lock actuator replacment

[4gin007]

This write up is to help explain what it takes to replace the actuator itself, not the entire lock assembly but specifically the actuator. Ill include removal of the door panel as Ive seen tons of questions asking how its done.

First remove these two pieces and remove the phillips head screws (2). One behind each piece.



remove this piece by gently prying it off



Then you will have to remove this clip by pushing the center inward one click, don't push it all the way through.



When 2 screws and one clip are removed you can then take the door panel off. Start by prying on a lower corner until the clip releases, then you can pull the panel around the edges releasing the rest of the clips, all around the door panel. The interior door handle will be connected to the panel still, you will have to remove the cables that are on the handle and lock itself. Unplug the power window switch, power lock and door panel light and remove the door panel. Set it aside.

Next pull the weather guard away from the door shell. It has the potential to become messy. Start here and pull 1/3 of it away. Also unplug the lock actuator at this time.





Next remove the run channel for the window. First remove the rubber seal from the metal channel. Then remove the one 10mm bolt holding the run channel to the door shell. Reach into the door shell, grab the run channel and pull down on it until it releases. Remove, set aside.



Next step is to remove the 3 torx bolts holding the latch assembly, located on the outer section of the door shell. I didn't have a torx bit so I used a flat tip screw driver.

 

[4gin007]

Now comes the time where you will take the lock actuator out of the door. Slide the actuator down a bit to get it off the exterior door handle rod that is connected to it. (latch is still in door shell with the torx bolts removed at this time)



Now that the actuator is out, this piece of plastic is going to be the first thing you remove. Its easy. Also remove the 3 screws that are visible on the assembly.



Now comes the tricky part and the time consuming part. You have to separate the two halves of the actuator casing. Start by removing the brass latch. Its held on by the white clip, just pry straight up on it to release it.



also remove the lock cable



now start releasing all these clips. All the way around the case. Be easy with them. I broke one.



Be gentle as you can when separating the halves. There are some components inside the latch that can and will fall out during this process. They are easy to figure out and put back into the right place, if they fall out or move. Whatever you do don't try to gorilla the case apart as the pieces could fly into the "never find that again zone".

Now that you have the lock assembly open this is the actuator you want to replace. Just grab it and remove it. That simple.

 

[4gin007]

Your new one may come with the right spiral gear on it or it may not, but no worries because it just slides off. I got a used actuator from a junk yard door that came into the shop. It was longer than the 4runner one so I had to cut and file it down to the correct size. Install the spiral gear, onto the new actuator, the one that was on your 4runner to begin with. After you've made the exchange go ahead and put the two halves back together and install the brass latch. Put the 3 screws back into the assembly and install the lock cable. Hopefully everything went together perfectly, all though it may take some time and a couple of tries to get the halves back together. Just be patient, it'll click into place once its all lined up. And remember to walk away from the latch assembly if its giving you a problem, come back to it later.

These are the only tools I used minus the 1/4 ratchet (it doesn't like photos)



This solution to a faulty lock is way cheaper than buying a lock assembly. The lock on the driver door was sporadic, sometimes it worked other times it did not. All four doors have this assembly and they can all have the actuator replaced if you have the ability to do it. My cost for the actuator was free, but I have seen them on Ebay for about 20 bucs. A lock assembly can be upwards of 140 bucs. I took a chance by doing this and it worked out for me.

 

[Cascade4R]

Important: Test before shutting the door

Appreciate the info on replacing the motor. It worked for me, sort of. Unfortunately I failed to test the actuator repair fully before I shut the door. The new motor seemed to work as the lock mechanism flipped back and forth with the electric door switches. So I shut the door only to find out that the ability to open the door wasn't working. :hurt:
Should have used a screwdriver to flip the latch and use the door handles to check unlatching as a test before shutting the door. Hard lesson learned as pulling the trim panel and getting the actuator out of a closed door ain't easy. And the money saved by just buying the motor is out the door (pun intended), as getting the actuator to release the door involves destroying the actuator assembly.

TEST YOUR REPAIR!