Step-by-Step Replacing the Door Handle on a 1st gen Tacoma

The door handles on the 1st gen Tacoma are all more than two decades old at this point, and given that they are constantly exposed to the weather, UV, and large temperature swings, it's no wonder that the plastic they are made of is starting to break more frequently. Luckily, they are relatively easy to replace, and doing so requires no special tools.

Parts

From a parts perspective, you really only need to gather up the door handles, and perhaps a few clips in case any originals are broken during the removal of the interior door panel. As always, you may choose between several OEM and aftermarket options for the door handles, each listed below.

Tacoma

• OEM - The OEM handles are made of plastic, but are very durable and come in both black and chrome to match your existing door handles
  • Black
    • Front (L: 69220-35020 | R: 69210-35020)
    • Rear (L: 69240-35080 | R:69230-35080)
  • Chrome
    • Front (L: 69220-35030 | R: 69210-35030)
    • Rear (L: 69240-35070 | R:69230-35070)
• Aftermarket Metal - These metal replacements only come in black but fit well and are less likely to break than any plastic handle. This is the recommended option.
  • Black
    • Front (Left | Right)
    • Rear (Left | Right)
  • Silver
    • Front (Left | Right)
    • Rear (Left | Right)
• Aftermarket Plastic - These are significantly cheaper than the metal aftermarket handles, but are not recommended as all brands tend to break easily.
  • Black
    • Front (Left | Right)
    • Rear (Left | Right)
  • Silver
    • Front (Left | Right)
    • Rear (Left | Right)

Tools

The only tools necessary for this job are as follows:

• Flat Screw Driver
• Phillips Screw Driver
• 10mm socket. This is a great set, but not cheap.
• A selection of 3-, 6-, ad 9-inch socket extensions.
• A set of picks in order to pry apart small plastic retainers.

Doing the Job

Removing Trim from the Interior Door Panel

Before removing the interior door panel, all of the trim pieces (arm rest, door latch release, etc.) must be removed.

1. Make sure the window is up. You'll need access through the door cavity, which would be blocked if the window is down, and the ability to raise it later will be limited since the window controls will be removed/unplugged.
2. Using a pick or flat head screwdriver, pop out the two plastic covers on the arm rest and remove the two Philips screws. Note that the arm rest will stay in place.
   

   

3. Using a philips screwdriver, remove the single screw securing the interior door lever. Then, carefully push the door lever forward to unclip it from the door.
   

   

   

4. Using a small pick tool, carefully release the clip that secures the door lever to the metal rod that connects it to the door latch by prying it towards you, being careful to not break the clip. Once the metal rod is released, remove the interior door lever.
   

   

   

5. Remove the arm rest control panel with a flat screwdriver by prying up from the front edge. Note: if you pry on the rear edge, you will break the rear clip. As you lift out the control panel, unplug any electronics that are connected to it - for power windows, door locks, and mirror adjustments.
   

   

6. Remove the small triangular trim piece near the side mirror by simply prying on it from the bottom to release the clips.
   

   

Removing the Interior Door Panel

With the trim pieces removed from the door panel, removing the door panel itself is reasonably easy.

1. Using a Philips screwdriver, depress the center of the clip at the upper-forward corner of the interior panel and remove the clip.
   

   

2. Starting along the bottom edge, slowly pry the interior door panel away from the door. Once you find the location of a door clip, pry carefully on each side of the clip until it releases; then move on to the next clip. Eventually, all the clips will be released, and you can lift the panel up and over the door lock to remove it from the door.
   

   

   

3. Peel back the vapor barrier to expose the cavity that allows access to the door handle.
   

   

Disconnecting and Removing the Door Handle

The door handle is secured by two (2) 10mm bolts and conncted to two metal rods by a couple of plastic clips.

1. Using a small pick, locate the clip that secures the lock rod to the key cylinder, and pull the clip toward you to disengage it from the locking mechanism. Then pop the rod out of the lock cylinder.
   

   

2. Using a small pick, remove the plastic cover that allows access to the 10mm bolt that secures the door handle.
3. Using a 10mm socket (with necessary extension), remove the rear 10mm bolt and set it aside.
4. Remove the lock cylinder from the handle and set it aside.
5. Using a small pick, locate the clip that secures the interior door handle rod to the door handle. Pull the clip down and forward to unlock the rod.
   

   

6. Using a flat screwdriver, pry the rod out of the plastic clip. Note: the clip may break during this process which is not a problem; a new clip is included on the new door handle.
   

   

7. Using a 10mm socket (with necessary extension), remove the front 10mm bolt and set it aside.
8. From the exterior of the door, lift up on the door handle to remove it from the door.
   

   

Connecting the New Door Handle

With the old door handle removed, installation is mostly just the reverse of removal.

1. From the exterior of the door, insert the upper side of the door handle into the opening.
2. Push up on the top edge as you pivot the lower edge into the opening, then lower the handle so that it is captured by the clips on the back of the door skin.
3. Insert the interior door handle rod into the plastic clip on the new door handle.
4. Lock the interior door handle rod in place by rotating the plastic clip to capture it.
5. Using a 10mm socket (with necessary extension), install the front 10mm bolt until it is finger tight.
6. Insert the lock cylinder, aligning the anchor tab with the hole for the rear 10mm bolt.
7. Using a 10mm socket (with necessary extension), install the rear 10mm bolt until it is finger tight.
8. Reconnect the lock rod to the key cylinder, then rotate the plastic clip to capture it.
9. Torque the two 10mm bolts to 43 in-lbs. (3.5 ft-lbs). Just snug them up.
10. Reinsert the plastic cover that allows access to the 10mm bolt that secures the door handle.

Installing the Interior Door Panel

1. Reinstall the vapor barrier. Note: if the butyl tape is no longer sticky, use some tape to secure the vapor barrier around the perimeter.
2. Place the door panel over the door lock indicator, then rotate it down and align the clips.
3. Beginning along the top edge, push the interior door panel toward the door in order to engage one clip at a time. Repeat around the entire edge of the interior door panel.
4. Insert the final clip through the interior door panel and press the locking mechanism into place to secure the front upper corner of the interior door panel.

Installing the Trim on the Interior Door Panel

1. Install the small triangular trim piece near the side mirror by simply pushing it into place.
2. Install the arm rest control panel by installing the rear edge first and then rotating the front down into position.
3. Insert the door lever into place and secure the metal rod using the small plastic clip.
4. Using a Philips screwdriver, secure the door lever in the interior door panel.
5. Install two (2) Philips screws that secure the arm rest to the metal door. Note: these screws grab on plastic inserts in the metal door, so don't over tighten them.
6. Install the two plastic covers over the screws in the arm rest.

You're done!