T-SB-0275-17

T-SB-0275-17
August 18, 2017
RAV4 Power Back Door Actuator Mount Separation
Service
Category
Vehicle Exterior
Section
Door/Hatch
Market USA
Applicability
YEAR(S)
MODEL(S)
2016 - 2017
RAV4 HV
2013 - 2017
RAV4
ADDITIONAL INFORMATION
SUPERSESSION NOTICE
The information contained in this bulletin supersedes SB No. T-SB-0168-13.
The entire bulletin has been updated.
Service Bulletin No. T-SB-0168-13 is obsolete and any printed versions should be discarded.
Be sure to review the entire content of this bulletin before proceeding.
Introduction
Some 2013 – 2017 model year RAV4 and 2016 – 2017 model year RAV4 HV vehicles may
exhibit a condition in which the LH or RH power back door actuator (power back door unit
assembly set) separates from the ball mount bracket (back door damper stay bracket) on the
hatch or body side. Additionally, wiring on the actuator may be damaged, causing the power back
door to become inoperative with DTCs B2226, B2227, B2228, or B2229 present. Follow the
Repair Procedure in this bulletin to address this condition.
© 2017 Toyota Motor Sales, USA
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RAV4 Power Back Door Actuator Mount Separation
Production Change Information
This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs
shown below.
MODEL
PLANT
DRIVETRAIN
PRODUCTION CHANGE EFFECTIVE VIN
AWD
2T3RFREV#HW650379
2T3JFREV#HW650379
2T3DFREV#HW650379
2WD
2T3WFREV#HW374831
2T3NFREV#HW374831
2T3YFREV#HW374831
AWD
JTMRFREV#HJ147875
JTMJFREV#HJ147875
JTMDFREV#HJ147875
2WD
JTMWFREV#HJ133029
JTMNFREV#HJ133029
JTMYFREV#HJ133029
AWD
JTMRFREV#HJ704453
JTMJFREV#HJ704453
JTMDFREV#HJ704453
2WD
JTMWFREV#HJ712818
JTMNFREV#HJ712818
JTMYFREV#HJ712818
AWD
JTMRFREV#HD212171
JTMJFREV#HD212171
JTMDFREV#HD212171
2WD
JTMWFREV#HD102947
JTMNFREV#HD102947
JTMYFREV#HD102947
AWD
JTMRJREV#HD112252
JTMDJREV#HD112252
TMMC
Takaoka #1
RAV4
Takaoka #2
Shokki
RAV4 HV
© 2017 Toyota Motor Sales, USA
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RAV4 Power Back Door Actuator Mount Separation
Warranty Information
OP CODE
BD1635
DESCRIPTION
R & R Unit Assy Set, Power Back Door, RH and LH*
TIME
OFP
T1
T2
0.6
68910-49065
68920-49065
68910-09060
68920-09050
9A
40
* If necessary, sublet repair of body damage caused by power back door actuator mount separation.
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.
Parts Information
PART NUMBER
PART NAME
QTY
68910-49069
Unit Assy Set, Power Back Door, RH
1
68920-49065
68920-49069
Unit Assy Set, Power Back Door, LH
1
68910-09060
68910-09091
Unit Assy Set, Power Back Door, RH
1
68920-09050
68920-09061
Unit Assy Set, Power Back Door, LH
1
90159-50365
90159-A0038
Screw, W/Washer Tapping
8
PREVIOUS
NEW
68910-49065
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.
© 2017 Toyota Motor Sales, USA
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RAV4 Power Back Door Actuator Mount Separation
Required Tools & Equipment (Continued)
REQUIRED EQUIPMENT
SUPPLIER
Techstream 2.0*
Techstream Lite
PART NUMBER
QTY
TS2UNIT
ADE
Techstream Lite (Green Cable)
TSLITEPDLR01
1
TSLP2DLR01
* Essential SST.
NOTE
ONLY ONE of the Techstream units listed above is required.
Software version 12.10.018 or later is required.
Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE)
at 1-800-368-6787.
Repair Procedure
1. Confirm that the vehicle exhibits one of the following conditions and proceed as noted below.

Power back door actuator mount separation: Continue to step 2.

Inoperative power back door: Go to step 3.
2. Confirm that the vehicle exhibits a power back door actuator (power back door unit assembly
set) that has separated from the ball mount bracket (back door damper stay bracket) on the
hatch or body side.
NOTICE
Power back door actuator mount separation may cause hatch misalignment or body damage
to the hatch, hatch opening area, roof panel, and hinges. This damage should be repaired
under warranty, including sublet to a body shop if necessary.
BEFORE proceeding with the repair:
A. Visually check for body damage to the hatch, hatch opening area, roof panel, and hinges
caused by power back door actuator mount separation and repair if necessary.
B. Confirm hatch alignment and adjust or repair if necessary.
Refer to the Technical Information System (TIS), applicable model and model year
Repair Manual:

2013 / 2014 / 2015 / 2016 / 2017 RAV4:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Back Door: Adjustment”

2016 / 2017 RAV4 HV:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Back Door: Adjustment”
© 2017 Toyota Motor Sales, USA
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August 18, 2017
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RAV4 Power Back Door Actuator Mount Separation
Repair Procedure (Continued)
3. If the vehicle exhibits an inoperative power back door with no mount separation, use the
following procedure to diagnose the condition.
A. Check for DTCs using Techstream.
B. If DTC B2227 or B2229 is present,
check the RH power back door actuator
for wiring damage in the location shown.
Figure 1.
C. If DTC B2226 or B2228 is present,
check the LH power back door actuator
for wiring damage in the location shown.
D. If wiring damage is identified, proceed to
step 4.
E. If no wiring damage is identified, this
bulletin does NOT apply. Continue
diagnosis using the applicable
Repair Manual.
© 2017 Toyota Motor Sales, USA
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RAV4 Power Back Door Actuator Mount Separation
Repair Procedure (Continued)
4. Remove and replace the LH and RH power
back door actuators (power back door
RH/LH unit assembly set) with NEW
level parts.
Figure 2.
While removing the screws (4 LH and
4 RH) on the power back door touch
sensors as shown, confirm hex head size.
If the existing screws have 10 mm hex
heads, they MUST be replaced with NEW
8 mm hex head screws (screw with
washer tapping).
Refer to TIS, applicable model and model
year Repair Manual:

2013 / 2014 / 2015 / 2016 / 2017 RAV4:
Vehicle Exterior – Door/Hatch –
“Door/Hatch: Power Back Door Drive
Unit: Removal”

2013 / 2014 / 2015 / 2016 / 2017 RAV4:
Vehicle Exterior – Door/Hatch –
“Door/Hatch: Power Back Door Drive
Unit: Installation”

2016 / 2017 RAV4 HV:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door Drive Unit: Removal”

2016 / 2017 RAV4 HV:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door Drive Unit: Installation”
NOTE
Both power back door actuators MUST be replaced at the same time.
10 mm hex head screws on the touch sensors MUST be replaced with 8 mm hex
head screws.
© 2017 Toyota Motor Sales, USA
T-SB-0275-17
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RAV4 Power Back Door Actuator Mount Separation
Repair Procedure (Continued)
5. 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 2 mm of free-play as shown.
To check for free-play: first push, then pull, then push again on the power back door actuator
unit near each socket.
Is free-play present?

YES — Continue to step 6.

NO — The ball mount is NOT fully seated in the socket. Push firmly on the socket until the
joint engages, then recheck for free-play.
Figure 3. Expected Free-play Condition
Figure 4. No Free-play Condition
1
1
2 mm Free-play: Ball Mount is Fully Seated in
the Socket
2
No Free-play: Ball Mount is NOT Fully Seated
in the Socket
6. Perform the power back door initialization procedure.
Refer to TIS, applicable model and model year Repair Manual:

2013 / 2014 / 2015 / 2016 / 2017 RAV4:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door System: Initialization”

2016 / 2017 RAV4 HV:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door System: Initialization”
© 2017 Toyota Motor Sales, USA
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August 18, 2017
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RAV4 Power Back Door Actuator Mount Separation
Repair Procedure (Continued)
7. Confirm normal operation of the power back door. Test jam protection operation in opening
and closing directions.
Refer to TIS, applicable model and model year Repair Manual:

2013 / 2014 / 2015 / 2016 / 2017 RAV4:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door System: Operation Check”

2016 / 2017 RAV4 HV:
Vehicle Exterior – Door/Hatch – “Door/Hatch: Power Back Door System: Operation Check”
NOTE
Jam protection operation MUST be confirmed BEFORE returning the vehicle to the customer.
© 2017 Toyota Motor Sales, USA