2006 Rear Driver Door Replacement Issue

Discussion in 'Gen 2 Prius Technical Discussion' started by BellBoy, Aug 14, 2025.

  1. BellBoy

    BellBoy Member

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    Hey all, been lurking here for years as my 2006 Prius has been purring along wonderfully. A few months ago, a guy on a motorcycle slammed into my left rear door. I wanted to replace it with a salvaged door and I found one in great shape with the same color (blue).

    However...I get it home and start to assess what's needed to remove/replace it and to my dread I realized that my maxed out car with the JBL sound system has a rear speaker in the door panel by the door handle. The one I got doesn't have it. Crap.

    The place I bought it from is willing to take it back if it won't work, but before I did I wanted to ask the brains here if I could swap the door panels. I'm guessing that the wiring harness might be different, but I don't know for sure. I'm hoping that Toyota built them all with the same wiring harness for simplicity. I'm not looking forward to transferring the harness from the old door to the new--or if it's even possible given that they're not the same package.

    Can anyone advise me on the chances that I can still use this door? Thanks.
     
  2. Tombukt2

    Tombukt2 Senior Member

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    You should be able to move the whole wiring harness from the door you have to the door you bought which will have all ya need pretty quick to do. You should be good should be plenty of videos of people moving door harness similar on most Asian cars
     
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  3. BellBoy

    BellBoy Member

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    Thanks for the response. After searching until my fingers bled, I realized that I should just call a dealer to get an answer about the harness. Turns out that the wiring harness is different for the 9 speaker JBL system that my trim package 8 has. The dealer supplied me with the part number (5215447070). For the 2006 (and perhaps later models) there were two wiring harnesses for the back door--my trim package and every other package. Just FYI, the other harness number is the same except the last two numbers are "60" instead of "70".

    I popped off the inner door shell and found out a couple of things. First, the harness part number is correct. Second, I finally found out the noise that had been coming from that door (even before the accident) was from the two blocks of rigid foam had broken loose from the inside door shell and were rattling around inside. Ugh, that was so bloody frustrating. Now I can take some hot glue and re-adhere them to keep them from moving. I also realized that the second speaker in the door shell (by the door handle) doesn't have or require a cut out in the metal of the door shell to accommodate it, so the new door shell can be used with no problems.
     
  4. Tombukt2

    Tombukt2 Senior Member

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    Yes all that . The JBL w GPS and disc changer and tweets on door use additional wiring . Usually just pull door harness on you're original damaged door put it in new door you gonna use generally can't go wrong but.
     
  5. BellBoy

    BellBoy Member

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    Hey, thanks for the response.

    Just an update on how it went for anyone that's interested...

    So I got the new door and the old in the same room and started cannibalizing parts. I had to make a run to get some tools that I'd need. I found out the hard way (by looking) that the speakers are riveted into place--so I needed a rivet gun and rivets that would work. Thanks to YouTube, I found a video that detailed the speaker replacement and that I'd need 3/16" rivets.

    I also needed some butyl tape to seal up the moisture barrier. I couldn't find any tape at any auto parts store that didn't require shipping, so I hit a home store and I was able to find some, but it was basically a roofing/window sealing product. It was over double the width of what was on the door and most of the old stuff was dry rotted anyway, so I said eff it and used it and it worked just fine.

    I drilled out the rivets from both speakers and I was shocked to see how much better the JBL speakers are over the base package speakers. It was like picking up a fully loaded hamburger in one hand and a rice cake in the other--it was really that much of a difference. I tested my newly acquired riveting skills (since I had none) on the cheapo speaker and since I was happy enough with that job, I put the JBL into the new door and it was fine.

    I used the old new door to figure out how to remove the wiring harness without damaging the cables, but also tried to remove the clips without damaging them. I'm glad I did because I stupidly cut the tape that held the wires to a couple of the clips to get the harness off the door, but that allowed me to better inspect how the clips could be removed on my old door. The biggest pain in the butt was the last fastener that was under the speaker. Even with the speaker removed it was a total pain to figure out how to unclasp it. It is kinda like a zip tie, but trying to unlock it was an exercise in futility. I wound up destroying it to get the cable out while being careful to not damage the wiring.

    The new door's window was tinted and by the looks of it a little kid with no experience could have done a better job. My old door's window was tinted and while I could pull the window out and replace it, the amount of work that would be required--like connecting both doors to power to be able to lower them enough to remove them--seemed like way more of a hassle than just getting the window re-tinted properly.

    So...to wrap up...I wound up transferring the wiring harness, the speaker(s), and the inside door panel to the new door. To get the door off easily I left one bracket on the old door, so I retrieved that and put it back onto the frame. I was able to put the door on easily--with help from a step stool to hold the door while I put in the bolts. The door fit like the last piece of a jigsaw puzzle--nothing to bend to make it fit and it closed as solid as it was right off the factory line. I fired up the car and the speakers, power windows, and power locks worked perfectly.

    Toyota makes great damn cars!
     
  6. Tombukt2

    Tombukt2 Senior Member

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    Just used bolts and lock nuts on speakers after drilling rivets . I had to use different spacers
     
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