CAR: 2003 4Runner SR5
ISSUE: Broken rear lift gate lock (does not lock--tries to electronically lock but lock will not engage)
HISTORY: One random day, I tried to close my rear lift gate and it would NOT close. The mechanism would try to lock electronically and it just would not latch no matter how I try to close it. Slamming definitely does not work. Nonetheless, I ended up closing the rear lift gate with a pull strap and attaching it one of the tie down loops. After a few days, I tried the rear lift gate door again, and it started working. Not wanting to have the rear door open suddenly some day or have it not lock again, I pre-emptively replaced the rear door lock (Toyota Part # 69110-35090; the latest part number as of this posting; purchased on eBay for $160 from Global Parts Warehouse). I thought I'd write this as a concise summary of previous postings and to make things as clear as possible. Read the original post for great pictures of the process.
TOOLS NEEDED
10mm socket and ratchet
Wide flat head screwdriver (long--works pretty good) or a plastic trim removal kit (preferred method; see notes below)
Thin, small flat head screwdriver [harness disconnecting]
Optional: razor blade, duct tape (rear plastic repair)
FIX SUMMARY (time needed: approximatley 45 minutes)
1. Rolled up all of the windows (front driver's and rear lift gate were most important, and if you have a sunroof, close it).
2. Open up the rear lift gate.
3.
IMPORTANT STEP: Disconnect the negative terminal to the battery. I had to also disconnect the grounding bolt as the fit to the negative terminal was a bit tight. This step is important for reintializing the car ECU at later step so it recoginizes the new lock. Record your favorite radio stations so you can reprogram them later. The battery must be disconnected for at least 10 minutes, and don't reconnect the battery until your new lock has been installed for it to be recognized properly.
4. Pop off the black pastic cover on the lower edge of the rear lift gate door that covers the lock mechanism. Use a wide tape covered screwdriver (to avoid scratches to the paint), and pop out the middle of the cover at the outer edge, bottom edge that is most closest to the inside of the cabin (when the door is closed). Even better is to use a kit from Harbor Freight tools (Part #67021 )--I used the edge that has a wedged lip to do this.
5 Piece Auto Trim and Molding Tool Set
5. Remove the three lower bolts on the lock that were revealed from step 4.
6. Remove the small plastic cover that is over the rear door strap by popping the cover off from the upper edge. Use this image as guide for the next few steps:
http://www.toyota-4runner.org/600822-post4.html
7. Remove the bolt that holds the rear door strap (a 10mm socket).
8. Pop off the large main rear liftgate plastic panel cover by pulling up on the panel (held by 10 clips). Use one of the flat trim removal tools (or covered screwdriver) to help you get started. Start at the lower middle of the panel (by the lock mechanism) and work in a flat trim removal tool (or screwdriver) and pop up the panel. Work your way along the trim to get the panel clips up sequentially. No need to remove the whole rear cover or panel weatherstripping near the top, just pop the clips out and let the panel hang so you get enough clearance. See diagram post in 6 for a guide.
9. Disconnect the rear lift gate lock wiring harness. Once the plastic rear trim (step 8) is lifted off enough for clearance, you'll see the wiring harness for the lock on the driver's side of the lift gate frame. One side of the harness has a locking tab--push a small, thin, flathead screw driver in there to push the tab in while you slide out the wiring harness to the door lock.
10. Remove the lower part of plastic cover sheet from the metal frame. Carefully pull the plastic cover off (mostly on the the lower edge), while separately the pliable rubberized weatherstrip cement with either a thin, blunt screwdriver (or if you're really careful, a blade). Don't cut the plastic cover, just separate it from the frame by cutting/splitting the weatherstrip. You'll be retacking this back on so be careful with the plastic sheet (you can always use duct tape for repairs, but try to miniize the damage. You only need to remove enough weatherstrip so you can get access to the door lock and to slide it out to remove it.
11. Remove the cable clip. On the white door lock plastic enclosure, you'll see a floating black covered cable that's held by a plastic clip (has 2 pressure side tabs), and that clip goes into the door lock enclosure. Use needle nose pliers (or a flat head screwdriver) to push in the side tabs of the clip so it releases and you can remove the plastic clip from the white plastic lock enclosure.
12. Remove the rear lift gate frame bolt that goes to the back of the lock mechanism. The lock mechanism and enclosure is now free.
13. Remove the door lock mechanism. You'll need to loosen the wiring harness rubber grommet to the door frame before you can remove the lock, and slide it under the plastic sheet.
14. Install the new door lock. Remove the string on the new door lock before the install (or leave it hanging as it's a relase for the lock, so you can test it before actually closing and locking the door--but there is no real need to leave the string). For reinstall, follow steps backward from 13 to 4.
15.
IMPORTANT STEP: Reinitialize the rear door lock computer. Reconnect the negative terminal of the battery. Turn key to "ON" position, but do not start car. Then follow the next set of sequences:
- a. The driver's side window "AUTO" switch will be flashing (i.e. "not initialized"). Roll down the driver's side window all the way down. Hold the up button to roll up the driver's side window until it closes--hold it down another 1-2 seconds after it fully closes, the "AUTO" light will illuminate steadily.
- b. [Only if you have a sunroof]. Open up the sunrooff all the way. Close the sunroof all the way by holding the close button--hold it down another 1-2 seconds after it fully closes.
- c. Lower the rear liftgate window all the way. Raise the rear liftgate window all the way up by holding the close button--hold it down another 1-2 seconds after it fully closes.
- d. Start the car and leave it on.
http://www.toyota-4runner.org/178185-post2.html
16. Test the new rear lift gate. With the car still on, go to the back tailgate and open it--it should work like a charm.
17. Reprogram your radio stations if you haven't done so (tune in the station you want, then push and hold which memory preset button you for a few seconds, and it will keep the station in memory). Enjoy!
Notes: For reinitializing and recognizing the newly installed rear lift gate lock, some people have been able to just disconnect the main power wiring harness to their rear lift gate ECU for 10 minutes and reconnecting it after connecting in the new rear lift gate lock, and they were able to avoid step 3 and 15 (battery disconnect, reconnect method). I initially replaced my lock without doing steps 3 and 15 and my new lock didn't work. I had to reinitialize the ECU before it would work. You must reinitialize the ECU whether how I outlined it (battery disconnect method) or disconnecting the rear lift gate ECU power harness. I would imagine that disconnecting the fuse(s) to the rear ECU could work as well (but the fuse block is somewhat non-descript and I am not sure which ones to disconnect).
Nice work to the original poster and those that contributed. My new rear tailgate lock works great.