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Help with replacing tailgate handle

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Silverfox

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I have a 2002 Toyota Sienna with a broken tailgate handle. I cannot open from the outside. Need to take back pannel off from inside with tailgate closed.

 

So if I can find out how to get the panel off I think I can fix it myself. I have googled and found some directions just not for a 2002 which appears to be a little different.

 

Talked with the Toyota service dept to have it serviced and with the attitude I felt as if I was getting set up for a large service charge because they did not wantcwm33.gif or are not capable of the job. Like they had never done it before and had no clue as to how so numbers of over $200 plus depending on this or that. Just not a good feeling. This the second time I have walked away feeling like they do not care enough about their customers or $$kooky.gif . Last time was an ignition switch/key problem. Simply told moon.gifgo to a locksmith have a good day.

 

mad.gif enough vent

 

I am hoping someone knows and is willing to guide me as to how?headscratch.gif

 

Thanks

 

Jim

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My '01 Sequoia same thing. A real PITA. You can find the part on line and do it yourself in an hour or so. I think the part was 40-50 bucks. I could do it in 1/2hour now that I know what I looking for etc. Go onto the Toyota forums or Tundra Nation forum and do a search...there will be plenty of folks on there with the same issue. Love my Sequoia and this is the only issue I have had in 10 yrs.

 

You have to get the panel off...should just pull off ir you get a screwdriver behind it. I have a power window in my Sequoia and it was a real PITA to work behind. You prob don't have that in the Sienna so everything should be stright forward. Its the whole handle that needs replacing - the fixture where the ball on the end of the wire goes in was plastic on mine and had finally given out.

 

I just googled 'sienna tailgate handle fix' it and picked a site findonefindall. There are some pics on there and it looks straightforward, He jimmy rigged it instead of replacing the handle but you get a good idea of how to get to it to replace it.

 

 

PICT0008.JPG

You go to open your rear door and snap! The handle breaks - Now What?

This happens to a lot of Sienna vans (1999,2000,2001), and also to lots of different Toyotas as well, judging by a search on the web. Why? Plastic handles. Why, in heavens name, would they use plastic handles? It happened to us, my wife tried to open the rear door, but heard a crack, then the handle went limp. Sounds familiar?

 

What now? Take it to a dealership and be charged hundreds to repair? The web says "new handle- $64.00 at the dealer,

most quoted over $300.00 to have them do it"

From the web, I also found out they just break again!

What was needed was a "better than replacement" fix.

TIP - TAKE LOTS OF DIGITAL PICTURES BEFORE EACH PART IS REMOVED! (WITH A GOOD CAMERA WITH A GOOD SIZED SCREEN)

1st Problem - The door won't open at all.

(One contributor did suggest you might be able to grab the loose cable and pull it form the outside - but we have not tried this)

Here's what we did....

 

Lower rear seats, climb in rear.

Remove 10mm bolts under plastic covers on pull down handle and also remove the 10mm bolt that holds the strap on.

Pull off rear panel - See picture. It is held on by about 10 white push-in clips. The clips may fall off and go everywhere - don't worry, they will go back on.

springclips.JPG

Wrestle cover out of inside of van. Now you have access to the latch, pull up the lever, opening the rear door. Fall out of van carefully. I didn't. Ouch.

 

PICT0005.JPG

"Where is your wallet?" â„¢

Remove the internal (3) 10mm nuts holding the lock/handle cover plate on. Squeeze the white clip in the end position.

Pull this away from the door a little. The backup light wires are still attached, so you cannot pull far. Remove the 2 screws that hold the handle to this plate, and remove the latch cable (it just pulls off). You can now see where the handle has broken.

OK, I have got it off. How did you fix it?

Rather than replace the handle for another one that will break again, I drilled a hole through both the handle and the broken arm piece and bolted them together. While glue alone would never last (the torque on the handle is considerable), many folks have suggested superglue to hold them together while you drill the bore hole - use a slow drill rpm! (Thanks Wolfwar99). Just be careful, fingers are more expensive than the $300 fix don't forget! Mike (see below) reminded me to say "use a drill press to make the bore hole" Good idea! I did, of course - never thought anyone would consider doing it by hand! Also, you will have to enlarge the square hole in the metal plate to stop the nut from catching on it. I forgot this and many comments have suggested including this important step. PLEASE BE CAREFUL WITH THE DRILLING PART!

 

This fix is a bit of a fiddle (OK quite a fiddle), but the result is a permanent fix. See pictures & comments below.

PICT0002.JPG

Here you see the handle with a close-up of the break. This was after the

screw was inserted. The screw and nut came out of the "big box of loose screws" we all seem to have, so your sizing may vary. Use a strong one. Stainless steel is a good idea as it won't rust. If anyone comes up with a recommended size - please email & we will include it here!

 

From Rob - 1 1/4" 4-40 screw, but I ended up using a size 8-32, 1 1/4 ". The nut ended up being a bit large so I used a drill and Dremmel sander bit to enlarge the hole a bit.

More pictures of the fix.

PICT0001.JPGcable.jpg

Once you have repaired the handle, reverse the procedure and put your van back into service. Cost? $2 in a screw and nut. Some thread lock might be a good idea too.

Mike sent us some pictures of his fix, they show the hole enlargement and screw position better than mine. Thanks Mike!

mikesfix.JPG

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