T - SB - 0062 - 21 August 2, 2021 HVAC Blower Motor Only Operates on High Speed Service Category Vehicle Interior Section Heating/Air Conditioning Market USA © 2021 Toyota Motor Sales, USA Page 1 of 10 Applicability YEAR(S) MODEL(S) ADDITIONAL INFORMATION 2005 - 2018 Tacoma Introduction Some 2005 – 2018 model year Tacoma vehicles may exhibit a condition where the HVAC blower motor only operates on h igh speed and all other blower speeds are inoperative. The blower resistor and resistor connector have been updated Follow the Repair Procedure in this bulletin to address this condition. Wa rranty Information OP CODE DESCRIPTION TIME OFP T1 T2 AC2020 HVAC Blower Motor Resistor and Connector Repair 1.1 87138 - #####* 72 41 *Warranty claim MUST be submitted with the correct 10 - digit OFP for the vehicle being repaired by searching Resistor, Blower (8 7138 ) in the Electronic Parts Catalog using the VIN filter APPLICABLE WARRANTY 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. T - SB - 0062 - 21 August 2, 2021 Page 2 of 10 HVAC Blower Motor Only Operates on High Speed © 2021 Toyota Motor Sales, USA Parts Information PART NUMBER PART NAME QTY PREVIOUS (4 - pin Flat Connector) NEW (4 - pin Square Connector) 87138 - 04052 87138 - 04070 Resistor, Blower 1 82141 - 04M40 82141 - 04Q80 Wire, Instrument Panel 1 82999 - 52020 Terminal, Joint Repair 2 82999 - 30020 Terminal, Joint Repair 2 82999 - 30010 Terminal, Joint Repair (Heat Shrink Sleeve) 4 Required Tools & Equipment SPECIAL SERVICE TOOLS (SST) PART NUMBER QTY Wire Crimper (Non - i nsulated)* 09042 - 2C100 1 *Essential SST. REQUIRED EQUIPMENT SUPPLIER PART NUMBER QTY Techstream ADVI* ADE TSADVUNIT 1 T echstream 2.0 TS2UNIT T echstream Lite TSLITEPDLR01 Techstream Lite (Green Cable) TSLP2DLR01 *Essential SST. NOTE Additional SSTs may be ordered by calling 1 - 800 - 933 - 8335. NOTE Only ONE of the Techstream units listed above is required. Software version 16. 1 0.0 17 or later is required. Additional Techstream units may be ordered by calling Approved Dealer Equipment (ADE) at 1 - 800 - 368 - 6787. T - SB - 0062 - 21 August 2, 2021 Page 3 of 10 HVAC Blower Motor Only Operates on High Speed © 2021 Toyota Motor Sales, USA Repair Procedure 1. Does the HVAC blower motor ONLY operate on high speed? YES — Continue to step 2. NO — This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual. 2. Disconnect the negative ( – ) battery cable. 3. Disconnect the connector from the blower motor resistor and replace the blower motor resistor with a NEW blower motor resistor. Torque: 2.0 N*m (20 kgf*cm, 18 in*lbf) 4. Cut the OLD blower motor resistor connector from the wire harness using the NEW blower motor resistor connector wire lead as a guide for proper length. Figure 1. 1 Existing Terminal 2 Cut 3 New Terminal W ith Lead NOTE The OLD blower motor resistor (flat 4 - pin connector) has been updated with the NEW style blower motor resistor (square 4 - pin connector) NOTICE If the length of the wire removed is not approximately the same length as the new piece, the following problems may develop: Too short — tension on the terminal, splice, or the connector, causing an open circuit. Too long — excessive wire near the connector m a y get pinched or abraded, causing a short. 1 2 3 T - SB - 0062 - 21 August 2, 2021 Page 4 of 10 HVAC Blower Motor Only Operates on High Speed © 2021 Toyota Motor Sales, USA Repair Procedure (continued) 5. C onnect the square 4 - pin blower motor resistor replacement connector to the I/P wire harness. The blower motor resistor has been updated from a flat 4 - pin connection style to a square 4 - pin connection style starting from 2019 model year Tacoma. Figure 2. Circuit 05 – 15MY IP Harness Color 16 – 1 8 MY IP Harness Color B16 (Square Style) Pin Number B4 (Flat Style) Pin Number M2 Blue - Black Blue 1 3 M1 Green - Yellow Green 2 4 HI White - Blue White 3 2 LO White - Black White - Black 4 1 NOTE The vehicle I/P wire harness colors change depending on the model year as shown in Figure 2 : 2005 – 2015 2016 – 2018 Connector B16 B16 r B16 Connector B4 05 – 15MY EWD 16 – 18MY EWD 1 2 3 4 4 3 2 1 T - SB - 0062 - 21 August 2, 2021 Page 5 of 10 HVAC Blower Motor Only Operates on High Speed © 2021 Toyota Motor Sales, USA Repair Procedure (continued) 6. Strip the insulation from the wire on the vehicle side harness and the lead to the NEW blower resistor connector. Start stripping at least 8 mm (0.31 in.) to 11 mm (0.43 in.) away from the end of the existing harness at the vehicle side and from the end of the NEW blower resistor connector. Figure 3. 1 Stripped I nsulation L ength (Approximately 8 – 11 mm ) 2 Vehicle I/P Harness 3 Replacement Connector NOTICE Make sure not to damage the wires when stripping the wire harness leads. AFTER finishing the operation, visually inspect the wires. If there is ANY damage, perform the operation again. 1 2 3 T - SB - 0062 - 21 August 2, 2021 Page 6 of 10 HVAC Blower Motor Only Operates on High Speed © 2021 Toyota Motor Sales, USA Repair Procedure (continued) Figure 4. A Good Example s 2 Wire Is Cut B Bad Example s 3 Insulation Remains on the Lead 1 Wire Insulation I s S tripped at a S lant NOTE Steps 7 – 1 2 will need to be repeated for each of the four wires on the blower motor resistor replacement connector. A B 1 2 3 T - SB - 0062 - 21 August 2, 2021 Page 7 of 10 HVAC Blower Motor Only Operates on High Speed © 2021 Toyota Motor Sales, USA Repair Procedure (continued) Figure 5. 1 Use Terminal, Joint Repair P/N: 82999 - 30020 3 2 Use Terminal, Joint Repair P/N: 82999 - 52020 4 NOTE Use Terminal, Joint Repair P/N: 82999 - 30020 when connecting wires 1 and 3 of the of the blower motor resistor replacement connector to the vehicles side I/P harness. Use Terminal, Joint Repair P/N: 82999 - 52020 when connecting wires 2 and 4 of the of the blower motor resistor replacement connector to the vehicles side I/P harness. Reference Figure 2. for wire connections between the blower motor resistor replacement connector to the vehicle side I/P harness wires. 1 2 3 4 T - SB - 0062 - 21 August 2, 2021 Page 8 of 10 HVAC Blower Motor Only Operates on High Speed © 2021 Toyota Motor Sales, USA Repair Procedure (continued) 7. Place the heat shrink sleeve (P/N: 82999 - 30010) over the end of the blower motor resistor replacement connector wire before moving to the next step. 8. Insert the stripped end of the wire harness from the blower motor resistor replacement connector and the vehicle side I/P harness into the Terminal, Joint Repair sleeve as far as it will go. Figure 6. 1 Terminal, Joint Repair Sleeve 2 Stripped Wire Ends Figure 7. 1 Crimp die location (2) for blower motor resistor replacement connector wires 2 and 4 with Terminal, Joint Repair Sleeve P/N: 82999 - 52020 2 Crimp die location (5.5) for blower motor resistor replacement connector wires 1 and 3 with Terminal, Joint Repair Sleeve P/N: 82999 - 300 20 1 c 2 c z 1 z 2 NOTE Confirm the heat shrink sleeve is placed over the end of the wire. NOTE If connecting blower motor resistor replacement connector wires 1 and 3, use Terminal, Joint Repair sleeve P/N: 82999 - 30020 with corresponding crimp die 5.5 mm (0.23 in.). If connecting blower motor resistor replacement connector wires 2 and 4, use Terminal, Joint Repair sleeve P/N: 82999 - 52020 with corresponding crimp die 2 mm (0.08 in.). Ensure the wires are fully inserted into the Terminal, Joint Repair sleev e. T - SB - 0062 - 21 August 2, 2021 Page 9 of 10 HVAC Blower Motor Only Operates on High Speed © 2021 Toyota Motor Sales, USA Repair Procedure (continued) 9. With the Terminal, Joint R epair sleeve correctly placed in the SST, and the wires fully inserted into the Terminal, Joint R epair sleeve, crimp each side of the sleeve in the area shown by closing the handles until they release. Figure 8. 1 Crimp This Portion 10. Lightly tug on each connection to ensure that the wires are securely crimped. Figure 9. 11. Position the heat shrink sleeve so it rests on the center of the connector. Figure 10. z 1 z 1 NOTE Place the Terminal, Joint Repair sleeve into the SST so that the split in the sleeve is in the half circle of the SST. SST 09042 - 2C100 is the only tool approved to perform this repair. Do NOT use any other tool to crim p the Terminal, Joint Repair sleeve. NOTICE If the wire connection is loose, repeat the process using a new Terminal, Joint Repair sleeve. T - SB - 0062 - 21 August 2, 2021 Page 10 of 10 HVAC Blower Motor Only Operates on High Speed © 2021 Toyota Motor Sales, USA Repair Procedure (continued) 12. Using a heat gun, heat the heat shrink sleeve until it shrinks and seals the repaired connection. Figure 11. 1 Adhesive 13. Connect the negative ( – ) battery cable. Torque: 5.4 N*m (55 kgf*cm, 48 in*lbf) 14. Verify the blower motor operates on all speeds. z 1 NOTICE When using the heat gun, keep the heat gun about 100 mm (3.9 in.) to 200 mm (7.8 in.) from the heat shrink sleeve. Protect the surrounding areas (i.e., wires, i nterior panels, etc.) from heat damage. NOTE During the sealing process, adhesive may seep from the heat shrink sleeve. This is a normal condition and part of the sealing properties of the heat shrink sleeve.