Canada - Body - Rust Stains On Exterior Door Handles
Bulletin
T-TCI-3686
Issue Date
December 23, 2011
Market
Canada
Title
DOOR HANDLE RUST STAIN
Service Category
Vehicle Exterior
Section
Door/Hatch
Market
Canada
APPLICABILITY:
INTRODUCTION:
Some 2008 - 2011 model year Highlander and Highlander HV vehicles may exhibit a condition where rust stains develop below one or more of the exterior door handles. Use the following repair information to address this condition.
PARTS INFORMATION:
WARRANTY INFORMATION:
REQUIRED TOOLS & EQUIPMENT:
NOTE
Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
TSB OVERVIEW:
This TSB will instruct you to replace the Door Handle nuts on all 4 doors. The TSB has been divided, refer to the Front Door repair procedure and the Rear Door repair procedure. Any rust stain(s) should be cleaned after disassembly and prior to reassembly.
REPAIR PROCEDURE:
Front Door Outside Handle Removal Procedure
NOTE
Perform the same procedure for the left and right front door handles.
1. Remove the front door lower frame bracket garnish by disengaging the claw and clip.
2. Remove the front door inside handle bezel plug by using the plastic pry tool and disengaging the 3 claws.
3. Remove the front door 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 window control switch.
4. Remove the assist grip cover by using the plastic pry tool and disengaging the 4 claws.
5. Remove the courtesy light assembly.
A. Using a plastic pry tool, disengage the claw and remove the courtesy light assembly.
B. Disconnect the connector.
6. Remove the front door trim board sub-assembly.
A. Remove the 3 screws.
B. Using a plastic pry tool, disengage the 9 clips.
NOTICE
Carefully remove the inner door panel by lifting the panel rather than pulling to prevent damage to inner belt molding weather strip. Damage may occur if the panel is not properly removed.
C. Disengage the 5 claws and separate the front door trim board sub-assembly from the front door inner glass weather-strip.
D. Disengage the 2 clamps.
E. Disconnect the front door lock remote control cable and front door inside locking cable.
7. Disconnect the front door latch connector.
8. Peel back the corner of the moisture barrier.
HINT
Use a razor blade between butyl tape and moisture barrier.
9. Remove the front door outside handle cover (for driver side).
A. Remove the hole plug.
B. Using a Torx socket (T30), loosen the screw and remove the front door outside handle cover and the door lock key cylinder as a unit.
Torque: 4.0 N-m (41 kgf-cm, 35 in-lbf)
HINT
The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly.
C. Using a plastic pry tool, disengage the 2 claws and remove the front door outside handle cover.
10. Remove the front door outside handle cover (for passenger side).
A. Remove the hole plug.
B. Using a Torx socket (T30), loosen the screw and remove the front door outside handle cover and the door lock key cylinder as a unit.
HINT
The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly.
11. Remove the front door outside handle assembly (w/o Smart Key System) by removing the front door outside handle assembly as shown.
12. Remove the front door outside handle assembly (w/Smart Key System).
A. Disconnect the connector.
HINT
Place a small pick under the connector tab to release.
B. Remove the front door outside handle assembly as shown.
13. Remove the front door outside handle pad by disengaging the 3 claws.
14. Remove the forward front door outside handle Torx screw by using a Torx socket (T30) and removing the screw.
Rear Door Outside Handle Removal Procedure
HINT
Perform the same procedure for the left and right rear door handles.
1. Remove the rear door inside handle bezel plug by using a plastic pry tool and disengaging the 3 claws.
2. Remove the rear door armrest upper base panel.
A. Using a plastic pry tool, disengage the 6 claws and 2 clips.
B. Disconnect the connector.
3. Remove the rear power window regulator switch assembly by disengaging the 2 claws.
4. Remove the door assist grip cover by using a plastic pry tool and disengaging the 4 claws.
5. Remove the door trim board sub-assembly.
A. Remove the 3 screws.
B. Using a plastic pry tool, disengage the 9 clips.
C. Disengage the 5 claws and separate the rear door trim board sub-assembly from the rear door inner glass weatherstrip.
NOTICE
Carefully remove the inner door panel by lifting the panel rather than pulling to prevent damage to inner belt molding weather strip. Damage may occur if the panel is not properly removed.
D. Disengage the 2 clamps.
E. Disconnect the front door lock remote control cable and rear door inside locking cable.
6. Disconnect the rear door latch connector and peel back the upper corner of the moisture barrier.
HINT
Use a razor blade between butyl tape and moisture barrier.
7. Remove the rear door lock assembly.
A. Using the Torx socket (T30), remove the 3 screws.
Torque: 5.0 N-m (51 kgf-cm, 44 in-lbf)
B. Move the rear door lock assembly downward and pull the release plate out of the rear door outside handle frame.
8. Remove the rear door outside handle cover.
A. Using a Torx socket wrench (T30), loosen the screw.
Torque: 4.0 N-m (41 kgf-cm, 35 in-lbf)
HINT
The screw cannot be removed because it is integrated into the rear door outside handle frame sub-assembly.
B. Disengage the claw and remove the rear door outside handle cover.
9. Remove the rear door outside handle assembly as shown.
10. Remove the rear door outside handle pad by disengaging the 3 claws.
11. Remove the forward rear door outside handle Torx screw by using a Torx socket (T30) as shown.
Installation Procedure
1. Clean the area around the door handles to remove any rust staining by using a micro finishing compound. If the rust cannot be removed by using adequate micro finishing compound, further refinishing techniques may need to be used such as a rubbing compound.
2. Install the new nut, re-using the original Torx screw removed previously, and then reassemble in reverse order.
Torque: 4.0 N-m (42 kgf-cm, 35 in-lbf)
3. Check operation of inner and outer door handles.
NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.