Body - Luggage Lid Will Not Properly Close
BODYBO030-06
Title:
LUGGAGE LID WILL NOT
PROPERLY OPEN
Models:
'05 - '07 Avalon
December 21, 2006
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
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 correction of a problem based upon a customer's specific complaint.
Parts Information
Parts Description
Repair Procedure
1. Paint the NEW hinges and torsion bars the same color as the vehicle exterior (NO clearcoat 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 Technical Information System (TIS):
^ 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 TIS:
^ 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 TIS:
^ 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 - "In tenor: Roof Headlining: Removal".
5. Remove the package tray panel assembly. Refer to TIS:
^ 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.
^ After installation of the torsion bars, to prevent a potential rattle noise concern, confirm that the torsion bars do NOT touch each other or the upper back panel when the trunk lid is closed. Apply EPT sealer from the Wind Noise Kit (P/N 08231-00810) as needed.