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Old 04-03-2010, 05:58 AM #1
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Rust beneath door handle(s)

I am creating a post to help those who are having rust stains streak from beneath the door handles. Apparently, this is due to a screw that is non-galvanized/stainless, that holds the door handle in place. I attempted yesterday to pull off the rear passenger panel to identify the type of screw it is, but ran into a hassle trying to pry off the door panel with a spatula (covered in electrical tape). Below are some photos showing the rust and the loosening of the panel. I will be picking up the trim tool today and reattempt this procedure. I will also pick up a roll of butyl tape to reapply the weather wrap, as I have the vehicle sprayed by Krown annually for rust prevention and would hate to have that stuff seep into the cabin. All four handles are having this issue, and I am worried about the rust getting into chips around the handle.

A side note: I am visiting the local autowreckers later today to see if they have a shell for the rear tailgate, as I am also noticing rust start to eat at around the plastic trim. If I can get one in the same colour, I will create a post for the install. I picked up this '05 about five months ago, and there was no indication of rust (it was still being driven by the dealers manager, was not entered into their inventory yet nor was it cleaned for customers, so they did not know about the rust issue).








...To Be Continued
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Old 04-04-2010, 01:00 PM #2
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A bit further

Ok, so I managed to remove the door panel by way of a spatula and brute force (not as difficult as I assumed). A further look hints that it is not the bolt that is rusting, but the washer/nut. I tried to remove the bolt with an allen key, but I feel I should wait until I can pick up a torx set to avoid possible damage to the head. This will have to wait until next weekend, as today is a holiday. The bolt to me looks galvanized, so I don't think it contributed to the rust.







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Old 04-05-2010, 10:08 AM #3
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This is great info. We don't get the rust out west like Ontario but this is great to know if I ever start seeing these streaks. Thx for the post.
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Old 04-05-2010, 01:16 PM #4
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Quote:
Originally Posted by gptoy96 View Post
This is great info. We don't get the rust out west like Ontario but this is great to know if I ever start seeing these streaks. Thx for the post.
Tell me about it. I hate the amount of salt/de-icing compound that we use here.

I have picked up a torx set, containing a T27 and T30, and will remove the nut/washer causing this issue. More pics to come.
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Old 04-10-2010, 11:04 AM #5
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Got it!

A couple of days ago, I tried to remove the bolt, with no luck. I let it sit in WD40 for a couple of hours, again, no luck. I then took my impact gun, and went at it in a non-agressive fashion. I ended up snapping the head of the bolt off, which allowed me to continue removing the assembly by way of the assistance of "drmorbius" (thanks!!). Here are the steps, continuing from my previous picture above:

Remove three screws holding the lock assembly.



Puncture white-circular seal (top-left of lock assembly) to get access to secondary screw holding door handle cover.


Look at that mess! I had to use Meguires X-Scratch to remove the rust stains, as nothing else would penetrate it. I cannot say for certain that there was no damage to the metal edge, as there was a bead-sized "stain" on the edge that was not coming off.


The handle assembly, indicating where the rusted nut sits. Don't mind the newspaper:





Here is the culprit. This is a unique nut, as it fits tightly into the plastic inner moulding of the handle, yet the "round" washer-like part is thin enough to still allow it to be secure, and also allow the rubber seal to fit flush with the door panel. I have installed a stainless steel bolt in the reverse fashion until I visit the dealer for this part. I cannot find it in the catalog, so I hope I don't have to purchase four door handle assemblies.





By snapping off the head, the handle was easily removable. If I were not able to break the head or unscrew the bolt entirely, then there will be no possible way for it to come off. The nut is covering almost a 1/2" of screw thread (length wise), so there was too much surface contact with the rust, which made it impossible to remove (and thus broke the head of the screw).
I will provide part numbers for the nut and bolt once I obtain them.

Elias
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Last edited by eliask08; 04-10-2010 at 11:06 AM. Reason: pics are a no-show
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Old 04-10-2010, 05:01 PM #6
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Home Depot it is

The dealer wanted $140/door (rear), and $99/door (front) for the inner assemblies. They did not sell the nut alone. I popped into home depot on my way back, and picked up aluminum Chicago screws, and plastic 8-32 nuts that I will strip the threads from (in order to maintain the hex column). I will use a bit of locktight on the screws (weakest version), for added support. I could not get any stainless/galvanized version, and all the other screws/nuts were too big.
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Lined Up: '06+ Headlight Assembly and Grill swap. - Headlight's done (sweet!), grille waiting. EBC Green pads and cross-drilled rotors installed. 3000k HID in fogs. Alpine INA-W900BT Nav unit installed with JBL bypass.

Last edited by eliask08; 04-11-2010 at 09:45 AM. Reason: Grammer, spelling, and a bunch of other engrish stuff
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Old 04-10-2010, 05:43 PM #7
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Excellent write-up!
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Old 06-04-2010, 03:32 PM #8
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Finished!

Just finishing this off, I have replaced all four with a Chicago-style bolt, and things seem to be fine despite the fact that they are aluminum. I had scratched the shit out of the door from around the rusted bolt while trying to take out the last of four, though cleaned and quickly followed it up with touch-up paint. This sits behind the plastic guard, so it is not visible. I will be wet-sanding the area behind the door handle to remove nail scratch marks (fingernails from previous owner) from all four doors, so I will visit this touch-up to see if it has cured/sealed alright (before the salt season hits).

Toyota Canada nor Brimmel Toyota (in Scarborough Ontario) would even contact me regarding this (ignored me completely, but still call me for service requests - go figure), which is a real shame as I am a devout fan. All I wanted was four 50-cent bolts, that's all.
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Old 05-21-2013, 04:08 PM #9
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Toyota Part Number for replacement nuts

Just called the toyota dealer and got the part number off of technical service bulliten SB0181-12. Part number for the door handle nut is 90179-05118 one per door.
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Old 05-21-2013, 04:46 PM #10
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will put some anti-seize on the nut helping this situation?
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Old 05-27-2013, 08:48 PM #11
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Quote:
Originally Posted by wolf4runner View Post
will put some anti-seize on the nut helping this situation?
Not really, as they would still rust. GMAN714 indicates there was a service bulletin, so clearly they were defective. This area is hit with a good amount of rain/slush/salt, so it should be galvanized or stainless.

Two years in and the Chicago screws are still holding.
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Old 05-28-2013, 12:34 PM #12
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Great post. I don't know why I didn't see this one the first time around, but am glad it was revived. I just noticed the rust stain on my rear left door, and was wondering what was going on, now I know. I guess I have another task for this summer...............
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Old 09-07-2016, 06:40 PM #13
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I dealt with the same problem but bought Toyota set:
90179-05118 nut
90386-08066 bush
69296-48010 bolt
New nuts are galvanized.

I followed https://www.youtube.com/watch?v=bFhs9b_SBz8 to remove rear panels. For fronts I suggest watching https://www.youtube.com/watch?v=yjhYKzE_yBg, she does it on Tacoma but how absorbing it is..
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Old 10-17-2016, 03:29 PM #14
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Quote:
Originally Posted by luckyluke View Post
I dealt with the same problem but bought Toyota set:
90179-05118 nut
90386-08066 bush
69296-48010 bolt
New nuts are galvanized.

I followed https://www.youtube.com/watch?v=bFhs9b_SBz8 to remove rear panels. For fronts I suggest watching https://www.youtube.com/watch?v=yjhYKzE_yBg, she does it on Tacoma but how absorbing it is..
Part numbers are very very helpful, thanks a lot for posting these. I ordered 4 sets of each of these and plan to take this project on next weekend. I only hope that I don't have to deal with stripped bolts like the OP, fingers crossed! Will post back with an update.
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Old 10-18-2016, 04:18 PM #15
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Quote:
Originally Posted by xxaarraa View Post
Part numbers are very very helpful, thanks a lot for posting these. I ordered 4 sets of each of these and plan to take this project on next weekend. I only hope that I don't have to deal with stripped bolts like the OP, fingers crossed! Will post back with an update.
No worries. Stripped/broken bolts are not a problem. I stripped all 4. It's easy to knock the rusted left overs out.
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