Toyota Tundra 2003 Repair Manual Set (P/N RM956U)

Use the repair procedures for component work, the New Car Features material to understand the changed control systems, and the wiring manual to trace circuits and connector locations.

Automatic transmission overhaul: The diagnostic tables refer internal A340E/A340F clutch-pack and geartrain repairs to the separate RM688U automatic transmission manual, which is not included.

PDF Search, Bookmarks and Diagram Detail

Search and navigation: The PDF has searchable text and embedded bookmarks. Some parent bookmarks return to the first page, and a few subsection links land before their headings. Small wiring labels require zooming, especially on the overall diagram sheets.

One printable PDF contains 2,807 pages, including the New Car Features chapter-cover page and the wiring manual’s unnumbered foreword.

Engine, Drivetrain and Vehicle-System Service

These selected workshop topics preview the contents; further sections cover routine maintenance checks and hood adjustment.

• Engine repair: Compression and valve-clearance inspection, timing-belt replacement, cylinder-head removal and overhaul, separate 2WD/4WD engine removal procedures, and cylinder-block overhaul for both engines.

• Transmission and clutch: Clutch-pedal, master-cylinder and release-cylinder service; clutch-unit inspection and installation; R150/R150F internal repair; and A340E/A340F valve-body, sensor, unit-removal and torque-converter procedures.

• Transfer and driveline: VF2A/VF2BM disassembly, oil-pump and shaft inspection, bearing and seal replacement, propeller-shaft and spider-bearing repair, A.D.D. control checks, and touch-select 2-4/high-low diagnosis.

• Suspension and axles: Wheel alignment, front hubs, drive shafts, front differential carrier, standard/LSD rear differentials, control arms, ball joints, leaf springs and sport-package rear stabilizer service.

• Brakes and steering: Brake hydraulics and friction parts, Load Sensing Proportioning and Bypass Valve testing and adjustment, ABS actuator and speed-sensor work, power-steering pressure tests and bleeding.

• Electrical and body systems: SRS and body electrical troubleshooting, power-window and door-lock controls, power slide back window diagnosis, trailer-towing circuits, and system-specific wiring diagrams.

• Air conditioning and heating: Refrigerant evacuation and charging, leak testing, compressor and magnetic-clutch work, and heater, cooling-unit and blower-unit service.

The troubleshooting material is written for service technicians with an understanding of the systems and basic electrical knowledge; it also calls for suitable scan tools, test equipment and Toyota Special Service Tools.

Engine Repair and Control-System Changes

Engine assembly illustrations identify non-reusable parts, sealant locations and engine-specific tools. Step-by-step procedures cover major engine work, while the separate 2WD and 4WD engine-unit sections account for driveline and front-axle hardware that changes access and removal work.

Supporting chapters address SFI, EVAP and PCV systems, cooling, lubrication, ignition, starting, charging, and exhaust/emissions components.

The New Car Features section explains the engine-specific ETCS-i arrangements, including the 2UZ-FE’s pedal-mounted accelerator-position sensor. It also describes A340 electronic line-pressure control and the change to Type T-IV ATF, alongside updates to standard ABS, HVAC, Toyota Vehicle Intrusion Protection (TVIP), cruise control and the power slide back window.

Drivetrain Inspection and Repair Depth

The manual-transmission chapters include shaft, gear, synchronizer and bearing inspection, component replacement and reassembly. The transfer sections add oil-pump inspection and assembly details for their respective configurations.

A340E/A340F coverage includes preliminary checks, stall and line-pressure testing, manual-shift isolation, solenoid and speed/temperature-sensor diagnosis, and torque-converter inspection. The manual-shifting test provides a way to distinguish an electrical-control problem from a mechanical transmission fault.

Diagnostic Flow and Circuit Troubleshooting

Toyota’s diagnostic structure covers both engine-control systems, the automatic transmission, ABS, SRS, TVIP and engine-specific cruise control. It connects customer problem analysis and DTC/freeze-frame capture with symptom confirmation, symptom simulation, circuit inspection and a confirmation test.

The diagnostic pages include check mode, active tests where supported, DLC3 communication checks, ECU terminal data, circuit descriptions, connector-face views and ordered inspection charts. This gives a technician a defined path for separating a sensor or actuator fault from a harness, connector, power-supply, ground or ECU problem instead of treating a stored code as a parts-replacement instruction.

Chassis, Body and Electrical Reference Material

Steering coverage extends to vane-pump overhaul and rack-and-pinion steering gear repair. Body procedures address doors, glass, seats and trim.

EWD491U provides relay locations, electrical wiring routing, ground-point maps, power-source current-flow charts, connector illustrations and connector part numbers. Circuit examples include Engine Control, Electronically Controlled Transmission and A/T Indicator, ABS, SRS, 4WD and Trailer Towing.

Safety Reminder: SRS repair must not begin until the ignition switch is in LOCK, the negative battery cable has been disconnected, and at least 90 seconds have elapsed; the restraint system retains backup power that can trigger deployment.

The steering-wheel spiral cable must be set to its neutral position before installation or cable disconnection and related faults can result. Hub and drive-shaft procedures warn against scratching the ABS speed-sensor rotor or damaging seals and boots; transfer installation warns that the input shaft can damage the adapter’s rear oil-seal lip.

Special Tools and Service Data

Preparation pages identify Toyota SSTs and their applications, including Valve Clearance Adjust Tool Set 09248-55040, Automatic Transmission Tool Set 09350-30020, LSPV Gauge Set 09709-29018, and Power Steering Pressure Gauge Set 09640-10010.

The service-data sections provide component-specific torque tables, pressure-test specifications, fluid types and capacities, wear limits, clearances, electrical test values and adjustment data.

A Preview of Thermostat Inspection Specifications

Both engine applications have a specified thermostat opening range of 80–84°C (176–183°F).

At 95°C (203°F), minimum thermostat valve lift is 8.5 mm (0.335 in.) for the 5VZ-FE and 10 mm (0.39 in.) for the 2UZ-FE.