KLE LIFT
INSTALLATION INSTRUCTIONS
1996-2003
KIT# TL221
WARNING
Read and understand all instructions, warnings, cau-
tions, and notes in this sheet and in your owners man-
ual before you begin the installation of this coil lift kit.
WARNING
Proper installation of a Performance Automotive
Group coil spring lift kit requires knowledge of the fac-
tory recommended procedures for disassembly and
assembly of original equipment components. We rec-
ommend that the factory shop manual and any special
tools necessary to your vehicle be on hand during the
installation. Installation of this coil lift kit without proper
knowledge of the factory recommended procedures
may affect the performance of these components and
the safety of your vehicle. We strongly recommend
that a certified mechanic familiar with the installation of
similar components install this coil lift kit.
WARNING
Ensure that your vehicle tires are properly blocked and
secured before you begin installation of this coil spring
lift kit.
CAUTION
It is the customer's responsibility to ensure that all
mounting hardware is correctly tightened before, dur-
ing and after use of coil spring lift kit. DO NOT
EXCEED manufacturer's load specifications for your
vehicle. Always operate your vehicle in a safe manner.
If your vehicle is equipped with any type of extra duty
suspension or special towing package, this coil lift kit
may not fit properly. If your vehicle is equipped with
any type of aftermarket springs, lift kits, or bushings.
this coil lift kit may not fit properly.
WARNING
Many states now have laws restricting bumper heights
and vehicle lifts. Local laws should be consulted to
determine if the changes you intend to make to your
vehicle comply with state laws.
WARNING
This coil spring lift kit should only be installed on vehi-
cles in good working condition. Before installation, the
vehicle should be thoroughly inspected for evidence of
corrosion or deformation. This coil lift kit should not be
installed on any vehicle that is suspected to have been
in a collision or misused. Failure to observe this warn-
ing may result in serious personal injury and/or severe
damage to your vehicle.
WARNING
To ensure the Supplemental Restraint System (SRS,
or air bag) is not accidentally deployed during coil /
shackle lift kit installation, always ground yourself and
the vehicle. Do not use power or pneumatic tools.
Exercise extreme caution while working near SRS
sensors and wiring. Do not allow anyone near air bags
during kit installation. Accidental deployment can result
in serious personal injury or death.
WARNING
Always wear eye protection when operating power
tools.
NOTE
Performance Automotive Group recommends using
the Loctite® supplied in the kit on all hardware unless
noted in the instructions.
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.
NOTE
Lift height may vary depending on vehicle configura-
tion, engine size, additional accessories, the factory
suspension package, and vehicles condition.
96-03 2 Tacoma Lift
1
Kit TL221 96-03 2 Tacoma Lift
2
Kit TL221
A. Before you start.
1. Read all warnings and instructions completely and
carefully before you begin.
2. Check to make sure the kit is complete (refer to the
Parts List, Section E).
3. Special tools, such as coil spring compressors, are
required for installation of this coil spring lift kit.
4. Only install this kit on the vehicle for which it is
intended. If anytime during the installation you
encounter something different from what is outlined
in the instructions, call technical support at (928)
636-3175.
5. Park the vehicle on a clean, dry, flat, level surface
and block the tires so the vehicle cannot roll in either
direction.
6. Disconnect both battery cables.
a. Disconnect the negative cable (1) first, then the
positive cable (2) from the battery (3).
B. Get ready to install front axle coil spring
lifts.
1. Lift front axle.
a. Remove two center wheel caps (4) from two
front wheels (5).
b. Loosen five lug nuts (6) each from two front
wheels (5).
c. Position hydraulic jack under frame (7), slowly lift
front of vehicle so that the front passenger tire
(8) is three to five inches off of ground. Position
jack stands under frame just in front of transmis-
sion support cross member (9). Lower frame
onto jack stands. Repeat process for driver side
frame.
d. Remove five lug nuts (6) each and two front
wheels (5) from axles (10).
NOTE
Keep track of hardware quantity and position. Kit parts
are prefaced by the word kit in italics. 96-03 2 Tacoma Lift
3
Kit TL221
2. Remove passenger side shock/strut assembly.
a. Remove three nuts (11) from shock/strut assem-
bly (12) and frame (7).
b. Remove nut (13), washer (14), bushing (15), and
sway bar (16) from sway bar link (17).
c. Remove nut (18), washer (19), and bolt (20)
from lower a-arm (21) and shock/strut assembly
(12).
d. Remove four bolts (22), from lower a-arm (21)
and spindle assembly (23).
NOTE
Newer vehicles are equipped with a single nut, no
bushings, and no washers on the sway bar link. 96-03 2 Tacoma Lift
4
Kit TL221
e. Remove shock/strut assembly (12) from vehicle.
f.
Mark shock/strut assembly (12) from top to bot-
tom as shown for use later in these instructions.
3. Remove passenger side coil spring.
a. Compress coil spring (24), remove nut (25),
washer (26), bushing (27), and bolt plate (28)
from compressed coil spring and shock/strut
(29).
C. Install the kit.
1. Install passenger side kit coil lift spacer.
a. Align the bolts on the bolt plate (28) and kit coil
spacer (30), transfer locating mark from bolt
plate to kit coil spacer.
NOTE
Step B.3.a below, requires the use of coil spring com-
pressors. Note position of coil spring for installation
later in these instructions. 96-03 2 Tacoma Lift
5
Kit TL221
b. Install kit shock bushing (31) on shock/strut (29).
c. Install kit coil spacer (30) on kit shock bushing
(31), compressed coil spring (24), and shock/
strut (29). Ensure kit shock bushing is in center
hole of kit coil spacer. Be sure align all marks.
d. Install kit shock bushing (31), washer (26), and
nut (25) on kit coil spacer (30) and shock/strut
(29).
e. Remove coil spring compressors from coil spring
(24).
2. Install shock/strut assembly passenger side hard-
ware.
a. Install shock/strut assembly (12) on frame (7)
with three kit 7/16 nylock nuts (32). Do not
tighten.
b. Install shock/strut assembly (12) on lower a-arm
(21) with bolt (20), washer (19), and nut (18).
c. Tighten nut (18) to 100 ft.-lb.and kit 7/16 nylock
nuts (32) to 47 ft.-lb.
NOTE
Performance Automotive Group recommends using
Loctite® supplied in the kit for all mounting hardware.
WARNING
Ensure that all OEM or aftermarket bump stops are
installed. Suspension over travel can result in serious
damage or failure of OEM components and aftermar-
ket equipment. 96-03 2 Tacoma Lift
6
Kit TL221
d. Install sway bar (16) on sway bar link (17) with
bushing (15), washer (14), and nut (13).
e. Install lower a-arm (21) on spindle assembly (23)
with four bolts (22). Tighten bolts to 59 ft.-lb.
f.
Repeat steps B.2.a. through C.2.d. for driver
side shock/strut assembly.
3. Finish front axle.
a. Install two front wheels (5) on front axles (10)
with five lug nuts (6) each.
b. Using a hydraulic jack, slowly lift front passenger
side of vehicle so that front tire (8) is three to five
inches off of ground. Remove jack stand from
frame (7). Lower vehicle to ground, repeat pro-
cess for driver side and tighten ten lug nuts (6) to
80 ft.-lb.
c. Install two center wheel caps (3) on two front
wheels (5).
D. Get ready to install rear axle shackle lifts.
1. Lift rear axle.
a. Using a hydraulic jack, slowly lift rear axle (33)
so that two rear tires (34) are three to five inches
off of ground. Position jack stands under frame
(7) just in front of leaf spring perches (35). Lower
frame onto jack stands. Do not remove hydraulic
jack pressure from axle. 96-03 2 Tacoma Lift
7
Kit TL221
b. Remove two bolts (36), washers (37), and
shocks (38) from rear axle (33).
2. Remove rear passenger side shackle hardware.
a. Remove two exhaust bushings (39) from back of
muffler (40) and bushing frame hangers (41).
b. Support exhaust pipe (42), remove exhaust pipe
bushing (43) from exhaust pipe and bushing
frame hanger (41).
c. Adjust rear axle (33) to release pressure from
leaf springs (44) and shackles (45).
d. Remove nut (46) from bolt (47), shackle (45),
and leaf spring (44).
e. Remove nut (48) and shackle (45) from leaf
spring perch (35).
f.
Remove two bushings (49) from leaf spring
perch (35). 96-03 2 Tacoma Lift
8
Kit TL221
3. Install kit lift shackle passenger side.
a. Position two kit greasable bushings (50) in leaf
spring perch (35).
b. Install kit shackle (51) on leaf spring perches
(35) with two kit 18mm USS washers (52), kit
18mm x 160mm bolt (53), and kit 18mm nylock
nut (54).
c. Install leaf spring (44) on kit shackle (51) with
two kit 14mm USS washers (55), kit 14mm x
110mm bolt (56), and kit 14mm nylock nut (57).
d. Tighten bolts (53 and 56) and nuts (54 and 57) to
90 lb-ft.
e. Install two kit exhaust bushings (58) on bushing
frame hangers (41) and back of muffler (40).
f.
Install kit exhaust bushing (58) on bushing frame
hanger (41) and exhaust pipe (42).
4. Install kit lift shackle driver side.
a. Repeat steps D.2.c. through D.3.d. for driver
side rear axle (33).
b. Lift rear axle (33) and install two shocks (38) on
rear axle with two washers (37) and bolts (36).
NOTE
Performance Automotive Group recommends using
Loctite® supp