Rear Door Disassembly

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

Disconnect the connector and remove the rear power window regulator switch assembly with rear 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 clockwise to remove the snap ring, rear door window regulator handle and plate.

Remove the screw and door pull handle.

Remove the clip and screw.

Detach the 9 clips and remove the rear door trim board.

Raise the 6 claws of the rear door inner glass weatherstrip as shown in the illustration, and then remove the rear door inner glass weatherstrip from the rear door trim board.

Put protective tape around the rear door outer glass weatherstrip.

Detach the 4 claws and remove the rear door outer glass weatherstrip.

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 rear 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.

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

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

Remove the 2 screws and rear door No. 2 trim bracket.

w/ Rear Speaker:
Pull out the rear door inside locking cable, rear door lock remote control cable and wire harness from the rear door service hole cover, and then remove the rear door service hole cover.

HINT:

Remove any remaining butyl tape from the rear door panel.

w/o Rear Speaker:
Pull out the rear door inside locking cable and rear door lock remote control cable from the rear door service hole cover, and then remove the rear door service hole cover.

HINT:

Remove any remaining butyl tape from the rear door panel.

Partially remove the rear door glass run as shown in the illustration.

Remove the 2 bolts.

Remove the rear door window division bar together with the rear door glass run as shown in the illustration.

Remove the rear door window division bar from the rear door glass run.

w/ Power Window:

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

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

3. Move the rear door glass so that the rear door glass channel 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 RM000004QR3003X.html).

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

w/o Power Window:

1. Temporarily install the rear door window regulator handle.
   

2. Move the rear door glass so that the rear door glass channel can be seen.
   

3. Remove the rear door window regulator handle.
   

Remove the rear door glass from the rear door window regulator assembly as shown in the illustration.

Remove the rear door glass by passing it through the cutout of the rear door panel in the direction indicated by the arrow in the illustration.

NOTICE:

Do not damage the door glass.

Remove the front side of the rear door glass run.

Using a screwdriver, remove the rear door glass channel.

HINT:

Tape the screwdriver tip before use.

Remove the rear door glass channel filler.

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 rear door window regulator may fall and become damaged.

   Text in Illustration

   *1	Temporary Bolt

3. Remove the 3 bolts and rear door window regulator.
   

4. Remove the temporary bolt from the rear 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 rear door window regulator may fall and become damaged.

   Text in Illustration

   *1	Temporary Bolt

2. Remove the 2 bolts and rear door window regulator.
   

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

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

w/ Power Door Lock:
(HILUX_TGN26 RM00000138Z00XX_02_0013.html)

w/o Power Door Lock:

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

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

Remove the rear door lock remote control cable.

Detach the 3 claws and open the cover.

Remove the rear door inside locking cable.

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

Remove the rear 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 and remove the rear door outside handle frame.

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

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

Remove the rear door panel cushion.

Remove the clip.

Detach the 32 clips and remove the rear door weatherstrip.

Remove the 3 bolts and rear door check.