Body - Front Door Window Glass Popping When Operated
T-SB-0027-10Rev2
January 25, 2010
Noise From Front Window / Door Check
Service Category
Vehicle Exterior
Section
Window/Glass
Market
USA
Applicability
TSB REVISION NOTICE
August 9, 2010 Rev2:
^ VIN information has been updated in the Production Change Information table.
April 19, 2010 Rev1:
^ Applicability has been updated to include 2010 model year Highlander vehicles.
Any previous printed versions of this service bulletin should be discarded.
Introduction
Some 2008 - 2010 vehicles may exhibit a condition where the front window makes a popping noise when operating up or down. The pop noise is heard after the window comes in contact with the door check. The door check has been modified to prevent contact. Use the following repair information to address this condition.
Warranty Information
APPLICABLE WARRANTY
^ This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
^ Warranty application is limited to occurrence of the specified condition described in this bulletin.
Production Change Information
This TSB applies to all 2008 - 2009 CBU (WMI = JTE) built vehicles produced BEFORE the Production Change Effective VINs shown.
This TSB applies to all 2010 NAP (WMI = 5TD) built vehicles produced BEFORE the Production Change Effective VINs shown.
Parts Information
Required Tools & Equipment
Repair Procedure
1. Replace the door check assembly.
NOTE
The procedure is the same for both the LH and RH sides.
For door check removal instructions refer to the Technical Information System applicable model year Repair Manual:
2. Disengage the claw and clip and remove the front door lower frame bracket garnish.
3. Using a plastic pry tool disengage the 3 claws and remove the front door inside handle bezel plug.
4. Remove the front armrest upper base panel.
A. Using a plastic pry tool disengage the 7 claws and clip and remove the front armrest upper base panel.
B. Disconnect the connector.
5. Using a plastic pry tool disengage the 4 claws and remove the assist grip cover.
6. Remove the courtesy light assembly.
A. Using a plastic pry tool disengage the claw and remove the courtesy light assembly.
B. Disconnect the connector.
7. Remove the front door trim board sub-assembly.
A. Remove the 3 screws.
B. Using a clip remover disengage the 9 clips.
C. Disengage the 5 claws and separate the front door trim board sub-assembly from the front door inner glass weatherstrip.
D. Disengage the 2 clamps.
E. Disconnect the front door lock remote control cable and front door inside locking cable.
8. Disengage the 3 clamps and remove the front door wire (for driver's side).
9. Remove front No.1 speaker assembly.
Refer to the Technical Information System applicable model year Repair Manual:
A. Disconnect the connector.
B. Remove the 4 bolts and front No.1 speaker assembly.
NOTICE
Do not touch the cone part of the speaker.
10. Remove the bolt 2 nuts and front door check assembly.
11. Install the NEW front door check assembly with the bolt and 2 nuts.
Bolt:
Torque: 27 N*m (275 kgf*cm, 20 ft*lbf)
Nut:
Torque: 8.0 N*m (82 kgf*cm, 71 in*lbf)
12. Reassemble the door in reverse order of removal.
13. Initialize power window control system (for Driver Side).
14. Operate the window up and down to confirm proper window operation and that the noise is no longer present.