T-SB-0033-19 Rev

T-SB-0033-19
Rev2
March 21, 2019
Snow Intrusion Preventing Front Door From Fully
Opening
Service
Category
Vehicle Exterior
Section
Body Structure
Market USA
Applicability
YEAR(S)
MODEL(S)
2016 - 2023
Tacoma
ADDITIONAL INFORMATION
REVISION NOTICE
March 29, 2023 Rev2:
 Applicability has been updated to include 2022 – 2023 model year Tacoma vehicles.
April 27, 2021 Rev1:
 Applicability has been updated to include 2020 – 2021 model year Tacoma vehicles.
Any previous printed versions of this bulletin should be discarded.
Introduction
Some 2016 – 2023 model year Tacoma vehicles may exhibit a condition where snow or ice builds
up between the right or left front door and front fender, preventing the front door from fully
opening. Follow the Repair Procedure in this bulletin to address this condition.
Warranty Information
OP CODE
DESCRIPTION
TIME
OFP
BD1901
Remove and Modify Foam Block, RH
0.7
53827-04020
Combo A
Opposite Side
0.6
53828-04020
T1
T2
99
99
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.
© 2023 Toyota Motor Sales, USA
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Snow Intrusion Preventing Front Door From Fully Opening
Parts Information
PART NUMBER
PART NAME
QTY
53827-04020
Protector, FR Fender Side, RH
1
53828-04020
Protector, FR Fender Side, LH
1
67895-04020
Weatherstrip, RR Door No. 3, RH*
1
53855-04010
Pad, FR Wheel Opening Extension No. 2, RH*
1
90189-06236
Grommet (Clip)
7 (per Side)
55355-0C050
Cushion, Instrument Panel, No. 1
1 (per Side)
*Even though the part descriptions say “RH,” the weatherstrip and pad are the same for the right and left sides.
Required Tools & Equipment
REQUIRED TOOLS & MATERIAL
QUANTITY
Heat Gun
1
Isopropyl Alcohol
1
Hacksaw or Equivalent Blade
1
Sandpaper or Handheld Sanding Tool
1
Repair Procedure
1. Confirm the condition exists.
Is there snow or ice buildup between the right or left front door and front fender that prevents
the front door from fully opening?

YES — Continue to step 2.

NO — This bulletin does NOT apply. Continue diagnosis using the applicable
Repair Manual.
2. Clean off the vehicle.
A. Remove the snow.
B. Melt ANY ice using a heat gun.
NOTICE
Be careful NOT to damage the finished surface while using the heat gun.
C. Open the door to a fully open position.
© 2023 Toyota Motor Sales, USA
T-SB-0033-19
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March 21, 2019
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Snow Intrusion Preventing Front Door From Fully Opening
Repair Procedure (continued)
3. Place the vehicle on a lift to remove the right or left front tire and wheel.
4. Remove the right or left front mudguard by removing the five bolts.
Refer to TIS, applicable model and model year Repair Manual:

2016 – 2023 Tacoma:
Vehicle Exterior – Exterior Panels/Trim – “Exterior: Fender Panel Mudguard: Removal”
5. Remove the right or left front fender wheel
opening molding next to the door.
Refer to TIS, applicable model and model
year Repair Manual:

Figure 1.
4
3
2016 – 2023 Tacoma:
Vehicle Exterior – Exterior Panels/Trim –
“Exterior: Wheel Opening
Moulding: Removal”
2
1
A. Peel back the section next to the door.
5
6
7
8
9
NOTE
BEFORE removing the right or left front
fender wheel opening molding, make sure
the vehicle is at room temperature.
The front wheel opening extension pad
is a nonreusable part.
B. Cut away the seven clips closest to the
door side of the front fender liner.
1
Peel Back Section
2
Front Wheel Opening Extension Pad
3
No. 1 Front Wheel Opening Extension Pad
4
No. 2 Front Wheel Opening Extension Pad
5
Front Fender Wheel Opening Molding
6
Bolt
7
Bolt With Mudguard
8
RR
9
Outboard
© 2023 Toyota Motor Sales, USA
T-SB-0033-19
Rev2
March 21, 2019
Snow Intrusion Preventing Front Door From Fully Opening
Repair Procedure (continued)
C. Cut a 105-mm (4.1-in.) extrusion section from the RR door No. 3 weatherstrip
(do NOT use the injection molded joints).
NOTE
RR door No. 3 weatherstrip (P/N 67895-04020) can be used for both the right and
left countermeasure.
Figure 2.
1
2
3
1
RR Door No. 3 Weatherstrip
2
Weatherstrip Extrusion Section
© 2023 Toyota Motor Sales, USA
3
Cut 105 mm (4.1 in.)
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Snow Intrusion Preventing Front Door From Fully Opening
Repair Procedure (continued)
6. If the vehicle has been exposed to a cold
environment for an extended period, use a
heat gun to bring the A-pillar section to
room temperature (between 60°F – 100°F).
Figure 3.
1
7. Clean the A-pillar section using isopropyl
alcohol and allow it to dry for one minute.
2
1
A-pillar Section
2
Area That Must Reach Room Temperature
© 2023 Toyota Motor Sales, USA
T-SB-0033-19
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March 21, 2019
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Snow Intrusion Preventing Front Door From Fully Opening
Repair Procedure (continued)
8. Install the weatherstrip extrusion from the door opening side.
A. Pull back 1/3 of the tape for temporary placement. Then starting at the front fender well,
remove the rest of the tape to press the weatherstrip fully onto the body side outer panel.
B. Refer to the installation reference points as shown to apply the weatherstrip
extrusion section.
NOTE
Figure 4 shows an example of a no-good orientation of the weatherstrip extrusion section that
should look like a “u,” not an “n.” The open channel will be facing up.
Figure 4.
7
5
1
3
2
6
4
1
Relative Distance to Bolt Washer, 5 mm
5
Panel, Cowel Top Side
2
FR Position Relative Distance to Front Door
Hinge Upper, 5 mm
6
Front Door Hinge Upper
3
RR Position Relative Distance to Front Door
Hinge Upper, 30 mm
7
Bolt Washer
4
Countermeasure Weatherstrip Extrusion “n”
Orientation—No Good
9. Apply continuous pressure to the weatherstrip extrusion to ensure proper adhesion
(approximately 20 – 30 seconds).
10. Allow to fully cure and keep the vehicle between 60°F – 100°F for AT LEAST 20 minutes.
© 2023 Toyota Motor Sales, USA
T-SB-0033-19
Rev2
March 21, 2019
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Snow Intrusion Preventing Front Door From Fully Opening
Repair Procedure (continued)
11. Remove the front fender side protector (P/N 53827-04020 for right or 53828-04020 for left)
from inside the front fender well.
12. Using a hacksaw or equivalent blade, cut the material from the inboard side of the front fender
protector (P/N 53827-04020 for right or 53828-04020 for left), following the front fender side
protector cutout.
13. Smooth the cut surfaces using sandpaper or
a handheld sanding tool.
Figure 5.
1
2
3
1
Before
2
After
3
Cut Surface
14. Trim the instrument panel No. 1 cushion (55355-0C050) (EPT sponge material with tape
backing) to approximately 550 mm (21.6 in.) in length (original length 1,323 mm).
© 2023 Toyota Motor Sales, USA
T-SB-0033-19
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March 21, 2019
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Snow Intrusion Preventing Front Door From Fully Opening
Repair Procedure (continued)
15. Install the EPT sponge material to the outer
surface of the front fender side protector.
Figure 6.
1
2
Start on the outboard side, wrap under the
bottom face of the protector, and then end on
the inboard side. (The sponge material should
be one continuous piece.)
3
1
Old
2
New
3
EPT Sponge Attachment Location
Figure 7.
4
2
3
2
3
1
1
EPT Sponge
2
265 mm
3
285 mm
4
© 2023 Toyota Motor Sales, USA
5 mm
T-SB-0033-19
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March 21, 2019
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Snow Intrusion Preventing Front Door From Fully Opening
Repair Procedure (continued)
16. Install the countermeasure front fender side protector. Ensure the EPT sponge has not been
damaged or has fallen off the front fender side protector AFTER installation.
17. Inspect the countermeasure weatherstrip channel area. Ensure the front fender side protector
has not damaged the weatherstrip channel adhesion to the panel.
18. Reinstall the following parts:
Figure 8.
A. Front fender wheel opening molding
(right/left).
4
3
B. Front fender liner (right/left). Replace the
five clips closest to the door side.
2
C. Front mudguard (right/left)
(if applicable).
1
D. Tire and wheel (right/left).
5
6
7
8
9
1
Peel Back Section
2
Front Wheel Opening Extension Pad
3
No. 1 Front Wheel Opening Extension Pad
4
No. 2 Front Wheel Opening Extension Pad
5
Front Fender Wheel Opening Molding
6
Bolt
7
Bolt With Mudguard
8
RR
9
Outboard
© 2023 Toyota Motor Sales, USA
T-SB-0033-19
Rev2
March 21, 2019
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Snow Intrusion Preventing Front Door From Fully Opening
Front Fender Side Protector Cutout
Block section should be cut out 20 mm (3/4 in.) deep.
84 mm
97 mm
(3¼ in.)
(3⅔ in.)
60 mm
(2¼ in.)
© 2023 Toyota Motor Sales, USA