Toyota Tundra Service Manual: Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

HINT:

• Use the same procedures for the RH side and LH side.
• The procedures listed below are 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 REAR 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 REAR UPPER DOOR ARMREST BASE PANEL LH

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

(b) Disconnect the connector.

5. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY

6. REMOVE REAR DOOR FRAME GARNISH LH

(a) Detach the 5 clips and remove the rear door frame garnish.

7. REMOVE REAR DOOR ARMREST COVER LH

8. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH

(a) Remove the 2 screws.

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

(c) for Standard:

(1) Detach the 10 clips and remove the trim board.

(d) for 12 Speakers:

(1) Detach the 10 clips and remove the trim board. Then disconnect the connector.

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

(f) Remove the inside handle.

9. REMOVE REAR NO. 2 SPEAKER ASSEMBLY (for 12 Speakers)

10. REMOVE REAR INNER DOOR GLASS WEATHERSTRIP LH

11. REMOVE REAR NO. 2 DOOR TRIM BRACKET

(a) Remove the 2 screws and bracket.

12. REMOVE REAR SPEAKER ASSEMBLY

13. REMOVE REAR DOOR SERVICE HOLE COVER LH

(a) Disconnect the connector and 5 clamps.

(b) Remove the rear door service hole cover.

HINT:

Remove the remaining tape on the door.

14. REMOVE REAR DOOR GLASS RUN LH

(a) Remove the rear door glass run.

15. REMOVE REAR DOOR REAR LOWER WINDOW FRAME SUB-ASSEMBLY LH

(a) Remove the 2 bolts and rear door rear lower window frame. HINT: Remove the frame through the service hole. NOTICE: Be careful when removing the bolts as the frame may fall and become damaged.

16. REMOVE REAR DOOR GLASS SUB-ASSEMBLY LH

(a) Temporarily install the power window regulator switch.

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

(c) Remove the 2 bolts.

NOTICE:

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

(d) Remove the rear door glass from the rear door window regulator as shown in the illustration.

NOTICE:

Do not damage the door glass.

(e) Remove the power window regulator switch.

17. REMOVE REAR DOOR FRONT WINDOW GUIDE SUB-ASSEMBLY LH

(a) Remove the 2 bolts and rear lower front door window guide. HINT: Remove the frame through the service hole. NOTICE: Be careful when removing the bolts as the frame may fall and become damaged.

18. REMOVE REAR NO. 2 DOOR GLASS RUN LH

(a) Remove the rear door glass run from the rear front lower door window guide.

19. REMOVE REAR OUTER DOOR GLASS WEATHERSTRIP

20. REMOVE REAR 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 door window regulator.

21. REMOVE 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.

22. REMOVE REAR 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.

23. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

(a) Using a screwdriver, detach the claw.

(b) Remove the rear door lock remote control cable.

24. REMOVE REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH

(a) Using a screwdriver, detach the 3 claws. HINT: Tape the screwdriver tip before use.

(b) Remove the rear door inside locking cable.

25. REMOVE REAR DOOR LOCK CHILD PROTECTION COVER LH

26. REMOVE REAR DOOR OUTSIDE HANDLE COVER LH

(a) Remove the hole plug.

(b) Using a T30 "TORX" wrench, loosen the screw and remove the rear door outside handle cover.

(c) Remove the cover.

27. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY 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.

28. REMOVE REAR 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.

29. REMOVE REAR DOOR LOCK OPEN ROD LH

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

30. REMOVE REAR NO. 2 DOOR WEATHERSTRIP LH

(a) Using a clip remover, detach the 10 clips and remove the weatherstrip. HINT: If clips are damaged during removal, replace them.

31. REMOVE REAR 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.

32. REMOVE REAR DOOR WEATHERSTRIP LH

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

(b) Using a clip remover, detach the 41 clips and remove the weatherstrip. HINT: If clips are damaged during removal, replace them.