Water Leaking Through Roof Rack Attachment Clips Due To Sealer Interference (T-SB-0040-24)

WATER LEAKING THROUGH ROOF RACK ATTACHMENT CLIPS DUE TO SEALER INTERFERENCE

TECHNICAL SERVICE BULLETIN

APPLICABILITY

YEAR(S)	MODEL(S)	ADDITIONAL INFORMATION
2020 - 2023	Highlander, Highlander HV

INTRODUCTION

Some 2020 - 2023 model year Highlander and Highlander Hybrid vehicles may exhibit a water leak from the roof rack attachment clips. This may be caused by the sealant in the roof channel obstructing the proper seating position for the clip gasket. Follow the Repair Procedure in this bulletin to address this condition.

PRODUCTION CHANGE INFORMATION

This bulletin applies to vehicles produced BEFORE  the Production Change Effective VINs shown below.

MODEL	PLANT	PRODUCTION CHANGE EFFECTIVE VIN
Highlander	TMMI East	5TD#D##H#PS500007
	TMMI West	5TD#D##H#PS000020
Highlander HV	TMMI East	5TD#A#AH#NS516596
	TMMI West	5TD#B##H#NS101814

WARRANTY INFORMATION

APPLICABLE WARRANTY

• This repair is covered under the Toyota Basic 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. 
• When filing claims for this repair, please follow Toyota Warranty Policy 4.21 (Leak Repairs). 

APPLICABLE WARRANTY

• This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 60,000 kilometers, whichever occurs first, from the vehicle's in-service date. 
• Warranty application is limited to occurrence of the specified condition described in this bulletin. 
• When filing claims for this repair, please follow Toyota Warranty Policy 4.21 (Leak Repairs). 

REQUIRED TOOLS & EQUIPMENT

REQUIRED TOOLS & MATERIAL	QUANTITY
Sharp Blade Such as Exacto or Razor Blade	1
Sandpaper (Various Grit Levels)	As Needed
Touch-up Paint (to Match Vehicle Color)	As Needed

PARTS INFORMATION

PART NUMBER	PART NAME	QTY
90467-08235	Rail Garnish Clip	6

REPAIR PROCEDURE

1. Confirm the condition exists.

   Is the vehicle exhibiting a water leak from the roof rack attachment clips?

   • YES  - Continue to step 2.
   • NO  - This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.
2. Remove the roof rack assembly on the side of the vehicle exhibiting the water intrusion.

   Refer to TIS, Applicable model and model year Repair Manual:

   • 2020 - 2022  Highlander and Highlander HV:

     Vehicle Exterior - Exterior Panels/Trim - Roof Rack - Removal 

   • 2023  Highlander and Highlander HV:

     Vehicle Exterior - Exterior Panels/Trim - Roof Rack - Removal 

3. Inspect the roof channel.

   Is there any sealant within 3 mm of the outside radius of the clip hole that may interfere with flush condition of the clip gasket, as shown in Figure 1?

   • YES  - Continue to step 4.
   • NO  - Replace the clip, ensure full seating of the clip, and go to step  7.
4. Using a razor-sharp edge, remove the sealant near the edge of the hole ensuring it will NOT interfere with the clip gasket and the surface is as flat as possible near the hole as shown in Figure 2.
5. Sand the area down to primer or ED coating (until it is uniformly flat).
6. Paint the affected area using a light coat of color matched touch up paint as shown in Figure 3.
7. Ensure the countermeasure clips and pad are NOT damaged. The NEW clip gasket will be orange (the old clip may have a black gasket).
8. Carefully install the six NEW roof rail garnish clips and reinstall the roof rail garnish.

   Refer to TIS, Applicable model and model year Repair Manual:

   • 2020 - 2023  Highlander and Highlander HV:

     Vehicle Exterior - Exterior Panels/Trim - Roof Rack - Installation 

9. Confirm the condition no longer exists.