2016-2021 Toyota Tacoma Snow Intrusion Preventing Front Door From Fully Opening T-SB-0033-19 Revision 1


Please see T-SB-0033-19 Revision 1 (Revision 1 needed)

2016-2021 Toyota Tacoma

April 27, 2021 Rev1
Applicability has been updated to include 2020 – 2021 model year Tacoma vehicles. Any previous printed versions of this bulletin should be discarded.

Some 2016 – 2021 model year Tacoma vehicles may exhibit a condition where snow or ice builds up between the right or left front door and front fender, preventing the front door from fully opening. Follow the Repair Procedure in this bulletin to address this condition.

This repair is covered under the Toyota Basic 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 occurrence of the specified condition described in this bulletin.

Repair Procedure:
1. Confirm the condition exists. Is there snow or ice buildup between the right or left front door and front fender that prevents the front door from fully opening?
YES — Continue to step 2.
NO — This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.

2. Clean off the vehicle.
A. Remove the snow.
B. Melt ANY ice using a heat gun.
C. Open the door to a fully open position

3. Place the vehicle on a lift to remove the right or left front tire and wheel.

4. Remove the right or left front mudguard by removing the five bolts.

5. Remove the right or left front fender wheel opening molding next to the door
A. Peel back the section next to the door.
B. Cut away the seven clips closest to the door side of the front fender liner.
C. Cut a 105-mm (4.1-in.) extrusion section from the RR door No. 3 weatherstrip (do NOT use the injection molded joints)

6. If the vehicle has been exposed to a cold environment for an extended period, use a heat gun to bring the A-pillar section to room temperature (between 60°F – 100°F)

7. Clean the A-pillar section using isopropyl alcohol and allow it to dry for 1 minute

8. Install the weatherstrip extrusion from the door opening side.
A. Pull back 1/3 of the tape for temporary placement. Then starting at the front fender well, remove the rest of the tape to press the weatherstrip fully onto the body side outer panel.
B. Refer to the installation reference points as shown to apply the weatherstrip extrusion section.

9. Apply continuous pressure to the weatherstrip extrusion to ensure proper adhesion (approximately 20 – 30 seconds).

10. Allow to fully cure and keep the vehicle between 60°F – 100°F for AT LEAST 20 minutes

11. Remove the front fender side protector (P/N 53827-04020 for right or 53828-04020 for left) from inside the front fender well.

12. Using a hacksaw or equivalent blade, cut the material from the inboard side of the front fender protector (P/N 53827-04020 for right or 53828-04020 for left), following the Front Fender Side Protector Cutout.

13. Smooth the cut surfaces using sandpaper or a handheld sanding tool.

14. Trim the instrument panel No. 1 cushion (55355-0C050) (EPT sponge material with tape backing) to approximately 550 mm (21.6 in.) in length (original length 1,323 mm).

15. Install the EPT sponge material to the outer surface of the front fender side protector. Start on the outboard side, wrap under the bottom face of the protector, and then end on the inboard side. (The sponge material should be one continuous piece.)

16. Install the countermeasure front fender side protector. Ensure the EPT sponge has not been damaged or has fallen off the front fender side protector AFTER installation.

17. Inspect the countermeasure weatherstrip channel area. Ensure the front fender side protector has not damaged the weatherstrip channel adhesion to the panel.

18. Reinstall the following parts:
A. Front fender wheel opening molding (right/left).
B. Front fender liner (right/left). Replace the five clips closest to the door side.
C. Front mudguard (right/left) (if applicable). D. Tire and wheel (right/left).