How to Replace Power Lock Actuator in Toyota RAV4
This is a 2003 RAV4 driver’s door actuator replacement. I am providing a description of my experience, in hopes of helping others. Was surprised I could not find anything. Not for a beginner.
1. Remove the door panel and look to this post for excellent description: http://rav4world.com/mods/4.2/interi...tallation.html
2. I would add, that to remove power window switch, gently pry up front and use a small screwdriver to press in the clip, and it will come right out. If force is used, the back fixed plastic clip will break (pics below).
3. Peel back the plastic on door carefully. The actuator is connected to the door latch and the whole mechanism needs to be disconnected. There are several bolts on door (behind where panel was), and at edge of door. Take out three bolts as indicated. Also disconnect power into actuator (see clip hanging loose). You can plug into new actuator and then activate to make sure this was your problem.
4. Take out three torx bolts at side of door holding latch inside door. Also take out screw at bottom of door. This holds flexible window track. (You will later fold that up and out of the way).
5. Take out the plastic piece at top of door edge. This is near lock, and will allow you to disconnect the rods connecting door handle, lock and latch.
6. The unit will now be loose. From the door, gently reach up into door insides and look for vertical metal rods coming out of the top of the latch, and going up to door handle and lock. Disconnect the plastic lock tabs with by gently pry away from bar. To disconnect the yellow clip, go to access hole in number 5 above and use piece of wood, or screwdriver on rod and tap out. (Plastic clip is pressure fit into hole, and you may not be able to pull out. I had to tap it out with hammer. Gentle).
7. Fold up flexible door track so its out of way, and you can now pull unit out of door with cables to power switch. **Leave cables going from power switch to unit, as these remain attached. There may be a wire clip to disconnect and give more play.
8. This is a view of unit pulled out of door (with cover on) and of the cover removed from actuator below.
9. There is one bolt fastening cover onto unit and two screws holding actuator in place. Remove. Note Actuator is still in place with two cables coming into it.
10. This picture shows two screws holding actuator to unit, and where it connects to latch unit cables. Carefully disconnect and put new actuator in line.
11. Assembly is the reverse. Don’t forget to reattach metal rods and clips. Keep power disconnected until done.
12. This is a view of power lock switch tab. Push this in and pull up and forward to remove this panel part.
Got part from Parts.com for about $75. They sent it out and I got it in 2 days. Very impressive response given I live in Hawaii. Let me know if this was helpful. I am not a mechanic, but was a serious auto hobbyist a longtime ago. This was a challenge, so I wanted to try and help others.