Front Door Disassembly

Using a moulding remover, detach the 2 clips and 4 claws.

Disconnect the connector and remove the power window regulator master switch assembly with front door armrest base panel.

Using a moulding remover, detach the 2 clips and 4 claws.

Disconnect the connector and remove the power window regulator switch assembly with front door armrest base panel.

Insert a clip remover between the plate and trim board.

HINT:

Tape the clip remover tip before use.

Turn the handle counterclockwise to remove the snap ring, front door window regulator handle and plate.

Detach the 2 clips and remove the front door lower frame bracket garnish.

Remove the screw and door pull handle.

for Double Cab:

1. Remove the clip and screw.
   

   Text in Illustration

   *1	Clip
   *2	Screw

2. Detach the 8 clips and remove the front door trim board.
   

for Single Cab:

1. Remove the clip and screw.
   

   Text in Illustration

   *1	Clip
   *2	Screw

2. Detach the 9 clips and remove the front door trim board.
   

for Double Cab:

1. Raise the 7 claws of the front door inner glass weatherstrip as shown in the illustration, and then remove the front door inner glass weatherstrip from the front door trim board.
   

for Single Cab:

1. Raise the 8 claws of the front door inner glass weatherstrip as shown in the illustration, and then remove the front door inner glass weatherstrip from the front door trim board.
   

Disconnect the connector.

Put a 5 mm (0.197 in.) drill bit into a drill.

Wind tape around the drill bit approximately 4 mm (0.157 in.) from the tip of the drill as shown in the illustration.

NOTICE:

Tape the 4 mm (0.157 in.) drill bit to prevent the drill bit from going to deep.

Lightly press the drill against the 3 rivets, drill off the flanges of the 3 rivets and remove the front No. 1 speaker assembly.

CAUTION:

Be careful of the drilled rivet as it may become hot.

NOTICE:

1. Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through.
   
2. Do not pry the rivet with the drill because this may cause damage to the installation holes of the rivet or the drill bit.
   

Continue drilling and push out the remaining rivet fragments.

Using a vacuum cleaner, remove the rivet fragments and shavings from the inside of the door.

Disconnect the connector.

Remove the screw and front No. 2 speaker assembly.

w/ Power Mirror Control System:
Disconnect the mirror connector.

Remove the 3 nuts.

Push down the claw and remove the outer rear view mirror assembly LH.

Detach the claw and 2 guides as indicated by the arrows in the order shown in the illustration.

Disconnect the front door inside locking cable and front door lock remote control cable and remove the front door inside handle.

Remove the 2 screws and front door No. 1 trim bracket.

Pull out the front door inside locking cable, front door lock remote control cable and wire harness from the front door service hole cover, and then remove the front door service hole cover.

HINT:

Remove any remaining butyl tape from the front door panel.

w/ Power Window:

1. Temporarily install the power window regulator master switch assembly with front door armrest base panel.
   

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

3. Move the front door glass sub-assembly so that the front door glass bolts can be seen.
   

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

   NOTICE:

   When disconnecting the cable, some systems need to be initialized after the cable is reconnected (HILUX_TGN26 RM000004QR3008X.html).

5. Remove the power window regulator master switch assembly with front door armrest base panel.
   

w/o Power Window:

1. Temporarily install the door window regulator handle.
   

2. Move the front door glass sub-assembly so that the front door glass bolts can be seen.
   

3. Remove the door window regulator handle.
   

Remove the 2 bolts.

NOTICE:

After the bolts are removed, do not allow the front door glass to fall.

Remove the front door glass as indicated by the arrows in the order shown in the illustration.

NOTICE:

Do not damage the front door glass.

Put protective tape around the front door outer glass weatherstrip.

Detach the 5 claws and remove the front door outer glass weatherstrip.

Remove the front door glass run.

w/ Power Window:

1. Disconnect the connector.
   

2. 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.

   Text in Illustration

   *1	Temporary Bolt

3. Remove the 5 bolts and front door window regulator.
   

4. Remove the temporary bolt from the front door window regulator.
   

w/o Power Window:

1. 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.

   Text in Illustration

   *1	Temporary Bolt

2. Remove the 4 bolts and front door window regulator.
   

3. Remove the temporary bolt from the front door window regulator.
   

Using a T25 "TORX" socket wrench, remove the 3 screws and power window regulator motor assembly LH.

Remove the 2 nuts and front door rear lower frame.

Remove the hole plug.

Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover together with door key cylinder.

Detach the 2 claws and remove the front door outside handle cover from the door key cylinder.

w/ Power Door Lock:
(HILUX_TGN26 RM00000138V01IX_02_0018.html)

w/o Power Door Lock:

1. Disconnect the front door inside locking cable and front door lock remote control cable from the clamps.
   

2. Using a T30 "TORX" socket wrench, remove the 3 screws and front door lock.
   

Remove the front door lock remote control cable.

Detach the 3 claws and open the cover.

Remove the front door inside locking cable.

Remove the front door outside handle by sliding and pulling it in the direction indicated by the arrow in the illustration.

Using a T30 "TORX" socket wrench, loosen the screw.

Detach the claw and remove the front door outside handle frame.

Rotate the snap in the direction indicated by the arrow in the illustration to detach the snap from the front door lock open rod.

Remove the front door lock open rod from the front door outside handle frame.

Detach the 2 claws and remove the front door front outside handle pad.

Detach the 2 claws and remove the front door rear outside handle pad.

Remove the 2 front door panel cushions.

for Double Cab:

1. Remove the clip.
   

2. Detach the 33 clips and remove the front door weatherstrip.
   

for Single Cab:

1. Remove the clip.
   

2. Detach the 34 clips and remove the front door weatherstrip.
   

Remove the 3 bolts and front door check.