1. Welcome to Tacoma World!

    You are currently viewing as a guest! To get full-access, you need to register for a FREE account.

    As a registered member, you’ll be able to:
    • Participate in all Tacoma discussion topics
    • Communicate privately with other Tacoma owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site

Notorious rear quarter window latch failures

Discussion in '1st Gen. Tacomas (1995-2004)' started by D60, Jan 23, 2016.

  1. Jan 23, 2016 at 8:09 AM
    #1
    D60

    D60 [OP] Active Member

    Joined:
    May 2, 2011
    Member:
    #55968
    Messages:
    34
    Gender:
    Male
    I was recently working on an '02 for some close friends. They busted out the left rear quarter window (extended cab) in an encounter w a ditch and tree.

    The little pivot that always breaks was, of course, broken, so I ordered the billet replacements from Amazon and thought I was set. But in the course of trying to push in the new roll pins I busted an ear off the cast Al bracket that bolts to the body.

    For reference, here's a shot of the body bracket (the long black piece) stolen from the web:
    TacomaWindowBodyBracket_zpseenttlw0_89df82e603e16f4bf542c276fe2c98ff8a04c258.jpg

    This was late at night and I really wanted to get the whole project buttoned up for delivery first thing the next morning. I know my dealer might have had the part, but that would mean driving 1.5 hours round trip the next morning.

    I'm a machinist and figured I'd at least try to replicate the bracket. I was not going to put much time into it but thought a one-shot Q&D (quick and dirty) approach might net results. As it turns out, I got lucky.

    I determined the bracket to be about 4 1/8" long, .785" high and if we assume the "Z" was solid stock, about 1/2" thick. So I grabbed a piece of 1/2" thick 6061 Al flat bar and saw cut to about 4 1/8". I milled it down to .785" high and then laid the broken bracket over it to determine about where I wanted to step it (note the sloppy Inkzall marks still visible and poor hand filing job - again I WAS IN A HURRY)

    I took the body mount portion down to .162" thick and just went to my rough line for length of this feature. I then flipped it over and thinned the piece that sticks out from behind the body panel "to taste." In reality, I think it could have stayed the full 1/2" thick.

    IMG_0266_zpseaahy6uh_4c64c4739645030265b6143430bf62710ad0e3ff.jpg

    I also roughly marked the mounting hole locations with a marker and drilled at 1/4" (factory is .236" or 6mm). Finally, I laid the OEM bracket on top, mocked up the busted ears about how they'd sit and determined the location for the roll pin hole. This was incredibly seat-of-the-pants but I got lucky.

    The billet pivots are about 3/8" high so I stood my piece up on end in the vise (at this point it was flexy and resulted in a lot of chatter, but I didn't care) and used a 3/8" end mill, centered in the .785", to go .480" deep.

    Here's the piece installed:
    IMG_0268_zpsf1bjvqqe_d2fc214ed2a50ede29ee761d36642c8d719acea4.jpg
    And when the body panel is back on most of my Q&D machining is hidden and it doesn't look half-bad:
    IMG_0272_zps0054eers_42fc239b3eb3b1595959178de33bdd29f8d19789.jpg
    It actually sucks the window nice and tight with a good click. I wouldn't necessarily recommend anyone try this when replacements are readily available, unless you're in a late-night time crunch like I was!
     
    FirstGen Jer likes this.
  2. Jan 23, 2016 at 1:15 PM
    #2
    EJPHI

    EJPHI Well-Known Member

    Joined:
    Jan 9, 2016
    Member:
    #174517
    Messages:
    61
    N CALI
    Vehicle:
    2003 2.4l 5sp 5 lug
    pt474 cruise control Alpine head unit
    D60,
    I bought those same pivots from Amazon. The instructions said the one should pound the roll pins out to remove the broken pivot pieces and then pound them in to the new pivots. I pressed the roll pins in and out because I thought pounding would break the frame support or worse.
     
  3. Jan 23, 2016 at 6:33 PM
    #3
    D60

    D60 [OP] Active Member

    Joined:
    May 2, 2011
    Member:
    #55968
    Messages:
    34
    Gender:
    Male
    Oh yeah, I agree............and it was partially my fault. It was getting late, I'd worked on the truck for 3 days doing clutch r&r, new taillights, new side window, new driver side mirror.........all as a result of the accident that broke out the window. Also rear hitch install so they'd have a rear recovery point in the future.

    I should have known better than to try to hammer the pins in place. Pressing definitely would have been better. A machinist should know that. I was tired and hurried, which, as usual, just wound up costing me MORE time in the end.

    edit: oh and I managed to put the t-case shifter in backwards, classic tired dumb*** move. But it's easily figured out when you can't drop into 2nd without hitting the t-case shifter LOL. Of course I had already totally buttoned it up and got to remove all the boots to re-do.
     
  4. Jan 23, 2016 at 6:40 PM
    #4
    EJPHI

    EJPHI Well-Known Member

    Joined:
    Jan 9, 2016
    Member:
    #174517
    Messages:
    61
    N CALI
    Vehicle:
    2003 2.4l 5sp 5 lug
    pt474 cruise control Alpine head unit
    I've done the rush to spend more time fixing my mistakes so I know what you mean.

    After replacing the broken pivot I tested the quality of the window seal compared to the other side which is still OK. I closed the window on a dollar bill and noted how much force was needed to pull the bill out. It was the same for both sides and there is no added noise at freeway speeds on the side I fixed.
     
  5. Jan 23, 2016 at 9:02 PM
    #5
    EJPHI

    EJPHI Well-Known Member

    Joined:
    Jan 9, 2016
    Member:
    #174517
    Messages:
    61
    N CALI
    Vehicle:
    2003 2.4l 5sp 5 lug
    pt474 cruise control Alpine head unit
    I forgot to say: nice job on the fabricated bracket.
     
  6. Jan 23, 2016 at 9:03 PM
    #6
    EJPHI

    EJPHI Well-Known Member

    Joined:
    Jan 9, 2016
    Member:
    #174517
    Messages:
    61
    N CALI
    Vehicle:
    2003 2.4l 5sp 5 lug
    pt474 cruise control Alpine head unit
    I forgot to say: nice job on the fabricated bracket.
     
  7. Jan 23, 2016 at 9:14 PM
    #7
    Jibber

    Jibber Active Member

    Joined:
    Dec 30, 2015
    Member:
    #173562
    Messages:
    39
    Gender:
    Male
    First Name:
    Jim
    Hopefully on the boat
    Vehicle:
    '95 and 79 Landcruiser and 01Taco
    ,,,,,,,,,, you make extras? I see a market for you.
     
    DustStorm4x4 likes this.
  8. Jan 23, 2016 at 9:19 PM
    #8
    DustStorm4x4

    DustStorm4x4 Well-Known Member

    Joined:
    Jul 2, 2015
    Member:
    #158634
    Messages:
    8,961
    Gender:
    Male
    TN
    Vehicle:
    04 Jeep LJ
    Start selling these for $5 a pair and you'll have your first buyer right here. I hate the OEM ones because they break WAY to easily.
     
  9. Jul 8, 2019 at 10:12 AM
    #9
    camelot142

    camelot142 Well-Known Member

    Joined:
    Nov 2, 2012
    Member:
    #90339
    Messages:
    89
    Gender:
    Male
    First Name:
    Brandon
    Southern California
    Vehicle:
    2002 Black Tacoma TRD
    Total Chaos Upper Arms, Kings Shocks
    do you guys have the part number or Amazon link to that little bracket piece? my friend years back was drunk and decided he wanted to kick my ext window out for extra leg space. haha I think I'm half deaf from not ever fixing it.
     
  10. Jul 8, 2019 at 10:25 AM
    #10
    camelot142

    camelot142 Well-Known Member

    Joined:
    Nov 2, 2012
    Member:
    #90339
    Messages:
    89
    Gender:
    Male
    First Name:
    Brandon
    Southern California
    Vehicle:
    2002 Black Tacoma TRD
    Total Chaos Upper Arms, Kings Shocks
  11. Jul 8, 2019 at 5:12 PM
    #11
    Aught2TaCO

    Aught2TaCO Well-Known Member

    Joined:
    Oct 25, 2012
    Member:
    #89813
    Messages:
    388
    Gender:
    Male
    First Name:
    Troy
    Wheat Ridge, CO
    Vehicle:
    '02 Taco TRD, aka Pearly
    Billie 5100's, new leafs, Falken WILDPEAK A/T 3W, 265/75/16E
    This is the guy who sells them https://www.tacomaworld.com/threads/xtra-cab-quarter-window-latch-repair.203493/ I was a field tester for his prototype sets (page 12) and they're still doing their job today.
    OP you have a bullet proof design, the truck will rust away before the mounting brackets :thumbsup:
     
    camelot142 likes this.
  12. Jul 9, 2019 at 10:45 AM
    #12
    camelot142

    camelot142 Well-Known Member

    Joined:
    Nov 2, 2012
    Member:
    #90339
    Messages:
    89
    Gender:
    Male
    First Name:
    Brandon
    Southern California
    Vehicle:
    2002 Black Tacoma TRD
    Total Chaos Upper Arms, Kings Shocks

Products Discussed in

To Top