Toyota Tundra Service Manual: Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

HINT:

• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
• A bolt without a torque specification is shown in the standard bolt chart (See page ).

PROCEDURE

1. INSTALL REAR DOOR WEATHERSTRIP LH

(a) Attach the 41 clips to install the weatherstrip. HINT: If clips are damaged during installation, replace them.

(b) Attach the 2 clips.

2. INSTALL REAR DOOR CHECK ASSEMBLY LH

(a) Apply MP grease to the sliding areas of the door check.

(b) Install the door check to the door panel with the 2 nuts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(c) Apply adhesive to the threads of the bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(d) Install the bolt.

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

3. INSTALL REAR NO. 2 DOOR WEATHERSTRIP LH

(a) Attach the 10 clips to install the weatherstrip.

4. INSTALL REAR DOOR LOCK OPEN ROD LH

5. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH

(a) Slide the outside handle frame to install it. NOTICE: If the release plate is not pulled and held when installing the outside handle, it will strike against the outside handle and become damaged.

(b) Using a T30 "TORX" wrench, tighten the screw.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

(c) Install the front and rear outside handle pads.

6. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH

(a) Install the handle by pushing it in the direction of the arrow in the illustration. NOTICE: If the bellcrank lever is not pulled and held when installing the handle, the bellcrank lever will interfere with the handle and become damaged.

7. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH

(a) Using a T30 ''TORX'' socket, install the cover with the screw. Torque: 4.0 N·m {41 kgf·cm, 35 in·lbf}

(b) Install the hole plug.

8. INSTALL REAR DOOR LOCK CHILD PROTECTION COVER LH

9. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH

(a) Install the rear door inside locking cable.

(b) Attach the 3 claws.

10. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

(a) Install the rear door lock remote control cable.

(b) Attach the claw.

11. INSTALL REAR DOOR LOCK ASSEMBLY LH

(a) Apply MP grease to the sliding and rotating parts of the rear door lock.

(b) Install a new door lock wire harness packing to the door lock.

NOTICE:

• When reusing a door lock that has been removed, replace the packing in the connecting part with new packing.
• Be careful that no grease or dirt sticks to the packing surface in the connecting part.
• Reusing removed packing or using damaged packing will allow water to penetrate through to the connecting part, resulting in a malfunction of the door lock.

(c) Using a T30 ''TORX'' wrench, install the door lock with the 3 screws. Torque: 5.0 N·m {51 kgf·cm, 44 in·lbf}

(d) Connect the connector.

12. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

(a) Apply MP grease to the sliding and rotating areas of the regulator motor.

(b) Using a T25 ''TORX'' driver, install the motor with the 3 screws. Torque: 5.4 N·m {55 kgf·cm, 48 in·lbf} HINT: For a new rear window regulator, the installation position of the regulator will be set when the self-tapping screws are installed.

13. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH

(a) Apply MP grease to the rear door power window regulator.

(b) Loosely install the temporary bolt onto the window regulator.

(c) Insert the window regulator into the door panel. Use the temporary bolt to hang the window regulator on the door panel.

(d) Temporarily install the window regulator with the 5 bolts, and tighten the temporary bolt so that it contacts the door panel.

(e) Tighten the 6 bolts in the order shown in the illustration.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

14. INSTALL REAR OUTER DOOR GLASS WEATHERSTRIP

15. INSTALL REAR NO. 2 DOOR GLASS RUN LH

(a) Install the rear door glass run to the rear door window front lower guide.

16. INSTALL REAR DOOR FRONT WINDOW GUIDE SUB-ASSEMBLY LH

(a) Install the rear door front window guide to the door panel with the 2 bolts.

17. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH

(a) Insert the door glass into the door panel along the glass run as indicated by the arrows in the illustration. NOTICE: Be careful not to damage the glass.

(b) Install the door glass to the window regulator with the 2 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

18. INSTALL REAR DOOR REAR LOWER WINDOW FRAME SUB-ASSEMBLY LH

(a) Install the rear door rear lower window frame to the door panel with the 2 bolts.

19. INSTALL REAR DOOR GLASS RUN LH

(a) Install the rear door glass run.

20. INSTALL REAR DOOR SERVICE HOLE COVER LH

(a) Attach the 5 clamps to install the rear door service hole cover. NOTICE: When installing the service hole cover, pull out the links through the service hole cover. There should be no wrinkles or folds after attaching the service hole cover. After attaching the service hole cover, check the sealing quality.

21. INSTALL REAR SPEAKER ASSEMBLY

22. INSTALL REAR NO. 2 DOOR TRIM BRACKET

(a) Install the bracket with the 2 screws.

23. INSTALL REAR INNER DOOR GLASS WEATHERSTRIP LH

24. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 12 Speakers)

25. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH

(a) Connect the 2 cables to the inside handle.

(b) Attach the inside handle's knob to the door trim board.

(c) for 12 Speakers:

(1) Connect the connector.

(d) Attach the 10 clips to install the door trim board.

(e) Install the inside handle and door trim board to the door trim panel with the screw.

(f) Install the door trim board to the door panel with the screw.

(g) Install the clip.

26. INSTALL REAR DOOR ARMREST COVER LH

27. INSTALL REAR DOOR FRAME GARNISH LH

(a) Attach the 5 clips to install the rear door frame garnish.

28. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY

29. INSTALL REAR UPPER DOOR ARMREST BASE PANEL LH

(a) Connect the connector.

(b) Attach the 2 clips and 5 claws to install the rear upper door armrest base panel LH.

30. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH

(a) Attach the 4 claws to install the bezel plug.

31. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL