T-SB-0023-16 Rev

T-SB-0023-16
Rev1
March 25, 2016
Power Back Door Inoperative
Service
Category
Vehicle Exterior
Section
Door/Hatch
Market USA
Applicability
YEAR(S)
MODEL(S)
ADDITIONAL INFORMATION
2014 - 2015
Highlander, Highlander HV
WMI(s): 5TD
VDS(s): BCRFH, BKRFH, DCRFH, DKRFH,
JCRFH, JKRFH, KKRFH, YKRFH, ZKRFH
Plant Code(s): S
SUPERSESSION NOTICE
The information contained in this bulletin supersedes SB No. T-SB-0027-15.
The entire bulletin has been updated.
Service Bulletin No. T-SB-0027-15 is Obsolete and any printed versions should be discarded.
Be sure to review the entire content of this bulletin before proceeding.
REVISION NOTICE
August 3, 2016 Rev1:
Warranty Information section has been updated with a NEW OP Code.
Any previous printed versions of this bulletin should be discarded.
Introduction
Some 2014 – 2015 model year Highlander and Highlander HV vehicles may exhibit a condition in
which the Power Back Door is inoperative or stops during operation. In some cases this condition
may be associated with cold weather. Follow the Repair Procedure in this bulletin to address
this condition.
© 2016 Toyota Motor Sales, USA
Page 1 of 7
T-SB-0023-16
Rev1
March 25, 2016
Page 2 of 7
Power Back Door Inoperative
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs
shown below.
MODEL
PLANT
DRIVETRAIN
PRODUCTION CHANGE EFFECTIVE VIN
5TDYKRFH#FS118557
2WD
5TDKKRFH#FS118557
5TDZKRFH#FS118557
Highlander
5TDDKRFH#FS221250
TMMI
4WD
5TDJKRFH#FS221250
5TDBKRFH#FS221250
5TDDCRFH#FS013629
Highlander HV
HV
5TDJCRFH#FS013629
5TDBCRFH#FS013629
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
T1
T2
9A
14
9A
71
BD1604
R & R Unit Assy Set, Power Back Door, RH & LH
0.6
68910-09020
68910-09021
68910-09030
68910-09031
68920-09020
68920-09021
68920-09030
68920-09031
EL1620
R & R Computer, Multiplex Network Door
0.5
89222-0E080
NOTE
OP Codes BD1604 and EL1620 are for separate repairs. Please reference the Repair Procedure
section of this document to determine which repair is needed.
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.
© 2016 Toyota Motor Sales, USA
T-SB-0023-16
Rev1
March 25, 2016
Page 3 of 7
Power Back Door Inoperative
Parts Information
NOTE
There is NO Power Back Door Unit Assembly service part number change specific to
this countermeasure.
PART NUMBER
PART NAME
SPEC
QTY
Computer, Multiplex Network Door
N/A
1
68910-09021 or 68910-09022
Unit Assy Set, Power Back Door, RH
1
68920-09021 or 68910-09051*
Unit Assy Set, Power Back Door, LH
Without
Subwoofer
68910-09031 or 68910-09040
Unit Assy Set, Power Back Door, RH
1
68920-09031 or 68910-09052*
Unit Assy Set, Power Back Door, LH
With
Subwoofer
PREVIOUS
NEW
89222-0E080
89222-0E081
1
1
*Note usual 5 digit P/N supersession from 68920 to 68910 on Unit Assy Set, Power Back Door, LH.
Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Plastic Pry Tool Kit*
00002-06020-01
1
* Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
Repair Procedure
1. Before proceeding with diagnosis, check the following:
A. Confirm the Power Back Door Main Switch (located in the glovebox) is turned ON.
B. Set the Power Back Door opening adjustment to position 5 (maximum opening position).
Refer to the Technical Information System (TIS), applicable model and model year
Repair Manual:

2014 / 2015 Highlander:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door System:
Customize Parameters”

2014 / 2015 Highlander HV:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door System:
Customize Parameters”
© 2016 Toyota Motor Sales, USA
T-SB-0023-16
Rev1
March 25, 2016
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Power Back Door Inoperative
Repair Procedure (Continued)
C. Confirm hatch alignment and adjust or repair if necessary.
Refer to TIS, applicable model and model year Repair Manual:

2014 / 2015 Highlander:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Back Door: Adjustment”

2014 / 2015 Highlander HV:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Back Door: Adjustment”
D. Confirm touch sensors are undamaged and operating normally.
2. Operate the Power Back Door and attempt to duplicate the condition.
NOTE
Some failure modes occur ONLY when the ambient temperature is below freezing. If the
customer experienced the condition in cold weather, cold soak the vehicle outside overnight,
then perform diagnosis in steps 2 – 4 (if required) before warming the vehicle in the shop.

If the Power Back Door begins to open or close, then stops, proceed to step 5.

If the Power Back Door is inoperative (no movement in the closing direction, no movement
beyond latch release in the opening direction), proceed to step 3.
3. Turn OFF the Power Back Door system using the main switch located in the glove
compartment and attempt to operate the back door manually.

If the door cannot be opened or closed manually, or if the force required to manually
operate the door is abnormally high, proceed to step 5.

If manual operating effort is normal, and the ambient temperature was below freezing when
the condition was duplicated, proceed to step 4.

If manual operating effort is normal, and the ambient temperature was above freezing when
the condition was duplicated, STOP. This bulletin does NOT apply. Continue diagnosis
using the applicable Repair Manual.
NOTE
The force required for manual operation may be higher in cold temperatures. If necessary, a
similar vehicle can be used for comparison.
© 2016 Toyota Motor Sales, USA
T-SB-0023-16
Rev1
March 25, 2016
Page 5 of 7
Power Back Door Inoperative
Repair Procedure (Continued)
4. Turn ON the Power Back Door system using the main switch located in the glove
compartment. Remove the back door trim panel and use a heat gun to warm the Door
Computer (Computer, Multiplex Network Door) for 2 – 3 minutes, then attempt to operate the
Power Back Door.

If normal operation is restored, replace the Door Computer and proceed to step 7.

If there is no change to the condition, STOP. This bulletin does NOT apply. Continue
diagnosis using the applicable Repair Manual.
Refer to TIS, applicable model and model year Repair Manual:

2014 / 2015 Highlander:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Back Door Closer ECU: Removal”

2014 / 2015 Highlander HV:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Back Door Closer ECU: Removal”

2014 / 2015 Highlander:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Back Door Closer ECU: Installation”

2014 / 2015 Highlander HV:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Back Door Closer ECU: Installation”
5. Remove and replace the LH and RH power back door actuators (Unit Assy Set, Power Back
Door). Refer to TIS, applicable model and model year Repair Manual:

2014 / 2015 Highlander:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door Drive Unit: Removal”

2014 / 2015 Highlander HV:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door Drive Unit: Removal”

2014 / 2015 Highlander:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door Drive Unit: Installation”

2014 / 2015 Highlander HV:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door Drive Unit: Installation”
© 2016 Toyota Motor Sales, USA
T-SB-0023-16
Rev1
March 25, 2016
Page 6 of 7
Power Back Door Inoperative
Repair Procedure (Continued)
6. After installing the NEW Power Back Door actuators, confirm that the ball and socket joints
(2 LH and 2 RH) are properly seated, and have approximately 1 mm of free-play as indicated
in Figure 1.
To check for free-play: first push, then pull, then push again on the power back door actuator
unit near each socket.

If free-play is present, continue to step 7.

If there is NO free-play as shown in Figure 2, the ball mount is NOT fully seated in
the socket.
Figure 1. Expected Free-Play Condition
1
1 mm Free-Play: Ball Mount is Fully Seated in
the Socket
Figure 2. No Free-Play Condition
2
No Free-Play: Ball Mount is Not Fully Seated
in the Socket
NOTICE
If the ball mount is NOT fully seated in the socket mount separation may occur, which may
cause damage to the vehicle.
Attempt to seat the joint by pushing on the actuator near the socket. If free play cannot be
achieved, replace the actuator and ball mounts with another NEW service part.
© 2016 Toyota Motor Sales, USA
T-SB-0023-16
Rev1
March 25, 2016
Page 7 of 7
Power Back Door Inoperative
Repair Procedure (Continued)
7. Perform the Power Back Door initialization procedure.
Refer to TIS, applicable model and model year Repair Manual:

2014 / 2015 Highlander:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door System: Initialization”

2014 / 2015 Highlander HV:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door System: Initialization”
8. Confirm normal Power Back Door operation.
Refer to TIS, applicable model and model year Repair Manual:

2014 / 2015 Highlander:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door System: Operation Check”

2014 / 2015 Highlander HV:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door System: Operation Check”
© 2016 Toyota Motor Sales, USA