Kit
For 1995.5-2004 Toyota Tacoma, 1996-2002 Toyota 4Runner & 2000-2006 Toyota Tundra/Sequoia


WARNING:
This procedure is moderately difficult. DO NOT ATTEMPT if you dont have decent
automotive mechanical knowledge, proper tools or you dont pay attention to details.
Before starting, read through the entire procedure thoroughly. If you feel competent
enough to handle this, take your time and follow the instructions carefully. If you feel
that you are not capable of completing any of the steps, call TOTAL CHAOS to assist
you with other options to help you install these items.



Tools Required for install: Propane
torch Pliers Pry
bar Mallet Alignment pin (to align bolt holes) 22mm Wrench & Socket 19mm Wrench & Socket Ratchet Safety
Glasses Gloves






ATTENTION:

Ensure there is a full, working fire extinguisher
(ABC classified) near you while performing
this procedure.

Always wear safety glasses or some form of
eye protection.



TOTAL CHAOS Fabrication Inc. is not responsible for any damage or injury that occurs while performing this procedure. These
instructions are offered as a guide to assist our customers. It is the customers responsibility to judge their competence on
completing this procedure. TOTAL CHAOS Fabrication Inc. manufactures and sells products intended for off-road use only and
carry no warranty whatsoever. Due to a number of factors, including but not limited to, driving conditions, terrain, driver
competence, quality of installation, vehicle maintenance, vehicle condition, and vehicle modifications, the customer releases
TOTAL CHAOS Fabrication Inc. from any liability caused by product or installation failure.


Ensure the vehicle is on level ground before beginning.


For all questions, contact TOTAL CHAOS Fabrication @ (951) 737-9682 M-Th 8:00 AM - 5:00 PM

Page: 1/2

1. Before going underneath the vehicle, ensure that the emergency brake is applied, the transmission is
in park (if applicable) and that wheel chocks will keep the vehicle from rolling.

2. Using a socket or wrench, loosen and remove the bolts that attach the rack and pinion to the frame.

3. Pull the rack and pinion back far enough so there is enough room to access the backside of the driver
side bushing. If necessary use a pry bar on the DRIVER SIDE of the rack in between the two
bushings to pull the rack back. Prying on the black side of the rack can cause it to break.

4. The rack will hang by the steering shaft, tie-rods and the power steering hoses. Remove the D-
shaped bushing from the passenger side.

5. ENSURE THERE IS A WORKING ABC CLASSIFIED FIRE EXTINGUSHER NEAR YOU BEFORE
BEGINNING THIS STEP! With a propane torch, heat the metal inner sleeve of the bushings inside of
the rack until the bushing is soft enough that you can remove the inner sleeve with a pair of pliers.
The rubber bushings will smoke and may catch fire.

6. Once the inner sleeves are removed, pull the remaining rubber bushings from the rack with a pair of
pliers. Wipe off any excess rubber from the inside of the holes.

7. Coat the inside and outside of the new rack bushings with a generous amount of grease. Slide the
bushing halves into their proper locations on the rack. Insert the inner sleeves into the rack bushings.
Use a mallet to tap them in until flush with the bushing.

8. Attach the new D-shape bushing (#3) to the rack.

9. Push the rack back into its proper location. Align the center bolt hole (#2) and then insert the bolt.
Attach the cap back onto the D-shaped bushing. Insert driver side bolt (#1) using factory hardware.
(TUNDRA ONLY Put supplied washer between the rack and the frame behind driver side bushing.)

10. Tighten the nuts to the bolts to approximately 80 ft./lbs. of torque.

REV. 01 06/05/07 Page: 2/2