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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Door / Hatch - Service Information (1 Of 2) >> Rear Door >> Disassembly [10/2022 - 11/2023] >> Procedure

Disassembly [10/2022 - 11/2023]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

  2. REMOVE BATTERY SERVICE HOLE COVER (for HV Model) 

    Refer to PROCEDURE - Step 1

  3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    for T24A-FTS:

    Refer to PROCEDURE - Step 1

    for A25A-FXS:

    Refer to PROCEDURE - Step 2

  4. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR UPPER ARMREST BASE PANEL 
    1. Apply protective tape to the rear door trim board sub-assembly as shown in the illustration.
      GTY929184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
    2. Using a moulding remover, disengage the 2 clips, 2 claws and 5 guides as shown in the illustration.
      GTY939278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector to remove the rear power window regulator switch assembly with rear door upper armrest base panel.
  5. REMOVE REAR DOOR INSIDE HANDLE BEZEL 
    1. Using a moulding remover, disengage the 3 claws to remove the rear door inside handle bezel.
      GTY897654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Using a screwdriver with its tip wrapped with protective tape, disengage the claw as shown in the illustration.
      GTY874814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    2. Remove the 3 screws.
      GTY939276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 9 clips as shown in the illustration.
      GTY899314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hand Here
      Remove in this Direction
    4. Disengage the 4 claws and guide as shown in the illustration.
      GTY921093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    5. w/ Illumination:
      1. Disengage the clamp.
        GTY939265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the connector.
    6. Disconnect the rear door lock open lever remote control cable and rear door inside lock/unlock knob locking cable as shown in the illustration to remove the rear door trim board sub-assembly.
      GTY926737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Door Inside Lock/Unlock Knob Locking Cable
      *2 Rear Door Lock Open Lever Remote Control Cable
      Remove in this Direction
  7. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Disengage the 3 claws to remove the rear door inside handle sub-assembly.
      GTY897597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE REAR DOOR ARMREST COVER 
    1. Disengage the claw to remove the rear door armrest cover as shown in the illustration.
      GTY853425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  9. REMOVE REAR CURTAIN SUB-ASSEMBLY (w/ Rear Door Sunshade) 
    1. Remove the 7 screws.
      GTY897596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage 3 guides to remove the rear curtain sub-assembly.
  10. REMOVE CURTAIN HOOK (w/ Rear Door Sunshade) 

    HINT: 

    Use the same procedure for both curtain hooks.

    1. Using a screwdriver with its tip wrapped with protective tape, push out the pin as shown in the illustration.
      GTY894147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      Insert Screwdriver Here
    2. Using a screwdriver with its tip wrapped with protective tape, disengage the pin.
      GTY867206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      Insert Screwdriver Here
    3. Disengage the 2 claws to remove the curtain hook as shown in the illustration.
      GTY870459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Push
      Remove in this Direction
  11. REMOVE REAR DOOR FRAME GARNISH 
    1. Using a clip remover, disengage the clip.
      GTY875652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    2. Disengage the 2 guides to remove the rear door frame garnish as shown in the illustration.
  12. REMOVE NO. 2 REAR DOOR FRAME GARNISH 
    1. Disengage the 3 claws to remove the No. 2 rear door frame garnish.
      GTY897628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE REAR SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 4

  14. REMOVE REAR DOOR CHECK ASSEMBLY 
    1. Remove the bolt, 2 nuts and rear door check assembly.
      GTY905743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  15. REMOVE REAR DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the 28 clips, guide and remove the rear door weatherstrip.
      GTY921434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape
  16. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP 
    1. Remove the rear door inner glass weatherstrip as shown in the illustration.
      GTY916483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  17. REMOVE NO. 1 REAR DOOR VENT SEAL 
    1. Disengage the 3 guides to remove the No. 1 rear door vent seal as shown in the illustration.
      GTY928414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  18. REMOVE QUARTER WINDOW UPPER STOP 
    1. Remove the quarter window upper stop as shown in the illustration.
      GTY859475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  19. REMOVE REAR DOOR SERVICE HOLE COVER 
    1. Disconnect the connector.
      GTY939266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps.
    3. Disengage the 7 clips and remove the rear door service hole cover.
      GTY897764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE REAR DOOR GLASS RUN 
    1. Remove the rear door glass run.
      GTY942711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY 
    1. Remove the screw, 2 bolts and rear door window division bar sub-assembly.
      GTY880345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Screw
      Bolt
  22. REMOVE REAR DOOR QUARTER WINDOW GLASS 
    1. Remove the rear door quarter window glass as shown in the illustration.
      GTY899406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  23. REMOVE REAR DOOR QUARTER WINDOW WEATHERSTRIP 
    1. Remove the rear door quarter window weatherstrip from the rear door quarter window glass.
      GTY897761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE REAR DOOR GLASS SUB-ASSEMBLY 
    1. Remove the hole plug.
      GTY897760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the rear power window regulator switch assembly.
    3. Connect the cable to the negative (-) auxiliary battery terminal.
    4. Turn the ignition switch to ON.
    5. Move the rear door glass sub-assembly so that the door glass bolts can be seen.
    6. Turn the ignition switch off.
    7. Disconnect the cable from the negative (-) auxiliary battery terminal.
    8. Disconnect the rear power window regulator switch assembly.
    9. Remove the 2 bolts.
      GTY897763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the rear door glass sub-assembly.

    10. Remove the rear door glass sub-assembly as shown in the illustration.
      NOTE:

      Do not damage the rear door glass sub-assembly.

      GTY924452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  25. REMOVE REAR DOOR WINDOW REGULATOR ASSEMBLY 
    1. Disconnect the connector.
      GTY897755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 nuts and rear door window regulator assembly.
  26. REMOVE REAR DOOR LOCK WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 8

  27. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Disengage the 2 claws and move the lever as shown in the illustration.
      GTY939305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the rear door outside handle assembly as shown in the illustration.
      GTY870483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  28. REMOVE REAR DOOR OUTSIDE HANDLE COVER 
    1. Using a T30 "TORX" socket wrench, loosen the screw.
      GTY897778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The screw cannot be removed because it is integrated into the rear door outside handle frame sub-assembly.

    2. Disengage the 2 claws to remove the rear door outside handle cover.
  29. REMOVE REAR DOOR FRONT OUTSIDE HANDLE PAD 
    1. Disengage the 2 claws and guide to remove the rear door front outside handle pad.
      GTY897777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE REAR DOOR REAR OUTSIDE HANDLE PAD 
    1. Disengage the claw and 3 guides to remove the rear door rear outside handle pad.
      GTY897779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Using a T30 "TORX" socket wrench, remove the screw.
      GTY897769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the claw and guide to remove the rear door outside handle frame sub-assembly as shown in the illustration.
      GTY917526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  32. REMOVE REAR DOOR LOCK CHILD PROTECTION COVER 
    1. Disengage the 6 claws to remove the rear door lock child protection cover.
      GTY897771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE REAR DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 15

  34. REMOVE REAR DOOR FRONT WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 3

  35. REMOVE REAR DOOR REAR WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 4

  36. REMOVE REAR DOOR UPPER WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 5

  37. REMOVE DOOR WINDOW FRAME MOULDING CLIP 
    1. Using a screwdriver with its tip wrapped with protective tape, disengage the 2 claws to remove the door window frame moulding clip.
      GTY842118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
  38. REMOVE REAR DOOR NO. 3 WEATHERSTRIP 
    1. Remove the rear door No. 3 weatherstrip.
      GTY854822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape - -
  39. REMOVE REAR DOOR PANEL CUSHION 
    1. Disengage the claw to remove the rear door panel cushion.
      GTY897742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE REAR DOOR LOWER OUTSIDE MOULDING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  41. REMOVE REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  42. REMOVE REAR DOOR UPPER OUTSIDE MOULDING PAD 

    Refer to PROCEDURE - Step 2

  43. REMOVE REAR DOOR NO. 2 WEATHERSTRIP 
    1. Disengage the 6 clips to remove the rear door No. 2 weatherstrip.
      GTY939296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE REAR DOOR FRONT OUTSIDE SEAL 
    1. Disengage the 4 claws and guide to remove the rear door front outside seal.
      GTY897738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE REAR DOOR DUST PROOF SEAL 
    1. Disengage the 3 claws to remove the 3 rear door dust proof seals.
      GTY897737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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