Installation (with pics) of OEM running boards for 2008+ Highlander

[aguevarra]

The Toyota installation instructions can be found here (http://mojavetrail.webng.com/HL_running_board_installation.pdf). The part # for the running boards is PT738-48080. Reading the instructions along with this pictorial should answer and, hopefully, simplify the install. There has been discussion that these do not have any drilling involved…WRONG!...but not much. Also, these are not the lighted version.

First you will have to remove all of the plastic underbody cover (both driver and passenger sides). Save and bag all the hardware so you don’t lose them. The driver side is 2 pieces and the passenger side is 1 piece.

There are templates included with the directions to assist in where to cut the covers. This is needed to reinstall the covers after the installation of the running boards.






DRIVERS SIDE:

The next step is to drill three 5.5mm (or 7/32”) holes along the pinch welds along the underbody. The kit includes sticker templates to position and align the holes properly for drilling. I forgot to take pictures when I did the driver side but here are the pics for the passenger side.

Sticker templates



Front



Middle



Rear


Next, you will have to scrape away some undercoating along the inner rocker panel. This will be the mounting point for the front bracket.





Remove the sticker covering the hole




Enlarge the hole to 18mm (or 3/4") using a unibit





Now locate the rubber grommet prior to the cross member to access the mounting point for the middle bracket.




Remove the rubber grommet




Enlarge the hole to 18mm (or 3/4") using a unibit




No drilling is needed for the rear bracket. Just remove the oval shaped rubber grommet.




The next steps are to insert the bolts and backing plate for the holes you just drilled for the front and middle brackets


The kit includes a coiled wire in which you can screw in the bolt so you don’t lose the bolt in the body (you might as well end the project right there if you were ever to lose the bolt in the inner rocker panels J)






Front




Middle




Insert bolt through the hole while still holding the coiled wire.





Thread the wire through the backing plate then insert the backing plate through the hole.




Pull on the wire to force the bolt through the backing plate and through the enlarged hole.



Put the rectangular shaped plate over the bolt then place washer over the plate to finally hold the bolt in place.




Please be careful when removing the wire from the bolt. It’s a little tricky when the washer is placed over the bolt. Just take your time here.



The next step is to do the same procedure for the middle enlarged hole for the middle bracket. The exception here is that it does need a rectangular shaped front plate.
The rear hole uses the larger bolt and screw. The procedure with the wire is the same. Since this mounting bolt is pointing down, gravity is helping here and does not need a washer to keep it in place.





Next, assemble the front, middle and rear brackets.


Front and middle brackets are identical




Rear bracket





Install the front bracket





Install the middle bracket. (Same as the front bracket)




Install the rear bracket. (forgot to take a pic of the driver side so here is the passenger side)




At this point, make sure to NOT TIGHTEN the bolts but just loosely secure all the bolts. This is because when you install the running board on the brackets, you want a certain amount of play so that you can line up all of the bolt holes. After all of the running board bolts are lined up in their respective brackets, tighten up all the bolts.



PASSENGER SIDE:

Same procedure as the drivers side with the exception of the middle bracket.

The middle bracket uses a different slot for the bolt to go through.




Here is the finished product, along with color keyed mud guards.

[TrailDust]

Outstanding write-up! Adding it to the DIY sticky in short order.



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[aguevarra]

Thanks. Glad I can be helpful.

[subvet]

Originally Posted by aguevarra

Thanks. Glad I can be helpful.

great write-up. I just installed boards on my 2011 and used this thread as a reference when the instructions were too sketchy.

thanks!

[earthltd]

How about a photo of what it looks like with the door open? showing how much is available to step on.

[coheedeehoc]

I was wondering if you knew where I can get the sticker templates. I purchased a set off of ebay and they were not included. Thanks.

[aguevarra]

Sorry coheedeehoc. Don't know where to get one. should have been one included in your set.

[dtown40]

aguevarra, what a great write up. Thanks for all your hard work.

[SWH]

Thanks a bunch for posting this. The pictures were a gigantic help. My 2010 didn't have the feature to align the middle bracket...no big deal, just a heads-up.

[becks]

Aguevarra,

That was a really nice write-up, and well documented. Looks like a lot of work. I'm sure those that want to add this mod will appreciate your well organized "how To".

[itsahog]

Thanks for doing that. Very good post.