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INSTALLATION STEPS:
1) Begin by unpacking and removing all components and hardware. Please verify that all
hardware, components, and mounting components are present. Please reference your
original order invoice and verify all items are accounted for.
a. PLEASE NOTE: If your vehicle is a trim level other than a TRD Off-Road or TRD
PRO, you will most likely need to replace the OEM fuel tank straps. If you are
replacing your OEM smooth fuel tank straps with OEM studded fuel tank straps
and these components were ordered from RCI or TOYOTA; please verify that the
part numbers in the Mounting Components Table match the part numbers on the
Toyota applied ID stickers.
b. SAFETY NOTE: Installation of fuel tank skid plate and fuel tank straps (if
applicable) should only be completed when the fuel tank is near empty! We
recommend as low as possible (this may vary based on your proximity to a fuel
station).
c. Begin on Step 2: if you are replacing the OEM smooth fuel tank straps.
d. Begin on Step 5: if you are only installing the fuel tank skid plate to your existing
OEM studded straps.
2) Replacement of the OEM fuel tank straps is very simple. Support of the fuel tank may
be necessary using a floor jack, jack stand, or wood board. Beginning with the rear
strap already mounted on your vehicle, loosen the retaining bolt securing the strap near
the outside of the vehicle. Once this fastener is removed, the strap should pivot freely
toward the inside of the vehicle. Locate the second mounting point and identify the pin
that allows the strap to hinge. A hairpin cotter should be in place at the end of the hinge
pin. Remove the cotter and tap the hinge pin out of the hinge.
3) Identify the replacement Studded Fuel Tank Strap (77602-040-20) and reverse the guide
in step 2.
a. After completion of steps 2-3 for the rear strap, repeat steps 2-3 for the front
strap(77601-040-20).
4) Verify secure installation of both studded fuel tank straps on the vehicle. Check that all
strap retaining bolts are snug and tightened to 30 ft/lbs.
5) If the vehicle is equipped with an OEM plastic fuel tank skid plate, this plate can be
easily removed by loosening the four hex nuts present. Two will be present at the front
and rear. These OEM hex nuts and washers can be discarded along with the existing
OEM fuel tank skid plate.
6) Align the new RCI Fuel Tank Skid Plate(C1) with the “notched” portion of the skid plate
towards the rear of the vehicle. Due to the size and weight of the skid plate, a floor jack,
stool, cooler, or helping hand may be needed. Attach one 5/16th washer(H2) and one M8
Nylon Locking Nut(H1) to the threads of the rear studded fuel tank strap. DO NOT
TIGHTEN. Once both studs in the center are secured, proceed to the front studs.
