User Tag List

Reply
 
Thread Tools Rate Thread Display Modes
Old 06-01-2017, 03:32 PM #1
lightfreak lightfreak is offline
Member
 
Join Date: Oct 2011
Location: Toronto
Posts: 360
lightfreak will become famous soon enough lightfreak will become famous soon enough
lightfreak lightfreak is offline
Member
 
Join Date: Oct 2011
Location: Toronto
Posts: 360
lightfreak will become famous soon enough lightfreak will become famous soon enough
DIY: Exterior Door Handle Removal

Exterior Door Handle Removal Tutorial - 4th Generation 4Runner ('03-'09)

Those of us in the salt belt have this nagging rust problem under the exterior door handles. It's been discussed here:
Rust beneath door handle(s)
Mine started showing rust several years ago and has gotten worse over time.

Whether you have rust or not, if you're just replacing the handle for some other reason , I highly recommend getting these 3 parts from Toyota, the original nut and bolt are very likely seized and you won't be able to re-use them.
You'll need one of each per door. Same for all 4 doors.

90179-05118 nut
90386-08066 plastic bushing
69296-48010 bolt

The nut is updated from Toyota and is now treated and should not rust in the future.


This first post covers the rear door handle removal, same procedure for both rear doors. Pics will show the driver's side rear door.
Will update thread later with front door tutorials. Driver Front and Passenger Front are slightly different due to the key lock.

Reference diagram of the rear door lock and handle


First you'll need to remove the inner door panel to gain access to everything. Here's a video showing how.
https://www.youtube.com/watch?v=bFhs9b_SBz8

TOOLS

No.2 Phillips
T-27 Torx Head
5/32 Allen Head
4mm Punch
Hammer
Panel Removal tool (if metal, wrap it with tape so you don't scratch your paint)

Tools need to be 4+ inches long to reach into the door.
I also used a stubby No.2 Phillips screwdriver for the screw holding the inner door handle/lock to the door panel, I find it easier.
Socket wrench and penetrating lubricant will also come in handy




Once you have the door panel removed, peel back the vapor barrier carefully, about half way. You can re-seal it later when you're done.

Note the 2 areas marked with a red arrow.
Peel off the white sticker covering the hole. There is a screw behind there you need access to.
Unhook the white connector.
Make note of the black ring around the connector, this ring is part of the lock mechinism inside the door.
Also make note of the blue film in the center of the vapor barrier , it has a slit in it which will come in handy shortly.

Next find the 3 torx screws on the side of the door, these hold in the lock mechnism.

Remove screws , socket wrench with torx head will come in handy here, they are on pretty tight.

The lock mechanism has 2 cables coming from it, and has the inner door handle/lock button on the other end of it.

To properly remove the lock mechanism, while supporting the lock on the screws side with your fingers, push the black ring through the hole until it clears,
then lower the lock mechanism 2 inches or so, then fish it out towards the opening of the vapor barrier.
Do this carefully, there is a plastic lever on the inside that interacts with the lock mech. Dropping it 2 inches will clear this lever. More on this plastic lever later.

Should look like this


Run the cables and inner door handle through the slit in the middle of the vapor barrier. Put aside.

With that out of the way now you can start taking apart the plastic door handle frame support which sits inside the door.

Look through the hole where you removed the white sticker earlier, there is an allen screw there.

Unscrew it 5 or 6 rotations until fully loose. NOTE this screw does NOT come out, there is a retainer in the frame support holding it in place. You just need to loosen it in order to remove the cap on the other side.

Here is the cap on the other side:


While holding the door handle slightly open, use your panel remover tool and pry out the flat side of the cap. It should pop right out.

Should look like this


Next you're going to remove the exterior door handle.

Get a good grip of the handle, give it a good tug in the direction of the arrow. Once released you can wiggle it out.


Next remove the black rubber pad that sits under the handle. (you can remove the other pad too, or just leave it on the door)

Should now look like this, revealing the rusted nut.

The nut clamps against the door skin. Make a mental note of this for later.


Next look through the vapor barrier opening, towards the top, you should see this.

That is the torx head bolt that is likely seized.
Give it a good twist and it should snap off clean.
Then take your punch and hammer and wack the bolt/nut from the inside out.
Get a friend to hold the door while you wack (LOL), or support the door with something sturdy.
I soaked it in Seafoam Deep Creep penetrating spray for a few minutes. Took a few hard wacks to pop out.


Once the nut is out, the door handle frame support should now be free.

Back to the exterior side, use some rubbing compound or scratch remover cream to clean the rust.



The new bushing slips over the new nut like so



Now it's just a matter of reversing all the steps.


When you're re-installing the door lock mechanism, swing the lever on the frame support towards the exterior, then put the lock mech in place ensuring the lever catches the part on the loch mech.

Lock mech on the left, lever from frame support on the right.

Another view



When done , I put a piece of tape over the hole where the sticker used to be, and greased the lock mech.

Should take about 30 minutes or less to complete one door.


Good luck!
---
--
-
__________________
2004 4Runner Limited V6 4WD ***SOLD***
385,000 Km
Titanium Metallic

Vehicles: '21 Highlander XSE V6 AWD | '21 Acura RDX SH-AWD Tech | '03 Honda CBR600F4i
lightfreak is offline   Reply With QuoteReply With Quote
Old 06-05-2017, 06:50 PM #2
luke87gt's Avatar
luke87gt luke87gt is offline
Member
 
Join Date: Jul 2015
Location: SF, CA
Posts: 631
luke87gt is on a distinguished road
luke87gt luke87gt is offline
Member
luke87gt's Avatar
 
Join Date: Jul 2015
Location: SF, CA
Posts: 631
luke87gt is on a distinguished road
Best write-up I've seen on this topic to date on this site. Great job!

Eager to see the pics of the front.

Luke
__________________
2006 4-Runner XSP V6
SCS Ray10 17x8.5 (Matte Black)
Falken ATW3 Wildpeak 265/70/17
Daystar 2.5/1.5
luke87gt is offline   Reply With QuoteReply With Quote
Old 06-10-2017, 12:08 AM #3
lightfreak lightfreak is offline
Member
 
Join Date: Oct 2011
Location: Toronto
Posts: 360
lightfreak will become famous soon enough lightfreak will become famous soon enough
lightfreak lightfreak is offline
Member
 
Join Date: Oct 2011
Location: Toronto
Posts: 360
lightfreak will become famous soon enough lightfreak will become famous soon enough
I was able to do the front passenger door today, and as promised here's the writeup.



Passenger Front Door Handle Removal

Here's the factory diagram for the front doors.



GOOD NEWS! If you're just replacing the door handle this will be a very quick job. No need to remove the door panel and there's no messing around with the lock mechanism!

Same tools in the first post will be fine.
I did recently pickup a plastic panel removal tool set , did come in handy and made the job easier and no worries scratching anything. I ended up using this one from the set


First, open the door and look for this rubber plug


Use the tool to remove the plug


Once removed, look in the hole, there's a torx bolt in there you will need to LOOSEN. It sits at an angle, I had no problem getting to it with the tools listed above. NOTE THIS BOLT DOES NOT COME OUT, there are retainer tabs holding it in the frame support. Just loosen it all the way.

This torx bolt screws into the door handle cap on the outside of the door.

Here's the cap on the outside of the door.

Use the tool to gently pry it out. Open the door handle a bit to get more space to work with.

Cap removed



Now just grab the handle and give it a good tug in the direction of the arrow, then wiggle it straight out.


Removed



If you're just replacing door handles, now just reverse the steps with the new door handle installed and you're done.



------
Below are additional steps to get to the door handle frame support.
The rusted bolt/washer on my passenger front wasn't as bad as the rears, but I replaced it anyway. I used same OEM replacement bolt/nut/bushing as posted above


First you'll need to get the door panel off. Good write-up here:
Idiots guide to door panel removal 4th Gen

**Make sure window is rolled UP ALL THE WAY**

Once the panel is removed , peel back the top part of the vapor barrier, so it looks like this



Next remove the front rubber door handle seal revealing the rusted nut underneath, and re-install the cap (I'll explain why shortly)

Spray some penetrating lube on the nut and let soak for a few minutes


Look inside the vapor barrier opening, this torx bolt securing the door handle frame support needs to be removed. As with the rear doors, it may be seized.

Give it a good turn , if it breaks off , use a punch and hammer to pound out the nut from the inside out (like with the rear door in the first post here)
If it doesn't break off, and the screw comes out , you will still need to use a punch to pound the nut from the inside out. I've found a 4.8mm punch actually fits better than the 4.0mm punch used in the first post. And a few wacks got the nut out clean

Nut and bolt still in one piece


The reason I re-installed the cap was to prevent the frame support from falling inside the door, Once the nut is pounded out there would otherwise be nothing holding the frame support in place. Unlike the rear doors, the passenger front door does't require the lock mech to be removed at all.
If the frame support falls inside the door the wrong way, you may need to remove the loch mech just to get the frame support back out. Hope that makes sense.


Next clean the rust off and insert the new nut/bushing into the frame support, clamping it against the door skin like the original. Then remove the cap, because the door handle won't go in with it installed.



Now just reverse all the steps, re-seal vapor barrier, put your panel back on and hopefully you don't need to do this ever again LOL.

Total time spent on passenger front , 25 minutes, including taking pictures.

I'll do a very short write-up of the driver's front soon, much of the steps are the same as the passenger.

Good luck!
---
--
-
__________________
2004 4Runner Limited V6 4WD ***SOLD***
385,000 Km
Titanium Metallic

Vehicles: '21 Highlander XSE V6 AWD | '21 Acura RDX SH-AWD Tech | '03 Honda CBR600F4i
lightfreak is offline   Reply With QuoteReply With Quote
Old 06-10-2017, 01:04 AM #4
CookieRoe's Avatar
CookieRoe CookieRoe is offline
Senior Member
 
Join Date: Mar 2010
Location: Chester County, PA
Age: 48
Posts: 3,803
Real Name: Ed
CookieRoe is a jewel in the rough CookieRoe is a jewel in the rough CookieRoe is a jewel in the rough
CookieRoe CookieRoe is offline
Senior Member
CookieRoe's Avatar
 
Join Date: Mar 2010
Location: Chester County, PA
Age: 48
Posts: 3,803
Real Name: Ed
CookieRoe is a jewel in the rough CookieRoe is a jewel in the rough CookieRoe is a jewel in the rough
Great write up, thanks!
__________________
Current: 2005 V6 Limited 4x4. SOLD: 2000 HiLux Surf SSR-G, 1997 HiLux Surf SSR-X Limited

CookieRoe is offline   Reply With QuoteReply With Quote
Old 06-22-2017, 01:41 AM #5
lightfreak lightfreak is offline
Member
 
Join Date: Oct 2011
Location: Toronto
Posts: 360
lightfreak will become famous soon enough lightfreak will become famous soon enough
lightfreak lightfreak is offline
Member
 
Join Date: Oct 2011
Location: Toronto
Posts: 360
lightfreak will become famous soon enough lightfreak will become famous soon enough
Driver's Front Door Handle Removal

Exact same procedure as the Passenger front!

The only difference is the door handle cap on the driver's side has a key lock assembly, just need to be a little careful you don't bend or break the arm.

Pry it out gently, working all corners little by little.
Once you get it out about this far, pull it straight out


Removed

While it's out, I cleaned and lubed it with di-electric lubricant.

The blurred part is the key code engraved on the side of the assembly. If you ever need this part replaced make sure you get the same coded part or your keys won't work. This code should match the little key code tag that originally came with the car when purchased new.


I also replaced the rusted nut and bolt on this door.
Snapped off clean with very little force. The bolt was barely hanging on.


New nut and most of the rust cleaned off. This was the worst out of the 4 doors



That completes this DIY tutorial. Any questions , just ask!

...
..
.
__________________
2004 4Runner Limited V6 4WD ***SOLD***
385,000 Km
Titanium Metallic

Vehicles: '21 Highlander XSE V6 AWD | '21 Acura RDX SH-AWD Tech | '03 Honda CBR600F4i
lightfreak is offline   Reply With QuoteReply With Quote
Old 07-16-2017, 09:36 AM #6
AdmiralAugbar's Avatar
AdmiralAugbar AdmiralAugbar is offline
Member
 
Join Date: Jun 2016
Location: Colorado
Posts: 248
AdmiralAugbar is on a distinguished road
AdmiralAugbar AdmiralAugbar is offline
Member
AdmiralAugbar's Avatar
 
Join Date: Jun 2016
Location: Colorado
Posts: 248
AdmiralAugbar is on a distinguished road
None of the pics are showing for me, anyone else?
__________________
2006 Limited V8 - 1.25" wheel spacers | 275/70/18 LT Falken A/T3W | Bilstein 5100s | OME 885 springs in front | FJ springs in rear | LED light bar | Rhino Rack X-Tray
AdmiralAugbar is offline   Reply With QuoteReply With Quote
Old 07-16-2017, 10:31 AM #7
AuSeeker AuSeeker is online now
Senior Member
 
Join Date: Nov 2016
Location: South Carolina
Posts: 4,617
Real Name: Skip
AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future
AuSeeker AuSeeker is online now
Senior Member
 
Join Date: Nov 2016
Location: South Carolina
Posts: 4,617
Real Name: Skip
AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future AuSeeker has a brilliant future
Quote:
Originally Posted by AdmiralAugbar View Post
None of the pics are showing for me, anyone else?
It's Photobucket, they now charge to post photos on forum/blogs, etc., no longer free, hopefully they will see the error of their greed and go back to the way it was, but you may be able to open the photos in another "tab" and view them on Photobucket by right clicking on the "photo" and clicking "open image in new tab", just worked for me using Chrome as my browser.
__________________
2004 Limited V8
AuSeeker is online now   Reply With QuoteReply With Quote
Old 09-01-2017, 07:42 PM #8
aai4ua aai4ua is offline
Junior Member
 
Join Date: Jun 2016
Location: Alabama
Posts: 8
aai4ua is on a distinguished road
aai4ua aai4ua is offline
Junior Member
 
Join Date: Jun 2016
Location: Alabama
Posts: 8
aai4ua is on a distinguished road
What parts do I need?

I am wanting to replace my chrome door handles for color keyed handles on my 2008. I know the door handle is 2 pieces for each door, but it looks like there is another part I may need (some sort lf pad?) Can anyone help me?
aai4ua is offline   Reply With QuoteReply With Quote
Old 02-13-2019, 01:23 AM #9
Liamdoor Liamdoor is offline
Junior Member
 
Join Date: Feb 2019
Location: Mumbai
Posts: 1
Liamdoor is on a distinguished road
Liamdoor Liamdoor is offline
Junior Member
 
Join Date: Feb 2019
Location: Mumbai
Posts: 1
Liamdoor is on a distinguished road
External Door Hardware

A bold classic ultra-modern finish on External Door Hardware. The mirror effect reflects light and colours of the atmosphere and will complement perfectly any fashionable colour scheming. Shiny Chrome is easy to clean and is low maintenance.

External Door Hardware | Brass External Door Hardware | Solid Brass External Door Hardware | Black Iron External Door Hardware
Liamdoor is offline   Reply With QuoteReply With Quote
Old 05-30-2021, 07:29 AM #10
NCHornet NCHornet is offline
Member
 
Join Date: May 2021
Location: Pinnacle , NC
Posts: 59
Real Name: Kevin
NCHornet is on a distinguished road
NCHornet NCHornet is offline
Member
 
Join Date: May 2021
Location: Pinnacle , NC
Posts: 59
Real Name: Kevin
NCHornet is on a distinguished road
Need Some Help Please

I know this is an old thread but I'm desperate, lol!!!! I have a 2007 Limited and I replaced the door actuator on the drivers door but I can't get the lock to fully seat back in place. It's not rocket science, I've replaced many Toyota actuators and never had an issue. The lock goes in but stops 3/16 to 1/4 from being fully seated. The t shaped rod is in the same orientation as the piece on the actuator goes into. I have tried pulling out slightly on the handle to see if that will allow it to drop in place and I made sure the retaining bolt is backed out as far as possible, but it still won't fully seat. The new actuator works when I push the lock and unlock switch on the door which it didn't do before, but for the life of me I can't get this lock to fully seat. I hope somebody can tell me what I need to do. Thanks in advance for your help. God Bless
NCH
__________________
2007 Limited 4wd 140k
NCHornet is offline   Reply With QuoteReply With Quote
Old 05-30-2021, 08:42 AM #11
NCHornet NCHornet is offline
Member
 
Join Date: May 2021
Location: Pinnacle , NC
Posts: 59
Real Name: Kevin
NCHornet is on a distinguished road
NCHornet NCHornet is offline
Member
 
Join Date: May 2021
Location: Pinnacle , NC
Posts: 59
Real Name: Kevin
NCHornet is on a distinguished road
Found The Problem

Going to post this in case anyone else runs into the same problem. I took the actuator out and the plastic "+" piece that the lock arm goes into is installed wrong. It will only go in if it's aligned correctly. The small pieces that form the + aren't the same, they are different thicknesses. Whoever assembled this has got them in wrong so it's impossible for the lock arm to be inserted. I sure hope that I can take this actuator apart and rotate that piece so it's in the correct alignment. I tried inserting a large screwdriver into it to see if I could rotate it, but of course I couldn't, that would be far to easy, right? Here goes nuttin.
NCH
__________________
2007 Limited 4wd 140k
NCHornet is offline   Reply With QuoteReply With Quote
Old 07-12-2021, 10:27 PM #12
poovs poovs is offline
Junior Member
 
Join Date: Oct 2015
Location: colorado
Posts: 19
poovs is on a distinguished road
poovs poovs is offline
Junior Member
 
Join Date: Oct 2015
Location: colorado
Posts: 19
poovs is on a distinguished road
Thx for this post. Helped me reattach the rear driver door handle cap that somehow loosened itself since 2009 and came completely off when we reached our campsite this past weekend.
A few differences on my 2009... The torx screws were all T30 (not T27). Also the screw holding the cap from the inside was also T30 (not 5/32 Allen).
I went ahead and applied some loctite to the screw while I was at it.

Sent from my Pixel 3a using Tapatalk
poovs is offline   Reply With QuoteReply With Quote
Old 05-01-2022, 09:35 PM #13
Eddie Haskell Eddie Haskell is offline
Member
 
Join Date: Jan 2019
Location: Near the Frozen Tundra of Lambeau Field
Posts: 43
Eddie Haskell is on a distinguished road
Eddie Haskell Eddie Haskell is offline
Member
 
Join Date: Jan 2019
Location: Near the Frozen Tundra of Lambeau Field
Posts: 43
Eddie Haskell is on a distinguished road
Thank You

I purchased 4 nuts, 4 bolts and 4 replacement bushings. Between drinking coffee and using the restroom, I started at 8 AM and was done at 11:30 AM, working in the rain.
The drivers side front had me baffled for a bit but I figured it out and got it done. I think the locking mechanism had me scared but in the end, it was no big deal.
No issues which is shocking! I guess 3 out of 4 bolts breaking would be an issue but good planning helped solve that before it was a problem.
I just recently purchased this 4th gen and those rust marks were bugging me so I’m glad that’s taken care of.
Thank again for the write up.
Eddie Haskell is offline   Reply With QuoteReply With Quote
Old 11-25-2022, 01:45 PM #14
[email protected] 2ettares@comcast.n is offline
Member
 
Join Date: Nov 2022
Location: Fremont
Posts: 55
2ettares@comcast.n is on a distinguished road
[email protected] 2ettares@comcast.n is offline
Member
 
Join Date: Nov 2022
Location: Fremont
Posts: 55
2ettares@comcast.n is on a distinguished road
Quote:
Originally Posted by lightfreak View Post
Exterior Door Handle Removal Tutorial - 4th Generation 4Runner ('03-'09)

Here is the cap on the other side:


While holding the door handle slightly open, use your panel remover tool and pry out the flat side of the cap. It should pop right out.

--
-
This looks like the passanger door. How does the driver's door cover with the key pop out?
2ettares@comcast.n is offline   Reply With QuoteReply With Quote
Old 11-27-2022, 12:36 PM #15
lightfreak lightfreak is offline
Member
 
Join Date: Oct 2011
Location: Toronto
Posts: 360
lightfreak will become famous soon enough lightfreak will become famous soon enough
lightfreak lightfreak is offline
Member
 
Join Date: Oct 2011
Location: Toronto
Posts: 360
lightfreak will become famous soon enough lightfreak will become famous soon enough
Quote:
Originally Posted by [email protected] View Post
This looks like the passanger door. How does the driver's door cover with the key pop out?
The instructions for the driver's door is on this thread, post #5

here's a direct link to it.
https://www.toyota-4runner.org/2729778-post5.html

The procedure is not much different actually between the front driver and passenger.
__________________
2004 4Runner Limited V6 4WD ***SOLD***
385,000 Km
Titanium Metallic

Vehicles: '21 Highlander XSE V6 AWD | '21 Acura RDX SH-AWD Tech | '03 Honda CBR600F4i
lightfreak is offline   Reply With QuoteReply With Quote
Reply

Thread Tools
Display Modes Rate This Thread
Rate This Thread:

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
Exterior Door Handle Buckles 4th Gen T4Rs 8 05-30-2017 11:19 PM
Exterior door handle inoperable Vincent96SR5 3rd gen T4Rs 16 11-02-2015 12:06 AM
Exterior drivers door handle loose? Crashnrondo 3rd gen T4Rs 1 09-11-2014 02:27 PM
Exterior door handle scratch guard? TheLast13 5th gen T4Rs 5 04-14-2014 03:05 PM
exterior door handle removal? mole177 4th Gen T4Rs 3 08-19-2009 06:01 AM

Powered by vBadvanced CMPS v3.2.2

All times are GMT -4. The time now is 04:25 PM.

Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2024, vBulletin Solutions Inc.
Search Engine Optimisation provided by DragonByte SEO (Pro) - vBulletin Mods & Addons Copyright © 2024 DragonByte Technologies Ltd.
Feedback Buttons provided by Advanced Post Thanks / Like (Lite) - vBulletin Mods & Addons Copyright © 2024 DragonByte Technologies Ltd.
User Alert System provided by Advanced User Tagging (Lite) - vBulletin Mods & Addons Copyright © 2024 DragonByte Technologies Ltd.
***This site is an unofficial Toyota site, and is not officially endorsed, supported, authorized by or affiliated with Toyota. All company, product, or service names references in this web site are used for identification purposes only and may be trademarks of their respective owners. The Toyota name, marks, designs and logos, as well as Toyota model names, are registered trademarks of Toyota Motor Corporation***Ad Management plugin by RedTyger
 
Copyright © 2020