Toyota Landcruiser SC 2400x1840 SGF TRAY BODY User manual

© Toyota Motor Corporation Australia Ltd. 2011. All rights reserved.
REPAIR MANUAL REFERENCE LANDCRUISER - Steel S/Cab Tray Body ISSUE: 27/07/2012 Page
Refer to ServiceNet Accessory Part No.: PZQ8460320 Fitting Instr. Part No.: PZQ8460320-FI 1 of 35
FITTING INSTRUCTIONS FOR
SC 2400x1840 SGF TRAY BODY
PART NUMBER: PZQ8460320
PRODUCTION DATE : SEPT 2012 ONWARDS
LANDCRUISER
PZQ8460320 - SC 2400x1840 Steel Galvanized; Flat Floor (SGF) TRAY BODY

© Toyota Motor Corporation Australia Ltd. 2011. All rights reserved.
REPAIR MANUAL REFERENCE LANDCRUISER - Steel S/Cab Tray Body ISSUE: 27/07/2012 Page
Refer to ServiceNet Accessory Part No.: PZQ8460320 Fitting Instr. Part No.: PZQ8460320-FI 2 of 35
GENERAL NOTES and CAUTIONS
General Notes
 Read the fitting instructions prior to accessory fitment.
 Install this accessory following the fitting instructions. Failure to follow these fitting instructions could result in
vehicle or accessory damage.
 Ensure all recyclable discarded vehicle or accessory components and packaging are recycled following local
recycling regulations.
General Vehicle and Accessory Warranty Notes and Cautions
 For correct installation and proper operation of the vehicle and accessory, Toyota Motor Corporation Australia
Ltd. recommends that this accessory is installed by a qualified Toyota Technician.
 During the accessory fitment ensure all Australian automotive safety practices and regulations are followed.
 Do not modify the vehicle in any way other than specified in these accessory fitting instructions as this may void
the warranty.
General Vehicle Notes and Cautions
 Inspect the vehicle and note any damage or concerns found prior to accessory fitment.
 If damage or concerns are found that interfere with the installation of the accessory, inform the dealer or customer
prior to the accessory fitment.
 Ensure special care is taken and the applicable repair manual is followed to prevent damage to the vehicle
and/or vehicle components.
 Protect and safely store any removed vehicle components.
 Ensure all bare metal surfaces are protected using Automotive Bare Metal Primer and Toyota Touch-Up Paint.
 Ensure metal swarf and dust is removed from all vehicle surfaces.

© Toyota Motor Corporation Australia Ltd. 2011. All rights reserved.
REPAIR MANUAL REFERENCE LANDCRUISER - Steel S/Cab Tray Body ISSUE: 27/07/2012 Page
Refer to ServiceNet Accessory Part No.: PZQ8460320 Fitting Instr. Part No.: PZQ8460320-FI 3 of 35
GENERAL NOTES and CAUTIONS
Tray Body General Notes and Cautions
 Minimum allowable gaps between chassis and tray body protrusions must be no less than 10mm.
 It is advisable to seek assistance from another person when lifting heavy components.
 Do not repair or modify this accessory in any way as this will void the warranty.
 Do not remove any of the accessory labels unless instructed in the accessory fitting instructions.
 This accessory is designed for vehicles sold new in Australia by Toyota Motor Corporation Australia Ltd. and may
be unsafe if used on any other vehicle.
 Ensure there is adequate room for fuel filler nozzles to access the vehicles fuel filler hose.
 Clean the tray body using only PH neutral cleaners and a soft, not abrasive cloth/sponge.
Tray Body Ratings
MAXIMUM LOADING CAPACITIES
Tray Body Deck: Vehicle payload capacity (minus accessories) (Refer Owners manual)
Headboard & Rear Rack: 150Kg (total weight shared over both headboard and rear rack)
Load Restraint Rails: (Lesser Value) 450Kg or Strap load capacity
*Maximum loading only applies to vehicles sold new in Australia by Toyota Motor Corporation Australia Ltd.
Check that all work practices comply with safety standards.
Please wear appropriate clothing and use personal protection equipment.
Fitting Time: 2:00
Hours : Minute Need assistance?
Toyota Genuine Accessory fitting time are provided as a guide only and are
based on the third time accessory installation time attained by a Toyota
Technician following the Toyota Service Management requirements. Toyota
Genuine Accessory fitting times are for the installation of the Toyota Genuine
Accessory only and do not include administration or vehicle processing time.
OE - Original Equipment
Toyota Dealer Enquiry:
Please contact TMCA Dealer Support
Group
Customer Enquiry:
Please contact your local Toyota Dealer, or
Toyota’s Customer Experience Centre
1800 TOYOTA (869 682)
2:30
Hours : Minute
(With Under Body
Tyre Hanger Option)

© Toyota Motor Corporation Australia Ltd. 2011. All rights reserved.
REPAIR MANUAL REFERENCE LANDCRUISER - Steel S/Cab Tray Body ISSUE: 27/07/2012 Page
Refer to ServiceNet Accessory Part No.: PZQ8460320 Fitting Instr. Part No.: PZQ8460320-FI 4 of 35
KIT CONTENTS
Kit 9PSTF240CSN: Tray Deck Assembly Kit
Item Description Qty
1 Deck Assembly - Galvanized Floor 1
2 Hinge Pin 8
3 M8x20 Hex Bolt 8
4 M8 Nyloc Nut 8
1
2
3
4
Note: Hinge Pins are pre-assembled to painted tray bodies
Kit 9PSHC64G2H / 9PSS03005: Headboard & Corner Post Step Kit
Item Description Qty
9PSHC64G2H Headboard Kit
1 Headboard Bow 1
2 Headboard Panel 1
3 Headboard Gusset - Right Hand 1
4 Headboard Gusset - Left Hand 1
5 Headboard Latch 2
6 3/8” Cone Lock Nut 2
7 3/8” x 5/32” x 3/32” Spring Washer 4
8 3/8” x 3/4” x 16G Round Washer 2
9PSS03005 Corner Post Step Kit
9 Corner Post Step - Left Hand 1
10 Corner Post Step - Right Hand 1
11 M8 16G Round Washer 28
12 M10x55 Hex Bolt 4
13 M10x25 Hex Bolt 4
14 M10 Nyloc Nut 8
15 M8x20 Hex Bolt 20
16 M8x30 Hex Bolt 4
17 M8 Nyloc Nut 24
1
16
5
9
14
3
4
15
13
12
67
118
2
10
17
Kit 9PMKT44: Mounting Kit
Item Description Qty
Loose Items
1 1218-119 Mount Rail 3
2 105-130 External Mount 6
3 105-130 Mount Leg 2
4 Fuel Bracket 1
Bolt Bag
5 Mount Lug 8
6 Mount Brace RH 1
7 Mount Brace LH 1
8 M12x30x4mm Round Washer 4
9 M12x38x4mm Round Washer 22
10 M12 Nyloc Nut 24
11 M12x40 Hex Bolt 20
12 M12x25 Hex Bolt 4
13 M8x20 Hex Bolt 2
14 M8 Nyloc Nuts 2
15 Spiral Wrap 1
16 Cable Tie 1
13
9
12 10
1
8
11
32
6
5
7
414
15
16

© Toyota Motor Corporation Australia Ltd. 2011. All rights reserved.
REPAIR MANUAL REFERENCE LANDCRUISER - Steel S/Cab Tray Body ISSUE: 27/07/2012 Page
Refer to ServiceNet Accessory Part No.: PZQ8460320 Fitting Instr. Part No.: PZQ8460320-FI 5 of 35
KIT CONTENTS - Continued
Kit 9PRK92NP: Rope Rail Kit
Item Description Qty
1 450mm Multi-fit Rope Rail 1
2 600mm Multi-fit Rope Rail 3
Bolt Bag
3 40x34x3mm Rope Rail Washer 8
4 M8x20 Hex Bolt 8
5 M8 Nyloc Nut 8
1
3
4
5
2
Kit 9PBKT73: Body Kit
3
2
15 14
16
11
12
10
9
Item Description Qty
Loose Items
1 Tail Light Bracket 2
2 PP guard bracket LH 4
3 PP guard bracket RH 4
4 Tail Light Wiring Harness Patch (2EH02) 2
5 Registration Plate Light Wiring Patch (2EH04) 2
6 Reflector Bracket (suits GPA and GPS trays) 2
7 Reflector Bracket (suits HDA and HDS trays) 2
8 Retro Reflector 2
Bolt Bag
9 Saddleclip [8x13] Slegers BLUE 6
10 Cable Ties 300 4.8mm Black 2
11 1/4x1 1/4 Mudguard Washer 6
12 1/4x3/4x16G Bright Steel Washer 38
13 M6x35 Pan Head Screw 2
14 M6x25 Hex Bolt 6
15 M6x16 Set Screw 38
16 M6 Nyloc Nut 44
4
5
68
7
13
1
Kit 9PGKT41: Guard Kit
Item Description Qty
Loose Items
1 PP Mudguard front 2
2 PP Mudguard rear 1
3 PP Mudguard rear Cutout LH 1
4 Mudflap - Toyota 355x297 1
5 Mudflap -Toyota LH cutout 355x297 1
3
1
2
4
5
1

© Toyota Motor Corporation Australia Ltd. 2011. All rights reserved.
REPAIR MANUAL REFERENCE LANDCRUISER - Steel S/Cab Tray Body ISSUE: 27/07/2012 Page
Refer to ServiceNet Accessory Part No.: PZQ8460320 Fitting Instr. Part No.: PZQ8460320-FI 6 of 35
KIT CONTENTS - Continued
Kit 9PSD240CNT: Dropside & Tailgate Kit
Item Description Qty
Loose Items
1 Dropside Left Side - partial assembly 1
2 Dropside Right Side - partial assembly 1
3 Tailgate - full assembly 1
4 Toyota Rear Decal 1
Bolt Bag
5 Hinge Strap 6
6 M6x16 Set Screw 12
7 M6 Nyloc Nut 12
8 E Clip 4
Note: Dropsides are fully assembled for painted tray bodies
2
1
3
5
67
4
8
Kit 9PTHHT22: Head Board Tyre Hanger Kit
Item Description Qty
Loose Items
1 HBTH Tyre Hanger Bracket 1
2 Number Plate Bracket (suit GPA,HDA Alloy trays) 1
3 Number Plate Bracket (suit SGF, SGC Steel trays) 1
4 Number Plate Extension Bracket 1
Bolt Bag
5 M10x25 Hex Bolt 2
6 M10 Nyloc Nut 2
7 M14 Flat Washer 1
8 M14x170 Hex Bolt (Steel Tyre) 1
9 M14x200 Hex Bolt (Alloy Tyre) 1
10 M8x20 Hex Bolt 2
11 M8 Nyloc Nut 2
12 M6x16 Set Screw 7
13 M6 Nyloc Nut 7
8
5
7
1
6
9
11
3
4
12
10
9
2

© Toyota Motor Corporation Australia Ltd. 2011. All rights reserved.
REPAIR MANUAL REFERENCE LANDCRUISER - Steel S/Cab Tray Body ISSUE: 27/07/2012 Page
Refer to ServiceNet Accessory Part No.: PZQ8460320 Fitting Instr. Part No.: PZQ8460320-FI 7 of 35
KIT CONTENTS - Continued
Kit 9PTHUT13: Under Body Tyre Hanger Kit
Item Description Qty
Loose Items
1 Front Hanger LH 1
2 Front Hanger RH 1
3 Side Rail LH 1
4 Side Rail RH 1
5 Front Bearer 1
6 Centre panel 1
7 Rear Bearer 1
8 Gate 1
9 Gate Bolt 1
10 Rear Hanger LH 1
11 Rear Hanger RH 1
12 Number Plate Bracket 1
13 Tyre spacer (wide tyre) 1
14 Lynch Pin and Chain 1
Bolt Bag
15 *Packer 50x65x12mm 8
16 1/4x3/4x16G Bright Steel Washer 4
17 M12x38x4mm Washer 2
18 *M12x50 Hex Bolt 8
19 M12x40 Hex Bolt 2
20 M10x25 Hex Bolt 10
21 M10x20 Hex Bolt 12
22 M8x20 Hex Bolt 2
23 M6x16 Hex Bolt 3
24 M12 Nyloc Nut 10
25 M10 Nyloc Nut 22
26 M8 Nyloc Nut 2
27 M6 Nyloc Nut 3
14
9
8
11
12
6
7
4
13
5
1
3
10
2
18 19 20 21
22 23 24 25 26 27 16 17
15
* Component to be used with Mount Kit UBTH option

© Toyota Motor Corporation Australia Ltd. 2011. All rights reserved.
REPAIR MANUAL REFERENCE LANDCRUISER - Steel S/Cab Tray Body ISSUE: 27/07/2012 Page
Refer to ServiceNet Accessory Part No.: PZQ8460320 Fitting Instr. Part No.: PZQ8460320-FI 8 of 35
TRAYBODY ASSEMBLY
COMPONENTS :
Item Description Qty
ADeck Assembly (Galvanized) 1
BHeadboard Kit 1
CCorner Post Kit 1
DDropside Assembly 1
EMount Kit 1
FRail Kit 1
GBody Kit 1
HGuard Kit 1
FIXINGS :
Description H/T Class Torque
M6 Countersunk Screw - 9Nm
M6 Set Screw 8.8 9Nm
M6 Hex Bolt 8.8 9Nm
M6 Pan Head Screw - 9Nm
M8 Hex Bolt 8.8 23Nm
M10 Hex Bolt 8.8 45Nm
M12 Hex Bolt 8.8 79Nm
M6 Nyloc Nut - -
M8 Nyloc Nut - -
M10 Nyloc Nut - -
M12 Nyloc Nut - -
A
D
B
C
H
G
F
G
H
H
E

© Toyota Motor Corporation Australia Ltd. 2011. All rights reserved.
REPAIR MANUAL REFERENCE LANDCRUISER - Steel S/Cab Tray Body ISSUE: 27/07/2012 Page
Refer to ServiceNet Accessory Part No.: PZQ8460320 Fitting Instr. Part No.: PZQ8460320-FI 9 of 35
TOOLS REQUIRED
1Screwdriver - Phillips 2Screwdriver - Flat 3Torque Wrench
4Ratchet 5Ratchet Extension 6Socket
- 10; 12; 13; 14; 16; 18; 19mm
7Spanner
- 10; 12; 13; 14; 16; 18; 19mm
8Tape Measure 9Drill Bit
Ø 8.5mm
10 Cordless Drill 11 Builders Square

© Toyota Motor Corporation Australia Ltd. 2011. All rights reserved.
REPAIR MANUAL REFERENCE LANDCRUISER - Steel S/Cab Tray Body ISSUE: 27/07/2012 Page
Refer to ServiceNet Accessory Part No.: PZQ8460320 Fitting Instr. Part No.: PZQ8460320-FI 10 of 35
IMPORTANT - Wrap tail lights in a clean cloth to prevent
damage while storing
STEP
2
Unplug, then unbolt the tail light assemblies from the
chassis and discard the fixings.
Remove the tail lights from the temporary tail light
brackets and retain the tail lights, screws and white
plastic retainers in a safe area for later use.
Discard the original tail light brackets.
Unplug and unwind
harness
Remove and
discard fixings
Original Tail
Light Bracket
IMPORTANT - Take care not to damage any components
of the vehicle
STEP
1
Using a 17mm socket, remove the spare tyre from the
vehicle chassis, as shown in adjacent diagram.
Remove and discard Steel Frame and “J” Bolt from
underneath tyre.
Disconnect wiring harness from registration plate
bracket.
Remove registration plate bracket from chassis and
set aside for later fitment.
IMPORTANT - Take care not to damage any components
of the vehicle
STEP
3
Unbolt the fuel filler from the temporary bracket
mounted to the chassis pad.
Discard the original fuel bracket.
Original fuel Bracket
Chassis Mount Pad
Remove and
discard fixings