Section 1024 (Rear Door): Disassembly

HINT:

A bolt without a torque specification is shown in the standard bolt table, (see SPECIFIED TORQUE FOR STANDARD BOLTS )

1. REMOVE INSIDE HANDLE BEZEL 
   1. Using a screwdriver, open the screw cap.

      HINT:

      Tape the screwdriver tip before use.

   2. Remove the screw.
   3. Using a screwdriver, remove the inside handle bezel as shown in Fig 1 .

   HINT:

   Tape the screwdriver tip before use.

   Fig 1: Removing Inside Handle Bezel

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE POWER WINDOW SWITCH 
   1. Using a screwdriver, remove the power window switch.
      Fig 2: Removing Power Window Switch

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Tape the screwdriver tip before use.

   2. Disconnect the connector.
3. REMOVE REAR ARMREST 
   1. Remove the screw.
   2. Using a screwdriver, remove the rear armrest.
      Fig 3: Removing Rear Armrest

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   Tape the screwdriver tip before use.

4. REMOVE DOOR TRIM 

   Using a screwdriver, disengage the clips, then pull the trim upward to remove it.

   Fig 4: Disengaging Clips

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   Tape the screwdriver tip before use.

5. REMOVE INSIDE HANDLE 

   Remove the screw and inside handle, and disconnect the 2 cables from the inside handle.

   Fig 5: Disconnecting Cables From Inside Handle

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE SERVICE HOLE COVER 
   1. Disconnect the connector.
   2. Remove the 2 screws and door trim bracket.
   3. Remove the service hole cover.
7. REMOVE SERVICE HOLE PLATE 

   Remove the 2 screws and service hole plate.

   Fig 6: Removing Service Hole Plate

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE DOOR GLASS RUN 
9. REMOVE REAR DOOR BELT MOLDING 
   1. Remove the screw.
   2. Apply protective tape to the outer surface as shown in Fig 6 to keep the surface from being scratched.
   3. Using a molding remover, remove the rear door belt molding as shown in Fig 7 .
      Fig 7: Removing Rear Door Belt Molding

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE DIVISION BAR 
    1. Remove the 2 bolts and screw.
       Fig 8: Removing Division Bar Bolts & Screw

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pull the division bar forward.
    3. Rotate the division bar 90° and pull it upward as shown in Fig 9 .
    Fig 9: Rotating Division Bar 90° & Pulling Upward

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE REAR DOOR QUARTER WINDOW GLASS 
    1. Remove the rear door quarter window glass as shown in Fig 10 .
       Fig 10: Removing Rear Door Quarter Window Glass

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Do not damage the glass. 
    2. Remove the quarter window weatherstrip from the glass.
12. REMOVE DOOR GLASS 

    HINT:

    Insert a shop rag inside the door panel to prevent scratching the glass.

    1. Open the door glass.
    2. Tilt the door glass and disconnect the roller of the regulator from the glass channel to remove the door glass.
    Fig 11: Removing Door Glass

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE WINDOW REGULATOR 
    1. Disconnect the connector.
    2. Remove the 4 bolts and window regulator.
14. REMOVE DOOR LOCK 
    1. Remove the child protection cover.
    2. Disconnect the 2 links from the outside handle and key cylinder.
       Fig 12: Removing Bolts & Window Regulator

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and screw.
    4. Using a torx socket wrench, remove the 3 torx screws and door lock.

       Torx socket wrench: T30 (Part No. 09042-00010 or locally manufactured tool) 

       Fig 13: Removing Torx Screws & Door Lock

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       HINT:

       Remove the door lock through the service hole.

    5. Disconnect the connector.
15. REMOVE OUTSIDE HANDLE 

    Remove the 2 bolts, rear door outside reinforcement extension and outside handle.

    Fig 14: Removing Outside Handle

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE CUSHIONS