Lower Back Door: Disassembly

REMOVE REAR MAT SET PLATE
1. Remove the 5 screws.
2. Using a screwdriver, remove the rear mat set plate.
HINT:

Tape up the screwdriver tip before use.

Fig 1: Removing Rear Mat Set Plate
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR TRIM
1. Insert a screwdriver between the door and the door trim to pry out.
  HINT:
  
  Tape up the screwdriver tip before use.
2. Remove the door trim.
Fig 2: Removing Back Door Trim
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE LOWER TORSION BAR
1. Remove the rear bumper. (See REAR BUMPER )
2. Remove the 4 bolts and the lower torsion bar as shown in the illustration.
3. Remove the torsion bar guide.
Fig 3: Removing Lower Torsion Bar
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REMOVE BACK DOOR INSIDE HANDLE
1. Remove the screw and the back door inside handle.
2. Remove the spacer.
Fig 4: Removing Back Door Inside Handle
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REMOVE BACK DOOR LOCK CONTROL
1. Remove the 2 screws.
  Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
2. Disconnect the door lock control cables, then remove the back door control.
Fig 5: Removing Back Door Lock Control
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SERVICE HOLE COVER
NOTE: Do not tear the service hole cover.
REMOVE KEY CYLINDER
1. Disconnect the connector.
2. Remove the 2 bolts and the key cylinder.
  Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
Fig 6: Removing Key Cylinder
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BACK DOOR LOCK
1. Disconnect the control cables from the clamps.
2. Using a torx wrench, remove the 6 screws and the back door locks.
  Torx wrench: T30 (Part No. 09042-00010 or locally manufactured tool)
  
  Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
  
  Fig 7: Removing Back Door Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  At the time of assembly, please refer to the following item. Apply MP grease to the rotating parts of the door lock.
  
  Fig 8: Identifying Grease Application Point
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Employ the same manner described above to the other side.
REMOVE REAR LAMP ASSEMBLY
1. Disconnect the connector.
2. Remove the 6 nuts.
3. Using a screwdriver, remove the rear lamp assemblies.
  HINT:
  
  Tape up the screwdriver tip before use.
4. Employ the same manner described above to the other side.
Fig 9: Removing Rear Lamp Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TAIL GATE STAY
1. Using a torx wrench, remove the 2 screws and the tail gate stay.
  Torx wrench: T30 (Part No. 09042-00010 or locally manufactured tool)
  
  Torque: 17.5 N.m (178 kgf.cm, 13 ft.lbf)
2. Employ the same manner described above to the other side.
Fig 10: Removing Tail Gate Stay
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002