Body/Frame - Radiator/Horn Mounts Cracking
T-SB-0032-12February 2, 2012
Radiator & Horn Mounts Cracking
Service Category
Vehicle Exterior
Section
Body Structure
Market
USA
Applicability
Introduction
Some 2007 - 2012 model year Tundra vehicles may exhibit a condition where cracking develops around the horn and/or radiator mounting locations on the core support. This may occur under continuous or frequent off highway driving conditions. Support brackets have been developed to reinforce the horn and radiator mounting location areas and address this condition.
Parts Information
Required Tools & Equipment
Warranty Information
Repair Procedure
Install the support brackets from the service part information list to reinforce the affected area(s).
Refer to the Standard Bolt Torque Specification list located in the repair manual for proper torque values unless otherwise specified below.
^ 2007 / 2008 / 2009 / 2010 / 2011 / 2012 Tundra:
General - Specifications - Standard Bolt - "Specified Torque For Standard Bolts"
1. Remove both horn assemblies from vehicle.
2. Drill out the spot welds that attach the broken horn bracket reinforcement to the upper radiator core support as shown. After welds are drilled out, enlarge hole using a 10 mm diameter drill.
3. Using the Bracket, Horn Mounting No.2 (P/N 53236-0C010) as a guide (identified by the dimple mark on the bend area), mark the locations of the top two holes to be drilled into the upper core support. Drill out the holes using a 10 mm diameter drill.
NOTICE
Do NOT drill into the engine room main wire harness that runs behind the core support.
4. To prevent corrosion, use automotive grade paint primer to coat the edges of the holes that were drilled into the upper core support. It is recommended to use a brush-on primer in order to provide a more accurate application. The core support should appear similar to the photo in Figure 2.
NOTE
Prior to bracket reinforcement installation, confirm mounting surfaces are flush and level. See figure.
5. Using two of the M6 X 18 Bolts (P/N 90105-A0144), attach the Bracket, Horn Mounting No.2, washers (P/N 90201-06005, 3 per bolt), and Bracket, Horn Mounting No.3 (P/N 53237-0C010) to the upper radiator core support through the holes in the horizontal portion of the core support. Use two M6 nuts, (P/N 90178-A0026) to secure the bolts.
6. Using two of the M6 X 14 bolts (P/N 90080-11427), attach the Bracket, Horn Mounting No.2 and Bracket, Horn Mounting No.3 to the vertical section of the upper radiator core support. Use two M6 nuts (P/N 90178-A0026) to secure the bolts.
7. Attach the horn assembly to the newly added reinforcement brackets using the same bolt that originally secured the horn assemblies (P/N 90080-11256); Secure the bolt using an M8 nut (P/N 90178-A0062). The completed assembly should appear as shown, repeat process for second horn assy.
Torque: 20 N*m (204 kgf*cm, 15 ft*lbf)
Radiator Bracket Reinforcement Installation Procedure (P/N 53210-0C010 and 53220-0C010)
1. Remove the plastic radiator side deflectors for LH and RH side (See Figure 4). If oil cooler is present it will be on the passenger side of the vehicle and must be unbolted and pulled towards the front of the truck. Fluid hoses may stay connected.
2. Remove the top mounting bolts from the radiator.
3. Unclip the engine room main wire harness from the front body mounting reinforcement.
4. Temporarily set the reinforcement brackets into place to mark the holes that need to be drilled. Drill two 10mm diameter holes into the upper core support.
NOTE
The bracket holes that can be used to mark the location of the holes to be drilled into the upper core support are shown (holes 3 and 4).
5. To prevent corrosion, use automotive grade paint primer to coat the edges of the holes that were drilled into the upper core support. It is recommended to use a brush-on primer in order to provide a more accurate application. The core support should appear similar to the photo in Figure 2.
6. Using two M8 x 14 mm bolts (P/N 91551-A0814) attach the radiator bracket through holes 1 and 2 from above picture to Front Body Mounting Reinforcement. Use two 8 mm nuts (P/N 90178-A0062) to secure.
7. Use one M6 x 12 mm bolt (P/N 90105-A0069) to attach the bracket to the Front Body Mounting Reinforcement through hole 5. Use a 6 mm nut (P/N 90178-A0026) to secure.
8. Use two M8 x 14 mm bolts (P/N 91551-A0814) to attach the bracket to the upper core support through holes 3 and 4. Use two 8 mm nuts (P/N 90178-A0062) to secure.
9. Use the original radiator bolt to re-secure the radiator to the new bracket through hole 6. The completed assembly should appear as shown (passenger side shown, looking towards front of vehicle).
Torque: 18 N*m (184 kgf*cm, 13 ft*lbf)
10. Reinstall radiator side deflectors and oil cooler assembly if removed in Step 2.
11. Re-clip engine harness to hole that was unclipped in Step 4.
12. Repeat procedure for second bracket.