Toyota Prius: Back Door Support

• Removal
• Installation
• Disposal

Removal

REMOVAL

CAUTION / NOTICE / HINT

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	BACK DOOR STAY ASSEMBLY	68960		-	-
2	BACK DOOR DAMPER STAY UPPER BRACKET	68946	-	-	-
3	BACK DOOR STAY BOLT	68961	-	-	-

●

Non-reusable part

-

-

PROCEDURE

1. REMOVE BACK DOOR STAY ASSEMBLY

(1) Using a screwdriver with its tip wrapped with protective tape, slightly raise the 2 stop rings as shown in the illustration.

(2) Disengage the 2 ball joints to remove the back door stay assembly.

2. REMOVE BACK DOOR DAMPER STAY UPPER BRACKET

3. REMOVE BACK DOOR STAY BOLT

Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	BACK DOOR STAY BOLT	68961		-	-
2	BACK DOOR DAMPER STAY UPPER BRACKET	68946		-	-
3	BACK DOOR STAY ASSEMBLY	68960		-	-

	N*m (kgf*cm, ft.*lbf): Specified torque	-	-
●	Non-reusable part	★	Precoated part

PROCEDURE

1. INSTALL BACK DOOR STAY BOLT

Cleaning Area

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-

(1) Clean the bolt holes in the Toyota Prius vehicle body.

(2) Install a new back door stay bolt.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

2. INSTALL BACK DOOR DAMPER STAY UPPER BRACKET

Cleaning Area

-

-

(1) Clean the bolt holes in the Toyota Prius vehicle body.

(2) Install the back door upper damper stay bracket with 2 new bolts.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

3. INSTALL BACK DOOR STAY ASSEMBLY

(1) Attach the 2 ball joints to install the back door stay assembly.

NOTICE:

Install the back door stay assembly while supporting the back door by hand.

(2) Check that the back door stay assembly is engaged to the ball joints and that it cannot be pulled out.

Disposal

DISPOSAL

CAUTION / NOTICE / HINT

PROCEDURE

1. DISPOSE OF BACK DOOR STAY ASSEMBLY

(a) Horizontally hold the back door stay assembly in a vise with the piston rod pulled out.

(b) Wear safety glasses. Gradually cut a part between A and B shown in the illustration using a metal saw to release the gas.

Area	Measurement
A-B	132.5 mm (5.217 in.)
C-D	115 mm (4.528 in.)
E-F	200 mm (7.874 in.)

CAUTION:

Although the gas inside the back door stay assembly is colorless, odorless and harmless, there is a possibility that metal debris could scatter. Therefore, cover it with a piece of cloth or other material.