Canada - Body - Luggage Lid Will Not Properly Close

Bulletin
TSB2694

Issue Date
February 9, 2007

Market
Canada

Title
LUGGAGE LID WILL NOT PROPERLY OPEN

Component
BODY COMPONENT

Models
'05 - '07 Avalon

INTRODUCTION:

Some 2005--2007 model year Avalon vehicles may have a condition where the trunk hinge torsion bars come out of place, causing the luggage lid to not open properly and/or not close properly. The locating tab for the stationary portion of the torsion bar may also be bent.

An improved hinge assembly and torsion bars have been released. The shape of the locating tab for the stationary portion of the torsion bar has been redesigned to retain the torsion bar more securely. The torsion bars have been improved to better stay in position.

Use the repair procedure in this TSB to improve this condition.

NOTE:
It is important to replace the torsion bars and hinge assemblies as a set. Both the torsion bars and hinge assemblies have been improved to work as a set.

APPLICABLE VEHICLES:
- 2005 - 2007 model year Avalon vehicles produced BEFORE the Production Change Effective VIN shown below.






PRODUCTION CHANGE INFORMATION:






WARRANTY INFORMATION:






PARTS INFORMATION:






PARTS DESCRIPTION:

REPAIR PROCEDURE:

1. Paint the NEW hinges and torsion bars the same color as the vehicle exterior (NO clear coat needed).
Note that ONLY the back edge of the hinge is visible when all trim covers are in place.

2. Remove the torsion bars.
Refer to the ETAS:
- 2005 model year Avalon Repair Manual, Vehicle Exterior -- Door/Hatch -- "Luggage Door Hinge Torsion Bar: Replacement".
- 2006 or 2007 model year Avalon Repair Manual, Vehicle Exterior -- Door/Hatch -- "Engine / Hood: Luggage Door Hinge Torsion Bar: Removal".

3. Remove the luggage compartment door.
Refer to ETAS:
- 2005 model year Avalon Repair Manual, Vehicle Exterior -- Door/Hatch --"Luggage Compartment Door: Overhaul".
- 2006 or 2007 model year Avalon Repair Manual, Vehicle Exterior -- Door/Hatch -- "Engine Hood / Door: Luggage Compartment Door: Disassembly".

4. Remove the C-pillar side inner garnish assembly.
Refer to ETAS:
- 2005 model year Avalon Repair Manual, Vehicle Interior -- Interior Trim -- "Roof Headlining Assembly: Replacement".
- 2006 or 2007 model year Avalon Repair Manual: Vehicle Interior -- Interior Trim -- "Interior: Roof Headlining: Removal".

5. Remove the package tray panel assembly.
Refer to ETAS:
- 2005 model year Avalon Repair Manual, Vehicle Interior -- Seat Belt -- "Rear Seat Inner W/center Belt Assy RH: Replacement".
- 2006 or 2007 model year Avalon Repair Manual, Vehicle Interior -- Seat Belt -- "Seat Belt: Rear Center Seat Inner Belt Assembly: Removal".

6. Fold back the sound deadening material below the package tray.
7. Remove the luggage hinge bolts (2 RH and 2 LH) to remove the hinge assembly.
8. Install the NEW torsion bars and hinge assemblies (both the LH and RH sides [4 parts total]).
Installation is the reverse of disassembly.

NOTE:
It is important to replace the torsion bars and hinge assemblies as a set. Both the torsion bars and hinge assemblies have been improved to work as a set.