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Toyota Skid Steer 4SDK3 4SDK4 4SDK5 4SDK6 4SDK8 4SDK10 factory workshop and repair manual

Tools & consumables
- Standard & deep sockets and ratchet set (metric sizes 10–32 mm commonly)
- Combination wrenches (metric)
- Torque wrench (range covering 10–200 Nm / 7–150 ft‑lb)
- Breaker bar
- Penetrating oil (PB Blaster or equivalent)
- Hammer, punch, cold chisel
- Pry bar
- Bench vise or hydraulic press (for removing/pressing bushings if needed)
- Wire brush and shop rags
- Grease (synthetic rubber bushing grease)
- Anti-seize compound and/or medium-strength thread locker (per OEM)
- Hydraulic jack or heavy-duty floor jack and suitable lift blocks
- Engine hoist or axle stands / heavy-duty jack stands rated for machine weight
- Wheel chocks
- Safety glasses, gloves, steel-toe boots
- Replacement parts: stabilizer (sway) bar if bent/cracked, sway bar end links, rubber/urethane bushings, mounting brackets/clamps, bolts/nuts/washers (prefer OEM or grade-matched fasteners)

Safety precautions (must do)
- Work on level, hard ground. Chock wheels, set parking brake, lower attachment/bucket to ground.
- Block attachment to prevent accidental lowering; do not rely solely on hydraulic locks—use mechanical blocks or supports.
- Disconnect battery negative to eliminate risk of accidental engine start or electrical hazard.
- Never work under the machine supported only by a jack. Use rated jack stands under manufacturer-specified lift points.
- Wear safety glasses and gloves. Keep body clear of pinch points when lowering/raising components.
- Use torque wrench for final tightening to OEM specs. If you don’t have OEM torque specs, do not “snug by feel” for safety-critical fasteners.

Preliminary inspection
1. Walk around and visually inspect the stabilizer bar, end links, bushings, and mounting brackets for cracks, heavy corrosion, deformation or missing fasteners.
2. With the machine on blocks (wheels supported), grab the bar and attempt to twist and move the end links by hand to check play.
3. Lift the wheels/axles slightly (or lift the frame per service manual) to unload the suspension and confirm noise/looseness during articulation.

Step‑by‑step repair (replace bushings and/or end links; replace bar if bent/cracked)
1. Preparation
- Park on flat ground, lower bucket, chock wheels, engage parking brake.
- Turn off engine, remove key, disconnect battery negative.
- Apply penetrating oil to all stabilizer mounting bolts, end link nuts, and bracket bolts; allow soak time (15–30 min).
- Position jack and jack stands at manufacturer lift points; raise machine until suspension is unloaded but stable on stands.

2. Remove obstructing components
- Remove wheels if necessary for access.
- If linkage/hoses block access, move or support them out of the way; do not stress hydraulic lines.

3. Remove end links
- Use appropriate sockets/wrenches on the link nut and bolt head. Hold bolt head with wrench while breaking nut with breaker bar if seized.
- If stud spins, use an open-end wrench on the internal hex or use penetrating oil and tap with hammer to free.
- Remove link assembly. If corroded, use hammer and punch to drive the bolt out. Replace any damaged bolts.

4. Remove mounting bracket clamps and bushings
- Remove the bracket/clamp bolts that hold the bushings to the frame. Support the bar so it won’t drop when the bracket is removed.
- Unclip or remove half‑shell bushing clamps. Take off old rubber/urethane bushings from the bar. If bushings are pressed in brackets, use a punch or press to remove them.

5. Remove stabilizer bar (if replacing)
- With brackets removed and links disconnected, slide the bar out from under the machine. Note orientation and any shims/spacers for reinstall.

6. Inspect parts
- Clean surfaces with wire brush. Inspect frame mounting points, link bolts, and bar for cracks or wear.
- If bar is bent, cracked, or has significant wear at the link mount points, replace it.
- Replace end links if ball joints show play or boots are torn.

7. Prepare new bushings & parts
- If reusing bar, clean mounting area thoroughly.
- Lightly grease the inside of the new rubber/urethane bushings with recommended bushing grease (don’t use petroleum grease on rubber). Do not over‑grease — a thin layer is enough.
- If bushings are split, align split to top or per OEM orientation.

8. Install stabilizer bar and bushings
- Position the bar in the correct orientation. Slide bushings onto the bar in their correct locations.
- Reinstall bracket clamps over bushings and loosely thread bolts to hold the bar in place. Do not torque fully until both sides are installed and the suspension is at normal ride height (if required by OEM).

9. Install end links
- Attach end links to sway bar and control arms/axle mounts. If links have grease fittings, pump a few shots before installation.
- Install new bolts/nuts if old ones are worn. If OEM calls for torque-to-yield hardware, replace with new.
- Tighten bolts finger tight initially.

10. Final tightening and torqueing
- Lower machine to normal ride height (if bushings were installed with the suspension loaded per manual). Some OEMs specify torque with the suspension loaded; check service manual.
- Torque bracket clamp bolts and end link bolts to OEM specifications using torque wrench. If specs unavailable, use torque wrench and torque to a conservative setting appropriate for bolt size and grade — but recommend obtaining OEM spec to avoid over/under torquing.
- Apply thread locker or anti-seize where specified (use medium-strength thread locker on fasteners that aren’t intended to be removed frequently; anti-seize on studs as needed).

11. Final checks
- Reconnect battery.
- Remove jack stands, lower machine to ground.
- Test articulation by raising/lowering the bucket and driving at low speed in a safe area. Listen for clunks.
- Re-check torque on all fasteners after short test drive (100–200 km or after first day of use).

How the tools are used (practical notes)
- Breaker bar: use to initially break loose seized nuts/bolts. Attach appropriate socket and apply slow steady force. Avoid sudden jerks.
- Penetrating oil: spray threads and let soak. Tap bolt heads to help penetration.
- Hammer & punch: use to drive out rusted bolts or to align holes. Use protective cap on bolt heads if hitting with hammer to avoid damage.
- Bench vise / hydraulic press: press out worn-in bushings from brackets or press new bushings in. Support housing and apply even pressure to avoid cocking the bushing.
- Torque wrench: set to specified torque. Tighten nuts to spec in one or two stages for accuracy. Do not use torque wrench as a breaker bar.
- Jack & jack stands: use rated stands; set stands under frame/axle points. Never trust the jack alone.

Common pitfalls & how to avoid them
- Working under an unsupported machine — always use rated jack stands and blocks.
- Reusing worn or corroded fasteners — replace bolts/nuts with proper grade replacements; seized fasteners that have been heat-treated by hammering often have reduced strength.
- Installing bushings dry or using wrong grease — use recommended rubber/urethane grease; installing dry can cause premature squeak/wear.
- Not following OEM torque or installing bushings with suspension unloaded when OEM requires loaded — can cause pre-load or binding; consult service manual.
- Incorrect orientation of split bushings or bar — mark orientation before removal or take photos.
- Failing to check adjacent components — worn control arms, bearings, or pivot pins can mimic sway-bar noise; inspect and replace as needed.
- Over-tightening bracket bolts causing bushing distortion — torque to spec only.

Replacement parts summary
- Rubber or polyurethane stabilizer bar bushings (split or solid per design)
- Bushing clamp brackets and bolts (if corroded)
- Stabilizer bar end links (complete link assemblies)
- Stabilizer bar (if bent, cracked, or heavily worn)
- New bolts/nuts/washers (use OEM or grade specified)

Notes
- Always get the Toyota skid steer service manual for model-specific procedures, lift points, part numbers and torque specs for 4SDK3/4SDK4/4SDK5/4SDK6/4SDK8/4SDK10 machines.
- If stabilizer bar damage is the result of impact (collision or severe obstruction), inspect surrounding frame and attachment mounts for damage before returning to service.
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