T-SB-0149-19 Rev

T-SB-0149-19
Rev1
October 22, 2019
Corrosion on the Back Door Steel Reinforcement Panel
Around the Opener Switch and Rear Camera
Service
Category
Vehicle Exterior
Section
Door/Hatch
Market USA
Applicability
YEAR(S)
MODEL(S)
2017 - 2021
Prius Prime
ADDITIONAL INFORMATION
REVISION NOTICE
February 10, 2021 Rev1:
 Applicability has been updated to include 2019 – 2021 model year Prius Prime vehicles.
 The Introduction, Production Change Information, and Repair Procedure sections have
been updated.
Any previous printed versions of this bulletin should be discarded.
Introduction
Some 2017 – 2021 model year Prius Prime vehicles may exhibit corrosion on the back door
sub-assembly steel reinforcement panel visible below the opener switch and rear camera.
Follow the Repair Procedure in this bulletin to address this condition.
Figure 1.
© 2021 Toyota Motor Sales, USA
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T-SB-0149-19
Rev1
October 22, 2019
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Corrosion on the Back Door Steel Reinforcement Panel Around the Opener
Switch and Rear Camera
Production Change Information
This bulletin applies to 2017 – 2021 Prius Prime vehicles produced BEFORE the Production Change
Effective VIN shown below.
MODEL
MODEL YEAR
DRIVETRAIN
PRODUCTION
DATE
PRODUCTION CHANGE EFFECTIVE VIN
Prius Prime
2017 – 2021
FWD
7/17/2020
JTDKAMFP#M3164034
Warranty Information
OP CODE
DESCRIPTION
TIME
BD1905*
Inspect to Confirm Condition – Sublet Repairs to
Body Shop
0.2
BD1906
Sand, Seal, and Refinish Back Door Opener
Switch Reinforcement – In-dealer Repair
2.5
OFP
T1
T2
67005-47911
67
17
*Use sublet type “ZZ” for body shop repair amount.
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.
 In cases where perforation is found, the Toyota Corrosion Perforation coverage is in effect for
5 years from the vehicle’s in-service date, regardless of the mileage. Unlike surface rust, rust
perforation is consistent with a physical hole all the way through the sheet metal.
Parts Information
PART NUMBER
PART NAME
QTY
67005-47911
Panel Sub-Assembly, Back Door
1
© 2021 Toyota Motor Sales, USA
T-SB-0149-19
Rev1
October 22, 2019
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Corrosion on the Back Door Steel Reinforcement Panel Around the Opener
Switch and Rear Camera
Required Tools & Material
REQUIRED TOOLS & MATERIAL
PART NUMBER
QUANTITY
FIELD REPAIR STEP NUMBER
Cavity Wax
3M™ 08852
1
Applicator Wand Kit (For Cavity Wax)
3M™ 08851
1
Sandpaper (80 – 180 grit)
Any
1
Waterborne Cleaner
PPG™ SWX35
1
Solvent Based Cleaner
PPG™ SX330
1
Etch Primer
PPG™ SXA1031
1
Two Part Epoxy Primer
3M™ DP90LV & DP401LF
1
Urethane Seam Sealer
3M™ 08367
1
6
Top Coat – Black Satin
Any
1
7
3
4
5
Repair Procedure
1. Confirm the condition exists.
Does the vehicle exhibit corrosion on the sub-assembly steel reinforcement panel visible
below the opener switch and rear camera?

YES — Continue to step 2.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
NOTE
 If perforation is found, photo documentation is required to be attached to Warranty claim.
 Unlike surface rust, rust perforation is consistent with a physical hole all the way through the
sheet metal.
© 2021 Toyota Motor Sales, USA
T-SB-0149-19
Rev1
October 22, 2019
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Corrosion on the Back Door Steel Reinforcement Panel Around the Opener
Switch and Rear Camera
Repair Procedure (continued)
2. Remove the rear deck trim cover, then remove the back door opener switch and
rear camera.
NOTE
 It is NOT necessary to remove the back door to complete this repair.
 Use proper Personal Protective Equipment (PPE) while performing
this repair.
 The back door steel reinforcement panel sits between two CFRP (Carbon Fiber Reinforced
Plastic) panels. The exterior CFRP panel is painted body color and the interior CFRP panel is
black (not coated).
Refer to TIS, applicable model and model year Repair Manual:

2017 – 2019 Prius Prime:
Vehicle Exterior – Door/Hatch – “Door / Hatch: Back Door: Disassembly”

2020 / 2021 Prius Prime:
Vehicle Exterior – Door/Hatch – “Door / Hatch: Back Door: Disassembly”

2017 – 2021 Prius Prime:
Vehicle Exterior – Door/Hatch – “Door / Hatch: Back Door Opener Switch: Removal”

2017 – 2021 Prius Prime:
Vehicle Exterior – Door/Hatch – “Park Assist / Monitoring: Television Camera: Removal”
3. Apply wax to the hidden portion of the back door steel reinforcement panel.
NOTE
 Only a small portion of the steel reinforcement panel is visible below the back door opener switch
when assembled (Figure 2).
 Coat the part of the steel reinforcement panel that is NOT visible with wax (Figure 3).
Figure 2.
Figure 3.
1
2
1
2
3
1
Back Door Opener Switch
1
Back Door Opener Switch Hole
2
Visible Steel Reinforcement Panel
2
Visible Steel Reinforcement Panel
3
Hidden Steel Reinforcement Panel
© 2021 Toyota Motor Sales, USA
T-SB-0149-19
Rev1
October 22, 2019
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Corrosion on the Back Door Steel Reinforcement Panel Around the Opener
Switch and Rear Camera
Repair Procedure (continued)
A. Lightly pry the interior CFRP and steel reinforcement panel apart with a
small pry tool (Figure 5).
B. Use an applicator wand kit to spray cavity wax in the cavity between the steel
reinforcement panel and the Interior CFRP panel (Figure 5).
Figure 4.
Figure 5.
1
2
z
z
4
1
5
z
z
3
z
1
Hole for Rear Camera
1
Exterior CFRP Panel
2
Cavity Between the Steel Reinforcement Panel
and Interior CFRP Panel
2
Pry Tool
3
Interior CFRP Panel
4
Steel Reinforcement Panel
5
Cavity Between the Steel Reinforcement
Panel and Interior CFRP Panel
© 2021 Toyota Motor Sales, USA
2
z
T-SB-0149-19
Rev1
October 22, 2019
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Corrosion on the Back Door Steel Reinforcement Panel Around the Opener
Switch and Rear Camera
Repair Procedure (continued)
4. Prepare the back door steel reinforcement panel visible surface below the back door opener
switch and rear camera holes for primer application.
NOTE
Mask the painted surrounding area to prevent damage.
A. Use 80 – 180 grit sandpaper to remove
rust from the exposed steel
reinforcement panel surface at the
back door opener switch and rear
camera hole locations (Figure 6).
Figure 6.
1
z
2
z
NOTE
 To remove organic contaminants, use
waterborne cleaner PPG™ SWX35
(or equivalent).
 To remove petroleum-based
contaminants such as cavity wax, use
solvent-based cleaner PPG™ SX330
(or equivalent).
1
Rear Camera Hole
2
Back Door Opener Switch Hole
© 2021 Toyota Motor Sales, USA
T-SB-0149-19
Rev1
October 22, 2019
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Corrosion on the Back Door Steel Reinforcement Panel Around the Opener
Switch and Rear Camera
Repair Procedure (continued)
5. Apply primer to the visible back door steel reinforcement panel.
A. Apply spray etch primer to the exposed
portions of the back door steel
reinforcement panel (Figure 7). Ensure
ALL of the exposed area is coated and
allow it to dry per the material
manufacturer’s recommendations.
Figure 7.
1
z
NOTE
Coat the exposed portions of the
back door steel reinforcement panel
surrounding both the door opener switch
and the rear camera.
1
Visible Back Door Steel Reinforcement Panel
B. Apply two-part epoxy primer to the
visible area of the back door steel
reinforcement panel surrounding the
back door opener switch and rear
camera holes and allow to dry per the
manufacturer’s recommendations.
6. Seal the gap between the back door interior panel and steel reinforcement panel.
A. Use urethane seam sealer to fill the
edge gap between the interior CFRP
panel and the steel reinforcement
panel (Figure 8) to prevent water
entry between the two panels.
Allow the sealer to dry per the
manufacturer’s recommendations.
NOTE
Figure 8.
1
z
6
5
To ensure proper fit of the back door
opener switch and rear camera to the
reinforcement panel when reassembling,
the sealer should be no more than
1.5 mm thick.
z2
4
z
z
z
3
z
1
Up
2
Rear
3
Cross-section
4
Steel Reinforcement Panel
5
Interior Panel
6
Sealer ≤ 1.5 mm Thick
© 2021 Toyota Motor Sales, USA
T-SB-0149-19
Rev1
October 22, 2019
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Corrosion on the Back Door Steel Reinforcement Panel Around the Opener
Switch and Rear Camera
Repair Procedure (continued)
7. Apply two top coats to the back door steel reinforcement panel.
A. Apply two coats of black satin top coat to the visible area of the back door steel
reinforcement panel surrounding the back door opener switch and rear camera holes
(Figure 7) and allow each coat to dry according to material manufacturer
recommendation. The completed repair is illustrated in Figure 9 and Figure 10.
NOTE
Coat the visible portions of the back door steel reinforcement panel surrounding both the door
opener switch and the rear camera.
Figure 9.
Figure 10.
1
1
Rear View of the Gap Between Interior CFRP
and Steel Reinforcement Panel Filled
With Sealer
Visible Front Area of Steel Reinforcement
Panel Painted Black With No Visible Rust
8. Install the back door opener switch and rear camera, then install the rear deck trim cover.
Refer to TIS, applicable model and model year Repair Manual:

2017 – 2021 Prius Prime:
Vehicle Exterior – Door/Hatch –
“Door / Hatch: Back Door Opener Switch: Installation”

2017 – 2021 Prius Prime:
Vehicle Exterior – Door/Hatch –
“Park Assist / Monitoring: Television Camera: Installation”

2017 – 2019 Prius Prime:
Vehicle Exterior – Door/Hatch –
“Door / Hatch: Back Door: Reassembly”

2020 / 2021 Prius Prime:
Vehicle Exterior – Door/Hatch –
“Door / Hatch: Back Door: Reassembly”
© 2021 Toyota Motor Sales, USA