Front and Rear Door Assemblies Page 1A5–1

Page 1A5–1

Section 1A5

Front and Rear Door Assemblies

ATTENTION

Before performing any service operation or other procedure described in this Section, refer to Section 00

Warnings, Cautions and Notes for correct workshop practices with regard to safety and/or property damage.

1 General Information............................................................................................................................... 2

1.1 General Description...............................................................................................................................................2

2 Service Operations – Rear Doors......................................................................................................... 3

2.1 Rear Door Trim Panel Assembly...........................................................................................................................3

Remove ...................................................................................................................................................................3

Disassemble ...........................................................................................................................................................4

Rear Door Power Window Switch.......................................................................................................................5

Rear Door Armrest Insert Assembly...................................................................................................................5

Rear Door Pull Cup.............................................................................................................................................6

Rear Door Radio Speaker Grille.........................................................................................................................6

Rear Door W indow Inner Sealing Strip...............................................................................................................6

Reinstall ..................................................................................................................................................................7

2.2 Rear Door Lock Assembly.....................................................................................................................................8

Remove ...................................................................................................................................................................8

Disassemble ...........................................................................................................................................................9

Reassemble ............................................................................................................................................................9

Reinstall ..................................................................................................................................................................9

2.3 Rear Door Window Channel Assembly..............................................................................................................10

Remove .................................................................................................................................................................10

Reinstall ................................................................................................................................................................12

3 Torque Wrench Specifications........................................................................................................... 13

Techline

Front and Rear Door Assemblies Page 1A5–2

Page 1A5–2

1 General Information

With the following exceptions, MY 2004 VY Regular Cab and Crew Cab Front and Rear Door Assemblies carries over

from MY 2004 VY and V2 Series vehicles and MY 2003 VY Regular Cab vehicles.

Crew Cab

• Rear doors

For Front and Rear Door Assemblies information not contained in this section, refer to Section 1A5 Front and Rear Door

Assemblies in the MY 2004 VY and V2 Series Service Information and Section 1A5 Front and Rear Door Assemblies in

the MY 2003 VY Regular Cab Service Information.

1.1 General Description

The rear door assemblies fitted to the Crew Cab are unique, however, they are similar to the rear door assemblies fitted

to the Sedan and Wagon. Differences in the Crew Cab rear doors as compared to Sedan and Wagon include:

• Rear door assembly

• Rear door trim panel assembly

• Rear door armrest insert assembly

• Rear door pull cup

• Rear door pull cup bracket

• Rear door seal

• Rear door locking rods

• Rear door power window switch location

• Rear door window channel assembly

• Rear door window inner sealing strip

Front and Rear Door Assemblies Page 1A5–3

Page 1A5–3

2 Service Operations – Rear Doors

2.1 Rear Door Trim Panel Assembly

LT Section – 14-270

Remove

The orange rear door locking rod knob

retainer will be damaged during this operation

and must be replaced.

1 Remove the rear window regulator handle assembly (if fitted), refer to Section 1A5 Front and Rear Door Assemblies

in the MY 2004 VY and V2 Series Service Information.

2 Remove the door inside handle assembly, refer to Section 1A5 Front and Rear Door Assemblies in the MY 2004

VY and V2 Series Service Information.

Take care not to damage the rear door

locking rod knob assembly.

3 Using a small flat bladed screwdriver or scriber (1),

gently prise the orange rear door locking rod knob

retainer (2) from the rear door locking rod knob

assembly (3).

4 Remove the rear door locking rod knob assembly from

the rear door locking rod.

5 Remove the screw (4) attaching the rear door locking

rod ferrule (5) to the rear door trim panel assembly

and remove the rear door locking rod ferrule.

Figure 1A5 – 1

6 Remove the screw (1) from the rear door pull cup.

Figure 1A5 – 2

Front and Rear Door Assemblies Page 1A5–4

Page 1A5–4

7 Remove the screws (1), in six places, attaching the

rear door trim panel assembly to the rear door

assembly.

8 Lift the rear door trip panel assembly upwards to

release it from the rear door inner channel and remove

the rear door trim panel assembly from the rear door

assembly.

NOTE

The wiring harness connectors will still be

connected.

9 Support the rear door trim panel assembly and

disconnect the rear door wiring harness connectors.

10 Remove the rear door trim panel assembly.

Figure 1A5 – 3

Disassemble

Figure 1A5 – 4

Legend

1 Rear Door Pull Cup

2 Rear Door Armrest Ins ert Assembly

3 Rear Door Armrest Ins ert Assembly Clip (2 Places)

4 Rear Door Power Window Switch (If Fitted)

5 Rear Door Radio Grille Speaker

6 Rear Door Trim Panel Assembly

7 Radio Rear Door Speaker Grille Retainer (7 Places)

8 Rear Door Insulator Assembly

9 Rear Door Armrest Ins ert Assembly Nut (4 Places)

10 Rear Door W i ndow Inner Sealing Stri p

Front and Rear Door Assemblies Page 1A5–5

Page 1A5–5

Rear Door Power Window Switch

Remove

1 From behind the rear door trim panel assembly, press

the tangs and remove the rear door power window

switch (1).

NOTE

For further information regarding service and

diagnosis of the rear door power window switch,

refer to Section 12J Body Control Module in the

MY 2004 VY and V2 Series Service Information.

Reinstall

1 Ensuring that the rear door power window switch

connector points upwards, press the rear door power

window switch into the rear door trim panel assembly.

Figure 1A5 – 5

Rear Door Armrest Inse rt Assemb l y

Remove

1 To allow access to the rear door armrest insert assembly attaching parts, peel back the rear door insulator

assembly from the upper portion of the rear door trim panel assembly, refer to Section 1A5 Front and Rear Door

Assemblies in the MY 2004 VY and V2 Series Service Information.

2 Remove the clips (1), in two places, by sliding them

away from the rear door trim panel assembly (2).

When removing the insert assembly door

armrest nuts, a rotating action may cut off

the shaft. If a shaft is cut off, replace the rear

door insert assembly.

3 Remove the rear door armrest insert assembly

nuts (3), in four places, attaching the rear door armrest

insert assembly (4) to the rear door trim panel

assembly.

4 Prise the rear door armrest insert assembly away from

the rear door trim panel assembly. Slide the rear door

armrest insert assembly towards the rear of the rear

door trim panel assembly and remove.

Reinstall

Reinstallation of the rear door armrest insert assembly is the

reverse of the removal procedure, noting the following:

1 Check that the rear door armrest insert assembly sits

flush against the entire length of the top contacting

surface of the rear door trim panel assembly.

2 Tighten the nuts to the specified torque.

Rear door armrest insert assembly nut

torque specific atio n .................................... 0.7 – 0.9 Nm

Figure 1A5 – 6

Front and Rear Door Assemblies Page 1A5–6

Page 1A5–6

Rear Door Pull Cup

Remove

1 Press the retaining tabs (1), in two places, on the rear

door pull cup (2) and remove the rear door pull cup

from the rear door armrest insert assembly (3).

Reinstall

Reinstallation of the rear door pull cup is the reverse of the

removal procedur e.

Figure 1A5 – 7

Rear Door Radio Speaker Grille

Remove

Take care when removing the rear door radio

speaker grille retainers not to break the

speaker grille shafts on which the retainers

are attached.

1 Remove the retainers (1), in seven places, attaching

the rear door radio speaker grille (2) to the rear door

trim panel assembly (3).

2 Remove the rear door radio speaker grille.

Figure 1A5 – 8

Reinstall

Reinstallation of the rear door radio speaker grille is the reverse of the removal procedure.

Rear Door Window Inner Sealing Strip

Remove

1 By pushing down on one end, progressively remove

the rear door window inner sealing strip (1) from the

rear door assembly (2).

Reinstall

Reinstallation of the rear door window inner sealing strip is

the reverse of the removal procedure, noting the following:

1 Align sealing strip with the edge of door trim.

Figure 1A5 – 9

Front and Rear Door Assemblies Page 1A5–7

Page 1A5–7

Reinstall

Reinstallation of the rear door trim panel assembly is the reverse of the removal procedure, noting the following:

1 Connect the rear door wiring harness connector to the rear door power window switch (if fitted).

2 Ensure that the rear door handle assembly and the rear inside handle rod are engaged before final fitment, refer to

Section 1A5 Front and Rear Door Assemblies in the MY 2004 VY and V2 Series Service Information.

NOTE

Screws along the bottom of the rear door trim are

wax tip sealing screws. If required, apply sealer

to the screws. Refer to Figure 1A5 – 3.

3 Tighten the screws to the specified torque.

Rear door trim panel assembly retaining

screw torque specification.......................... 1.0 – 3.0 Nm

Rear door pull cup retaining screw

torque specific atio n .................................... 1.0 – 3.0 Nm

Rear door locking rod ferrule retaining

screw torque specification.......................... 1.0 – 3.0 Nm

4 Refit the rear door locking rod knob assembly onto the rear door locking rod using a new orange locking rod knob

retainer, refer to Figure 1A5 – 1.

Front and Rear Door Assemblies Page 1A5–8

Page 1A5–8

2.2 Rear Door Lock Assembly

LT Section – 11-725

Remove

1 Remove the rear window regulator handle assembly (if fitted), refer to Section 1A5 Front Door Assemblies in the

MY 2004 VY and V2 Series Service Information.

2 Remove the rear door inside handle assembly, refer to Section 1A5 Front and Rear Door Assemblies in the

MY 2004 VY and V2 Series Service Information.

3 Remove the rear door trim panel assembly, refer to 2.1 Rear Door Trim Panel Assembly.

4 If required, remove the rear door trim panel assembly

brackets (1), in six places, from the rear door

assembly by levering out the centre pin of each

bracket.

5 If required, remove the screws (2), in three places,

attaching the rear door pull cup bracket (3) to the rear

door assembly and remove the rear door pull cup

bracket.

NOTE

The rear door seal needs only partial removal to

provide access to complete this procedure.

6 Carefully peel off the rear door seal (4) from the rear

door inner panel (5) to gain access for the following

steps.

Figure 1A5 – 10

7 Lever the bell crank assembly (1) with the rear door

locking rod (2) from the pivot shaft (3).

8 Remove the rear door locking bell crank rod (4) from

the retainer (5) and rear door lock assembly (6).

Figure 1A5 – 11

Front and Rear Door Assemblies Page 1A5–9

Page 1A5–9

9 Disconnect the rear door inside handle rod (1) from

the two retainers (2) and disengage the rod from the

rear door lock assembly (3) by releasing the rod

retainer.

10 The rear door outside handle rod assembly (4) will

disengage from the rear door lock assembly when the

lock assembly is removed.

Figure 1A5 – 12

11 Disconnect the door wiring harness connector (1) from

the rear door lock assembly (2).

12 If required, remove the rear door window channel

assembly, refer to 2.3 Rear Door Window Channel

Assembly.

13 Remove the screws (3), in three places, attaching the

rear door lock assembly to the door inner panel (4).

14 Remove the lock assembly through the aperture in the

door inner panel.

Figure 1A5 – 13

Disassemble

For disassembly procedures of the rear door lock assembly, refer to Section 1A5 Front and Rear Door Assemblies in the

MY 2004 VY and V2 Series Service Information.

Reassemble

For reassembly procedures of the rear door lock assembly, refer to Section 1A5 Front and Rear Door Assemblies in the

MY 2004 VY and V2 Series Service Information.

Reinstall

Reinstallation of the rear door lock assembly is the reverse of the removal procedure, noting the following:

1 Tighten the screws to the specified torque.

Rear door lock assembly attaching screw

torque specific atio n .................................... 3.0 – 5.0 Nm

Rear door pull cup bracket att achi ng screw

torque specific atio n .................................... 1.0 – 3.0 Nm

2 Ensure that the rear door outside handle rod assembly is engaged correctly with the rear door lock assembly.

3 Ensure that the rear door seal is correctly fitted to the door panel.

Front and Rear Door Assemblies Page 1A5–10

Page 1A5–10

2.3 Rear Door Window Channel Assembly

LT Section No. – 11-020

Remove

1 Remove the rear window regulator handle assembly (where fitted), refer to Section 1A5 Front and Rear Door

Assemblies in the MY 2004 VY and V2 Series Service Information.

2 Remove the rear door inside handle assembly, refer to Section 1A5 Front and Rear Door Assemblies in the

MY 2004 VY and V2 Series Service Information.

3 Remove the rear door trim panel assembly, refer to 2.1 Rear Door Trim Panel Assembly.

4 Remove the rear door belt outer reveal moulding assembly, refer to Section 1A5 Front and Rear Door Assemblies

in the MY 2004 VY and V2 Series Service Information.

5 Partly remove the rear door upper weatherstrip assembly, refer to Section 1A5 Front and Rear Door Assemblies in

the MY 2004 VY and V2 Series Service Information.

6 If required, remove the rear door trim panel assembly

brackets (1), in six places, from the rear door

assembly by levering out the centre pin of each

bracket.

7 If required, remove the screws (2), in three places,

attaching the rear door pull cup bracket (3) to the rear

door assembly and remove the rear door pull cup

bracket.

NOTE

The rear door seal needs only partial removal to

provide access to complete this procedure.

8 Carefully peel off the rear door seal (4) from the rear

door inner panel (5) to gain access for the following

steps.

Figure 1A5 – 14

9 Remove the rear door inner panel belt seal (1) from

the rear door assembly.

Figure 1A5 – 15

Front and Rear Door Assemblies Page 1A5–11

Page 1A5–11

10 Carefully remove the rear door window upper

weatherstrip assembly (1) from the rear door window

channel asse mbly (2).

NOTE

Remove the rear door window upper

weatherstrip assembly only from the rear door

window channel assembly. It is not necessary to

completely remove the rear door window upper

weatherstrip assembly.

Figure 1A5 – 16

11 Remove the screws (1), in two places, attaching the

rear door window channel assembly (2) to the top of

the rear door assembly.

12 Remove the screws (3), in two places, attaching the

rear door window channel assembly to the rear door

assembly.

Figure 1A5 – 17

13 Disengage the rear door window channel assembly (1)

from the rear door window assembly (2).

14 In an upward direction, remove the rear door window

channel assembly from the rear door assembly.

Figure 1A5 – 18

Front and Rear Door Assemblies Page 1A5–12

Page 1A5–12

Reinstall

Reinstallation of the rear door window channel assembly is the reverse of the removal procedure, noting the following:

1 Tighten the fasteners to the specified torque.

Rear door window channel assembly

lower retaining screw torque

specification..............................................6.0 – 14.0 Nm

Rear door window channel assembly

upper retaining screw torque

specification................................................2.5 – 3.5 Nm

Rear door pull cup bracket att achi ng

screw torque specification.......................... 1.0 – 3.0 Nm

2 If required, before installing door inner trim panel, adjust the rear door window and regulator, refer to Section 1A5

Front and Rear Door Assemblies in the MY 2004 VY and V2 Series Service Information.

3 Ensure that the rear door seal is correctly sealed against the rear door inner panel.

Front and Rear Door Assemblies Page 1A5–13

Page 1A5–13

3 Torque Wrench Specifications

Rear Door Armrest Insert Assembly Nut........................................0.7 – 0.9 Nm

Rear Door Lock Assembly Attaching Screw ..................................3.0 – 5.0 Nm

Rear Door Locking Rod Ferrule Retaining Screw..........................1.0 – 3.0 Nm

Rear Door Pull Cup Bracket Attaching Screw................................1.0 – 3.0 Nm

Rear Door Pull Cup Retaining Screw ............................................1.0 – 3.0 Nm

Rear Door Trim Panel Assembly Retaining Screw ........................1.0 – 3.0 Nm

Rear Door Window Channel Assembly Lower

Retaining Screw...........................................................................6.0 – 14.0 Nm

Rear Door Window Channel Assembly Upper

Retaining Screw ............................................................................2.5 – 3.5 Nm