5 8 x 6 Kit Clamps 10 Hose Vent Tube Kit Extension 1 x 6 Kit Clamps 20 Hose Filler Tube g Install fuel filler onto fuel tank with two factory hose clamps and factory clip DO NOT TIGHTEN h Install factory bolt onto frame and fuel filler i Adjust fuel filler and or kit extensions hose to body...

Page 20: ...member d Install passenger side parking brake cable to kit bracket with kit nut 1 4 Nylock and kit washer 1 4 SAE 2 Fuel lines a Install kit bracket 2 stand off to driver side stud with factory nut 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 c Install kit bracket 3 Z shaped to driver side stud with factory nut d Instal...

Page 21: ...side of Vehicle 1 Extended cab models Rear interior trim panels a Install body mount access covers Frame Brake Line Bracket Bolt Kit Bolt 1 4 x 1 Kit Washers 1 4 SAE Kit Nut 1 4 Nylock Factory Bolt Kit Bracket 2 Z Shaped Brake Line Bracket Access Cover b Install driver and passenger body mount access plates and bolts c Lay carpet down to cover driver and passenger body mount access plates d Instal...

Page 22: ...bolts d Return seatbacks to upright position and install three headrests onto seatbacks Access Cover Passenger Side Rear Panel Bolt Driver Side Rear Panel Bolts 3 Front interior trim panels a Install driver and passenger body mount bolt access cover b Lay carpet down to cover driver and passenger body mount access covers c Install driver and passenger kick panels d Install dead pedal Carpet Body M...

Page 23: ...ne 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 e Weld kit extension manual shifter in place f Grind off any excess welds g Install plastic cap to end of shift lever h Install shifter lever i Install shift and center consoles WARNING Welding should be performed by...

Page 24: ...en to 33 lb ft WARNING Verify the steering extension is securely installed as specified in the instructions Failure to do so may cause steering malfunction resulting in property dam age or serious personal injury Kit Extension Steering Upper Steering Shaft Steering Coupler Bolts Kit Extension Steering Alignment Mark Lower Steering Shaft Kit Bolt 3 8 x 1 1 4 Alignment Mark 2 Radiator a Cut off tabs...

Page 25: ...up clips Kit Washer 1 4 SAE Kit Nut 1 4 Nylock Kit Bracket 3 Radiator Kit Plates Radiator Block Off Kit Bolt 1 4 x 1 Kit Washer 1 4 SAE Kit Nut 1 4 Nylock Kit Plates Radiator Block Off Factory Pop up Clips f Install radiator cover to core support with five factory pop up clips g Install radiator cover to kit plates radiator block off with four kit clips push and four kit wash ers 1 4 SAE h Adjust ...

Page 26: ...e body bracket with kit tie zip Battery Body Bracket Wire Harness Alternator Bracket Kit Tie Zip Bracket Vent Hoses 5 Install driver and passenger brake line wire har nesses to brackets with two kit ties zip 6 Install wire harness clip to firewall bracket 7 Install heater hoses on clip and backside of engine Kit Tie Zip Wire Harness Bracket Clip Wire Harness Bracket Heater Hoses Clip ...

Page 27: ...Steering Lines Clamps Cut Marks Power Steering Lines Cut Marks Front Front f Install kit extension 7 16 OD x 5 L between cut power steering lines with two kit clamps 6 hose DO NOT TIGHTEN g Install kit extension 5 8 OD x 5 L between cut power steering lines with two kit clamps 10 hose DO NOT TIGHTEN h Install power steering reservoir lines clamps and three bolts onto vehicle i Adjust hoses and tig...

Page 28: ...ator and passenger side AC line bracket with nut AC Line Nut Rubber Isolator Clamp Install Kit Bracket 3 Z Shaped Here AC Line Bracket Nut AC Line Install Kit Bracket 3 W Stud Here Rubber Isolator AC Line Bracket d Install AC line to kit bracket 3 w stud with kit washer 1 4 SAE and kit nut 1 4 Nylock 12 6 cyl models Install airbox cover to engine with two clips Tighten clamp 13 4 cyl models Instal...

Page 29: ... Kit Bolts 3 8 x 1 Kit Washers 3 8 USS Kit Nuts 3 8 Nylock Front Bumper Kit Bracket Front Bumper Front Bumper Fascia Screws d Install two pop up clips to fender wells e Install five pop up clips to front bumper f Install two pop up clips two bolts and grill to core support g Install wiring harnesses to fog lights if equipped h Adjust bumper and tighten all hardware Fender Well Front Bumper Pop up ...

Page 30: ... All body lift components should be visually inspected and fasteners retorqued during routine vehi cle 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 warn ings related to ...

Page 31: ...31 05 06 Tacoma W O E Hitch 3 Kit 5613 Accessories The following accessories are also available Kit 6337 Gap Guards ...

Page 32: ... 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 Extension steering Qty Description 1 HP5613 Hardware Bag 2 Bolt 1 2 x 1 7 Bolt 1 4 20 x 1 2 Bolt 9 16 x 1 1 2 1 Bracket 2 stand off 2 Bracket 2 Z shaped 7 Bracket 3 radiator w stud 2 Bracket 3 Z shaped 4 Clamp 10 hose 2 Clamp 20 hose 4 Clamp 6 hose 4 Clip push 1 Extension 5 8 O...

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Performance 5613, Installation Instructions Manual

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