NHTSA ID Number: 10111288
Manufacturer Communication Number: T-SB-0038-15
TSB/Document Date: 2017-08-14
Summary
TSB: Some 2008 - 2013 model year Highlander and Highlander HV vehicles may exhibit a condition where the Power Back Door does NOT close properly. The back door may get to the fully closed position and then reverse to the open position. In cases where the Power Back Door does close, a pop or clunk noise may also be heard when the back door latch reaches the striker during the power close function. In some cases, Diagnostic Trouble Codes (DTCs) B2222 and/or U0230 may be present. Use the following information to inspect the Power Back Door and address this condition. NOTICE The purpose of this Service Bulletin is to provide repair instructions for the Power Back Door. It enhances the durability of the Power Back Door when using the Power Close function. When the Power Close function is used, if objects or cargo continually interferes with the closure of the back door, damage to the back door and/or back door hinges may occur. To minimize the possibility of damage occurring, before closing the Power Back Door, customers should always confirm that objects in the cargo area will not impede or interfere with the closing operation of the back door. Additionally, customers should not use any part of their body to intentionally activate the Jam Protection function of the Power Back Door. Please see the Owner's Manual for additional information on the Power Back Door Jam Protection function.
T-SB-0038-15
June 12, 2015
Power Back Door Does Not Close Properly
Service
Category
Vehicle Exterior
Section
Door/Hatch
Market
USA
Applicability
YEAR(S)
MODEL(S)
2008 – 2013
Highlander, Highlander
HV
ADDITIONAL INFORMATION
SUPERSESSION NOTICE
The information contained in this bulletin supersedes SB No. T-SB-0091-12.
• Applicability has been updated to include 2013 model year Highlander and
Highlander HV vehicles.
• The entire bulletin has been updated.
Service Bulletin No. T-SB-0091-12 is Obsolete and any printed versions should be discarded.
Be sure to review the entire content of this bulletin before proceeding.
Introduction
Some 2008 – 2013 model year Highlander and Highlander HV vehicles may exhibit a condition
where the Power Back Door does NOT close properly. The back door may get to the fully closed
position and then reverse to the open position. In cases where the Power Back Door does close,
a pop or clunk noise may also be heard when the back door latch reaches the striker during the
power close function. In some cases, Diagnostic Trouble Codes (DTCs) B2222 and/or U0230 may
be present. Use the following information to inspect the Power Back Door and address this condition.
NOTICE
The purpose of this Service Bulletin is to provide repair instructions for the Power Back Door. It
enhances the durability of the Power Back Door when using the Power Close function. When the
Power Close function is used, if objects or cargo continually interferes with the closure of the back
door, damage to the back door and/or back door hinges may occur.
To minimize the possibility of damage occurring, before closing the Power Back Door, customers
should always confirm that objects in the cargo area will not impede or interfere with the closing
operation of the back door. Additionally, customers should not use any part of their body to
intentionally activate the Jam Protection function of the Power Back Door. Please see the Owner’s
Manual for additional information on the Power Back Door Jam Protection function.
© 2015 Toyota
Motor Sales, USA
Page 1 of 8
June 12, 2015
T-SB-0038-15
Page 2 of 8
Power Back Door Does Not Close Properly
Warranty Information
OP CODE
BD1122
DESCRIPTION
Inspection of Rear Hinges, Hatch Assembly,
& Door Motor Only*
TIME
OFP
T1
T2
0.5
68810-48040
68810-48041
68810-48090
68810-0E070
68810-0E071
9A
13
* Use typical body shop sublet type "ZZ" other to claim practice for claiming preparation, repair, sealing, and painting of the
rear hinges and back door panel assembly.
APPLICABLE WARRANTY
• This repair is covered under the Toyota Comprehensive 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.
Required Tools & Equipment
REQUIRED EQUIPMENT
Techstream 2.0*
Techstream Lite
SUPPLIER
ADE
PART NUMBER
QTY
TS2UNIT
TSLITEPDLR01
* Essential SST.
NOTE
• Only ONE of the Techstream units listed above is required.
• Software version 10.10.018 or later is required.
• Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at
1-800-368-6787.
REQUIRED MATERIAL
QUANTITY
Feeler Gauge
As Needed
© 2015 Toyota Motor Sales, USA
1
June 12, 2015
T-SB-0038-15
Page 3 of 8
Power Back Door Does Not Close Properly
Parts Information
NOTE
Please review entire Inspection Procedure BEFORE ordering parts, all parts shown below may
NOT be necessary to correct this condition.
PART NUMBER
PART NAME
QTY
68810-0E120
Hinge Assy, Back Door, RH
(Pad Thickness = 2 mm)
1
68820-48030
68820-48031
68820-0E060
68820-0E061
68820-0E090
Hinge Assy, Back Door, LH
(Pad Thickness = 2 mm)
1
67005-48430
67005-48431
67005-0E230
67005-0E231
67005-0E232
Panel Sub-Assy, Back Door (PBD)
1
85007-09001
85007-09002
85007-48010
85007-49015
85007-49017
85007-49018
85007-09003
Motor Unit, Back Door
(Includes Upper Rod and Stud)
1
68975-0E010
68975-0E030
Plate, Back Door Stay
1
69356-48010
69356-48011
Back Door Upper Rod
(Includes Lift Arm Stud & Plate)
1
Bolt, w/Washer (for Hinge Assy)*
4
PREVIOUS
NEW
68810-48040
68810-48041
68810-0E070
68810-0E071
90080-11194*
* Non-reusable part.
© 2015 Toyota Motor Sales, USA
June 12, 2015
T-SB-0038-15
Page 4 of 8
Power Back Door Does Not Close Properly
Inspection Procedure
Inspect the Power Back Door Assembly.
1. Inspect the upper hinges for any gaps present by placing a 0.05 mm (0.002 in.) or greater
feeler gauge between the 2 bolts mounted to the back door as shown in Figure 1. If a gap
exists, replacement of both Back Door Hinges AND the Back Door Panel Sub-assembly is
required. Proceed to step 2.
If a gap is not found, STOP – this bulletin does NOT apply.
Figure 1.
1
1
Gap Location
© 2015 Toyota Motor Sales, USA
June 12, 2015
T-SB-0038-15
Page 5 of 8
Power Back Door Does Not Close Properly
Inspection Procedure (Continued)
2. Visually inspect the Back Door Upper Rod and Lift Arm Stud for bends or damage. If the Back
Door Upper Rod and Lift Arm Stud are damaged, then replace as necessary.
Figure 2.
NOTE
The Back Door Upper Rod and Lift Arm
Stud are available as separate service
parts from the Back Door Motor Unit if
found damaged or bent.
1
2
1
Lift Arm Stud
2
Back Door Upper Rod
3. Visually inspect the back door motor teeth for damage by opening the back door and manually
moving the door towards the half-closed position while observing the large gear teeth for
damage, as shown in Figure 3. If damage is found, replacement of the Back Door Motor Unit
and Back Door Stay Plate is required.
Figure 3.
4. Proceed to Repair Procedure.
© 2015 Toyota Motor Sales, USA
June 12, 2015
T-SB-0038-15
Page 6 of 8
Power Back Door Does Not Close Properly
Repair Procedure
1. Sublet vehicle repair of the back door and back door hinges refinishing to a body shop if
necessary. Repainting and repair of the back door and hinges should be done in accordance
with Toyota’s body repair recommendations.
Remove and replace the back door, hinges, lift arm, lift arm stud, PBD stud bracket, and PBD
motor as needed based off inspection procedures in this bulletin.
NOTE
Original centering bolts used for the hinge assemblies are NOT reusable. Substitute referenced
hardware in the Parts Information table (P/N 90080-11194).
Refer to the Technical Information System (TIS), applicable model and model year Repair
Manual and the following manuals:
• Toyota Fundamental Body Repair Procedures Manual (Pub. No. BRM002E), available from
the Materials Distribution Center (MDC) through Dealer Daily – Dealer Support Materials
Orders
• Toyota Collision Repair Manuals:
• Toyota 2008 – 2013 Highlander Collision Repair Manual (BM06J0U)
• Toyota 2008 – 2013 Highlander HV Collision Repair Manual (BM07V0U)
© 2015 Toyota Motor Sales, USA
T-SB-0038-15
June 12, 2015
Page 7 of 8
Power Back Door Does Not Close Properly
Repair Procedure (Continued)
NOTE
To ensure correct installation of the back door struts, note the markings on the assembly
(Figure 4). The markings indicate on which side of the car the strut should be installed, and the
direction of the braces on the strut.
Figure 4.
© 2015 Toyota Motor Sales, USA
June 12, 2015
T-SB-0038-15
Page 8 of 8
Power Back Door Does Not Close Properly
Repair Procedure (Continued)
2. Initialize the Power Back Door system.
Refer to TIS, applicable model and model year Repair Manual:
• 2008 / 2009 / 2010 / 2011 / 2012 / 2013 Highlander:
Vehicle Exterior – Door/Hatch – “Engine Hood / Door: Power Back Door System:
Initialization”
• 2008 / 2009 / 2010 / 2011 / 2012 / 2013 Highlander HV:
Vehicle Exterior – Door/Hatch – “Engine Hood / Door: Power Back Door System:
Initialization”
3. Confirm repair by opening and closing the back door in the power mode and ensuring
proper operation.
© 2015 Toyota Motor Sales, USA
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TSB/Document ID: T-SB-0038-15
Replacement Service Bulletin Number:
MFR Communication Date: 2015-06-12
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: STRUCTURE:BODY:DOOR
MFR Component System:
MFR Component Subsystem:
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