T-SB-0191-17_Rev

T-SB-0191-17
Rev1
February 28, 2017
Power Back Door System Has Abnormal Closing
Operation
Service
Category
Vehicle Exterior
Section
Door/Hatch
Market USA
Applicability
YEAR(S)
MODEL(S)
2008 - 2013
Highlander, Highlander HV
ADDITIONAL INFORMATION
REVISION NOTICE
July 13, 2017 Rev1:
The Repair Procedure, Parts Information and Required Tools & Equipment sections have
been updated.
Any previous printed versions of this bulletin should be discarded.
SUPERSESSION NOTICE
The information contained in this bulletin supersedes SB No. T-SB-0038-15.
The entire bulletin has been updated.
Service Bulletin No. T-SB-0038-15 is Obsolete and any printed versions should be discarded.
Be sure to review the entire content of this bulletin before proceeding.
© 2017 Toyota Motor Sales, USA
Page 1 of 7
T-SB-0191-17
Rev1
February 28, 2017
Page 2 of 7
Power Back Door System Has Abnormal Closing Operation
Introduction
Some 2008 – 2013 model year Highlander and Highlander HV vehicles may exhibit a condition
where the Power Back Door does not close properly. The Power Back Door may get to the fully
closed position and then reverse to the open position. In other cases, the door may close, but a
pop or clunk noise is heard when the door latch reaches the striker. Use the following information
to inspect the Power Back Door and address this condition.
NOTICE
The purpose of this Service Bulletin is to provide inspection and repair instructions for the Power
Back Door. It enhances the durability of the Power Back Door when operating using the Power
Close function. When the Power Close function is used, if objects or cargo are continually
interfering with the closure of the back door, damage to the back door and/or back door hinges
may occur.
To minimize the possibility of damage occurring, BEFORE closing the Power Back Door,
customers should ALWAYS confirm that objects in the cargo area will NOT impede or interfere
with the closing operation of the back door. Additionally, customers should NOT use ANY part of
their body to intentionally activate the Jam Protection function of the Power Back Door. See the
Owner’s Manual for additional information on the Power Back Door Jam Protection function.
Warranty Information
OP CODE
BD1620
DESCRIPTION
Hatch Deformation Inspection*
TIME
OFP
T1
T2
0.5
67005-0E230
67005-0E231
67005-0E232
67005-48430
67005-48431
67005-48432
9A
13
*Use typical body shop sublet type “ZZ” other for claiming preparation, repair, sealing, and painting of the rear hinges
and back door panel assembly.
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.
© 2017 Toyota Motor Sales, USA
T-SB-0191-17
Rev1
February 28, 2017
Page 3 of 7
Power Back Door System Has Abnormal Closing Operation
Parts Information
1.
Back Door Name Plates
NOTE
Order applicable parts from the tables below.
A. Highlander With or Without JBL 9 Speaker & Subwoofer
YEARS
ENGINE
1AR-FE
2008 – 2009
2WD
2GR-FE
4WD
1AR-FE
2010 – 2013
PART NUMBER
DRIVE TYPE
2WD
2GR-FE
4WD
75444-21220
75442-48090
75444-48090
90975-02071
–
1
–
1
–
1
1
1
1
1
1
1
–
–
–
1
–
–
–
1
1
–
–
1
B. Highlander HV With or Without JBL 9 Speaker & Subwoofer
YEARS
2008 – 2009
2010 – 2013
GRADE
PART NUMBER
75445-48090 75442-48090 75445-48070 75445-48080 75403-48010 90975-02071
Limited
1
1
–
1
–
1
Other
–
1
–
1
–
1
Limited
1
–
1
–
1
–
Other
–
–
1
–
1
–
© 2017 Toyota Motor Sales, USA
T-SB-0191-17
Rev1
February 28, 2017
Page 4 of 7
Power Back Door System Has Abnormal Closing Operation
Parts Information (Continued)
2.
Other Necessary Parts (Highlander and Highlander HV)
NOTE
Order ALL the applicable parts listed below. ALL parts replaced are subject to warranty
parts recovery.
Re-use parts that are NOT listed.
A. WITHOUT JBL 9 Speaker & Subwoofer
PART NUMBER
PART NAME
QTY
67005-48860
Panel Sub-assy, Back Door
1
04006-32148
Kit, Stay, Back Door, RH, w/o Woofer
1
04006-32248
Kit, Stay, Back Door, LH, w/o Woofer
1
04006-32548
Kit, Weatherstrip and PBD Bolt
1
04006-4110E
Kit, PBD Motor
1
04006-4120E
Kit, Hinge, Back Door
1
04006-4130E
Kit, Parts for Outside Garnish R/R
1
PART NUMBER
PART NAME
QTY
67005-48860
Panel Sub-assy, Back Door
1
04006-32348
Kit, Stay, Back Door, RH, w/Woofer
1
04006-32448
Kit, Stay, Back Door, LH, w/Woofer
1
04006-32548
Kit, Weatherstrip and PBD Bolt
1
04006-4110E
Kit, PBD Motor
1
04006-4120E
Kit, Hinge, Back Door
1
04006-4130E
Kit, Parts for Outside Garnish R/R
1
B. WITH JBL 9 Speaker & Subwoofer
Required Tools & Equipment
REQUIRED TOOLS & MATERIAL
QTY
Measuring Scale
1 set
Torque Wrench
1
© 2017 Toyota Motor Sales, USA
T-SB-0191-17
Rev1
February 28, 2017
Page 5 of 7
Power Back Door System Has Abnormal Closing Operation
Inspection Procedure
1. Visually inspect the Lift Arm Stud and Power
Back Door Bracket for bends or damage
as shown.
Figure 1.
Are the Power Back Door Bracket and Lift
Arm Stud damaged?
1
\

YES — Go to the Repair Procedure.

NO — Continue to step 2.
2
z
z
2. Remove the Power Back Door Upper Rod.
Refer to the Technical Information System
(TIS), applicable model and model year
Repair Manual:

2008 / 2009 / 2010 / 2011 / 2012 /
2013 Highlander:
Vehicle Exterior – Engine Hood/Door –
“Engine Hood/Door:
Back Door: Disassembly”

3
z
1
Lift Arm Stud
2
Power Back Door Bracket
3
Back Door Upper Rod
2008 / 2009 / 2010 / 2011 / 2012 / 2013
Highlander HV:
Vehicle Exterior – Engine Hood/Door –
“Engine Hood/Door:
Back Door: Disassembly”
3. Measure the current torque of the Lift Arm Stud.
Is the torque < 10N*m (102 kgf*cm, 89 in*lbf)?

YES — Go to the Repair Procedure.

NO — Continue to step 4.
4. Measure the lateral offset of the striker to latch relationship with the door unlatched and
slightly open.
A. Measure 31 mm from the left facing
surface of the passenger side on the
hatch latch and mark it. This is now the
latch opening center point.
Figure 2.
© 2017 Toyota Motor Sales, USA
T-SB-0191-17
Rev1
February 28, 2017
Page 6 of 7
Power Back Door System Has Abnormal Closing Operation
Inspection Procedure (Continued)
B. Measure the center mark of the latch
opening and compare it to the center
line of the striker.
Figure 3.
Is the latch < or = 3.1 mm from the
center line of the striker?

YES — This bulletin does NOT
apply. Continue diagnosis using the
applicable Repair Manual.

NO — Continue to the
Repair Procedure.
1
Striker Center Line
2
Gap
Figure 4. OK Condition
1
1
© 2017 Toyota Motor Sales, USA
Striker Center Line
T-SB-0191-17
Rev1
February 28, 2017
Page 7 of 7
Power Back Door System Has Abnormal Closing Operation
Repair Procedure
1. Sublet repair of the Power Back Door system and refinishing of body components to a body
shop. Repainting and repair of the back door and hinges should be done in accordance with
Toyota’s body repair recommendations.
Refer to TIS, applicable model and model year Repair Manual and the following manuals:

Toyota Body Repair Manual:
 Fundamental Body Repair Procedures

Toyota Collision Repair Manuals:
 2008 – 2013 Highlander Collision Repair Manual
 2008 – 2013 Highlander HV Collision Repair Manual
2. Confirm body fitment gaps and measurements.
Refer to TIS, applicable model and model year Repair Manual:

2008 / 2009 / 2010 / 2011 / 2012 / 2013 Highlander:
Vehicle Exterior – Door/Hatch – “Engine Hood / Door: Back Door: On-Vehicle Inspection”

2008 / 2009 / 2010 / 2011 / 2012 / 2013 Highlander HV:
Vehicle Exterior – Door/Hatch – “Engine Hood / Door: Back Door: On-Vehicle Inspection”
NOTE
Confirm the clearance between the body and back door including mating parts based on the
Repair Manual. If the door is outside of the measurement specification, adjust/repair using
the applicable Repair Manual.
3. Confirm the repair and proper operation.
© 2017 Toyota Motor Sales, USA