Dobinsons Manuals

Dobinsons DD59-538k Diff Drop Kit Toyota Hilux Revo Fitting Guide

This 8-page fitting guide from Dobinsons covers installation of the DD59-538k diff drop kit on the Toyota Hilux Revo. According to the document, the kit drops the diff approximately 35mm and should be used together with high clearance CV boot kits CV59-554k and CV59-557k, Dobinsons Upper Control arms and shock absorbers with an extended length of 580mm. The guide opens with a reminder to use the correct PPE and follow relevant workshop procedures.

The numbered steps walk through jacking and supporting the vehicle, removing the bash plates, unbolting the rear diff mount cross member and cradle arms, pressing the poly bushes and sleeves into the new cradle arms, and fitting the new right and left side mounts. Later steps cover tightening all bolts, bending the breather hose bracket, replacing the front 4mm i.d. vacuum hose on the 4wd locking solenoid, and refitting the bash plates, with separate notes for 2005 to 2015 and 2015 on models.

Covers: Jacking and supporting the vehicle · Removing the bash plates · Removing the rear diff mount · Installing the new rear mount · Assembling the new left and right cradle arms · Installing the right side cradle