Body - Front Door Won't Fully Open/Window Malfunctions

BODY
BO002-07

Title:
DOOR CHECK BENDING

Models
'03 - '07 GX 470

March 19, 2007

Introduction
Some customers may notice that the driver or passenger's door does not open fully or the window will not roll down fully. The door check assembly has been modified to correct this condition.

NOTE:
In some cases, the window channel may be damaged by the door check. On those cases, the door assembly will also need to be replaced.

Applicable Vehicles

^ 2003 - 2007 model year GX 470 vehicles produced BEFORE the Production Change Effective VIN shown below.





Production Change Information





Parts Information





Warranty Information

Applicable Warranty*:
This repair is covered under the Lexus Comprehensive Warranty. This warranty is in effect for 48 months or 50,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.

Repair Procedure

Replace the door check.

NOTE:
The procedure is the same for both the LH and RH sides.

Refer to the Technical Information System (TIS):

^ 2003, 2004, or 2005 model year GX 470 Repair Manual, Vehicle Exterior - Door/Hatch - "Front Door: Overhaul".

^ 2006 or 2007 model year GX 470 Repair Manual, Vehicle Exterior - Door/Hatch - "Engine / Hood: Front Door: Disassembly" and "Engine / Hood: Front Door: Reassembly".





1. Using a screwdriver, remove the front door lower frame bracket garnish.

HINT:

Tape the screwdriver tip before use.





2. Using the taped screwdriver, remove the front door inside handle bezel by disengaging the 3 claws.





3. Remove the front armrest assembly by disengaging the 2 clips.





4. Remove the power window regulator master switch assembly.

A. Using the taped screwdriver, disengage the 2 claws and 2 clips, and then remove the armrest base panel upper together with the master switch assembly.

B. Disconnect the master switch connector.

C. Remove the 3 screws and the master switch from the armrest base panel upper.

5. Remove the front door trim board sub-assembly.

A. Remove the 2 rubber cushions.

B. Remove the 3 screws and clip.

C. Using a clip remover, remove the other 10 clips.

D. Remove the trim board upward.

HINT:





In order to prevent the door panel from being damaged, cover the parts indicated by the arrows in the illustration with tape.





6. Remove the front door check assembly.

A. Remove the check cover.

B. Remove the 2 nuts, bolt, and the door check.

NOTE:
In some cases, the window channel may be damaged by the door check. If the window channel is damaged, the door assembly will also need to be replaced.

7. Install the NEW door check.

Torque: 5.0 N.m (50.7 kgf.cm, 44.0 in.lbf)

8. Reassemble in reverse order of disassembly.