How to remove door actuator for replacement or service

This is a helpful guide I wrote in haste to help myself in the future when I have to repair or replace another door actuator. Hopefully it helps someone else.

• Item 1, Latch Door, 69320-04040 - $86
• Item 3 Cable, Inside Locking, 69750-04020 - $18
• Item 5 handle rod connector
• Item 6, Handle Inside, 69205-02100-B1 - $27

Here it is all removed from the door.



As far as I know this isn't written up anywhere on TW. The best I found was a redirect to a Rav4 forum where someone posted pics of how to work on the door actuator.

DIY

Open door
Remove interior panel

Cut plastic weather barrier
Unplug electrical plug from door actuator
Remove inside door handle by popping black molded plastic piece out of hole and slide handle backwards towards rear of truck (it's between the yellow and green below)

Remove plastic shoe (service cover) from door edge.

Remove screw that holds lock into place.
Remove lock from outside of door.

Remove door handle connecting rod from inside door. Two part process!!!

First, unlock the connecting rod by flipping up the yellow plastic connector.

Second, Go back to service hole on door edge. Slip a long slot screwdriver into hole and rest screwdriver edge on rod, tap with dead blow hammer and rod will disengage.

Remove door handle connecting rod from inside the door by pulling straight up and away from door actuator.

Remove three screws from latch (door edge). The actuator will now be loose inside the door.
Reach inside door and play a short game of tetris to remove door actuator assembly (with cables and inside handle) from door.

Install in reverse order.