Toyota Tundra Service Manual: Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

HINT:

  • Use the same procedure for the RH and LH sides.
  • The procedure listed below is for the LH side.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (See page ).

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION:

Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH

(a) Using a screwdriver, detach the 4 claws and remove the inside handle bezel.

HINT:

Tape the screwdriver tip before use.

4. REMOVE FRONT UPPER ARMREST BASE PANEL LH

(a) Using a moulding remover A, detach the 2 clips and 5 claws, and remove the front upper armrest base panel LH.

(b) Disconnect the master switch connector.

5. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY

6. REMOVE FRONT LOWER DOOR FRAME BRACKET GARNISH LH

(a) Detach the 3 clips and remove the door lower frame bracket garnish.

7. REMOVE FRONT DOOR ARMREST COVER LH

8. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH

(a) Remove the 2 screws.

(b) Using a clip remover, remove the clip.

(c) Detach the 9 clips and remove the trim cover. Then disconnect the connector.

(d) Disconnect the 2 cables from the inside handle.

(e) Remove the inside handle.

9. REMOVE FRONT INNER DOOR GLASS WEATHERSTRIP LH

10. REMOVE SEAT MEMORY SWITCH (w/ Seat Memory Switch)

(a) Remove the 2 screws and seat memory switch.

11. REMOVE OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Power Mirror Control System)

(a) Disconnect the 2 ECU connectors.

(b) Remove the 2 screws and ECU.

12. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH

13. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY

14. REMOVE FRONT NO. 1 DOOR TRIM BRACKET

(a) Remove the 2 screws and bracket.

15. REMOVE FRONT DOOR SERVICE HOLE COVER LH

(a) Using a clip remover, detach the 2 clamps.

(b) Remove the front door service hole cover LH.

HINT:

Remove the remaining tape on the door.

16. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH

(a) for Driver Side:

(1) Temporarily install the power window regulator master switch.

(b) for Passenger Side:

(1) Temporarily install the power window regulator switch.

(c) Connect the cable to the negative (-) battery terminal.

(d) Move the door glass until the bolts appear in the service holes.

(e) Remove the 2 bolts.

NOTICE:

Be careful when removing the bolts as the glass may fall and become damaged.

(f) Remove the door glass in the direction indicated by the arrows in the illustration.

HINT:

Remove the glass upward.

NOTICE:

Be careful not to damage the glass.

(g) for Driver Side:

(1) Remove the power window regulator master switch.

(h) for Passenger Side:

(1) Remove the power window regulator switch.

(i) Disconnect the cable from the negative battery (-) terminal.

CAUTION:

Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

17. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH

(a) Disconnect the connector.

(b) Loosen the temporary bolt.

NOTICE:

Do not remove the temporary bolt. If the temporary bolt is removed, the front door window regulator may fall and become damaged.

(c) Remove the 5 bolts and window regulator.

(d) Remove the window regulator through the service hole.

(e) Remove the temporary bolt from the front door window regulator.

18. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

(a) Using a T25 "TORX" driver, remove the 3 screws and motor.

NOTICE:

Be careful when removing the screws as the motor may fall and become damaged.

19. REMOVE SIDE AIRBAG SENSOR ASSEMBLY LH

(a) Disconnect the connector.

(b) Remove the bolt and side airbag sensor.

20. REMOVE FRONT OUTER DOOR GLASS WEATHERSTRIP ASSEMBLY LH

21. REMOVE FRONT DOOR GLASS RUN LH

(a) Remove the front door glass run.

22. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY LH

(a) Remove the 2 bolts and front door rear lower frame.

HINT:

Remove the frame through the service hole.

NOTICE:

Be careful when removing the bolts as the frame may fall and become damaged.

23. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY LH

(a) Remove the 2 bolts and front door front lower frame.

HINT:

Remove the frame through the service hole.

NOTICE:

Be careful when removing the bolts as the frame may fall and become damaged.

24. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH

(a) Remove the hole plug.

(b) Using a T30 "TORX" wrench, loosen the screw and remove the front door outside handle cover and the door lock key cylinder as a unit.

(c) Remove the cylinder from the cover.

25. REMOVE FRONT DOOR LOCK ASSEMBLY LH

(a) Disconnect the connector.

(b) Using a T30 "TORX" wrench, remove the 3 screws and door lock.

HINT:

Remove the door lock through the service hole.

NOTICE:

Be careful when removing the bolts as the door lock may fall and become damaged.

26. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

(a) Remove the front door lock remote control cable assembly.

27. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH

(a) Using a screwdriver, detach the 3 claws.

HINT:

Tape the screwdriver tip before use.

(b) Remove the front door inside locking cable.

28. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH

(a) Remove the handle by sliding and pulling it in the direction indicated by the arrow in the illustration.

NOTICE:

If the release plate is not pulled and held when removing the handle, the release plate will interfere with the handle and become damaged.

29. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH

(a) Remove the front and rear outside handle pads.

(b) Using a T30 "TORX" wrench, loosen the screw.

(c) Slide the outside handle frame to remove it.

HINT:

Remove the outside handle frame through the service hole.

30. REMOVE FRONT DOOR LOCK OPEN ROD LH

(a) Remove the lock open rod from the outside handle frame.

31. REMOVE FRONT NO. 2 DOOR STIFFENER CUSHION

(a) Using a clip remover, remove the 2 clips and stiffener cushion.

32. REMOVE FRONT DOOR PANEL PROTECTOR LH

(a) Using a clip remover, detach the 8 clips and remove the door panel protector.

HINT:

If clips are damaged during removal, replace them.

33. REMOVE FRONT DOOR CHECK ASSEMBLY LH

(a) Remove the bolt, 2 nuts and door check.

HINT:

Remove the door check through the service hole.

NOTICE:

Be careful when removing the bolts as the door check may fall and become damaged.

34. REMOVE FRONT DOOR WEATHERSTRIP LH

(a) Using a clip remover, detach the 38 clips and remove the weatherstrip.

HINT:

If clips are damaged during removal, replace them.

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