Clunking Noise In the Full-Down Position

1. Remove front door trim panel on door where clunking noise is heard. (Refer to "Front Door Trim Panel" in the "Doors" section of the Body/Repair Service Manual.)

2. Carefully remove the lower rear section of the water deflector to gain access to the lower rear door structure access hole.





3. Verify that the front door window stop bumper is installed.

^ If front door window stop bumper is missing, proceed to next step.

^ If front door window stop bumper is not missing, check for other parts that may have become loose and repair as necessary.

4. Remove front door outer panel. (Refer to "Front Door Outer Panel" in the "Doors" section of the Body/Repair Service Manual.)

IMPORTANT:
The front side door insulator assembly is called the door sound deadener in the service manual.

5. Remove front side door insulator assembly. (Refer to "Door Sound Deadener Panel-Sedan/Wagon" in the "Doors" section of the Body/Repair Service Manual.)

6. Locate the front door window stop bumper inside the door structure. If front door window stop bumper is missing, replace with new front door window stop bumper (P/N 21098728).





7. Make sure that the mounting tabs on the front door window stop bumper mounting bracket are straight (parallel with the lower door structure). If tabs are not straight, use a pair of pliers or screwdriver to straighten the tabs so that they are parallel with the lower door structure.

8. Clean area around the front door window stop bumper bracket with alcohol and dry.





9. Apply a liberal amount of Kent Industries Ultra-Stick Black Adhesive (P/N 10190) or equivalent, to the underside cavity and the underside of the front door window stop bumper.

IMPORTANT:
Adhesive will squeeze out from under front door window stop bumper when it is installed.

10. Install the front door window stop bumper, making sure to engage both sides of the center tab of the bumper to the underside of the mounting bracket cutout. If both sides of the center tab are not under the bracket, the front door window stop bumper will come off.

11. Allow adhesive to dry according to manufacturer's recommendations.

12. Install the lower rear section of the water deflector. Make sure there are no creases left around the door structure mounting surface. If creases are present, there could be water leaks and/or dust intrusion.

13. Install front door trim panel. (Refer to "Front Door Trim Panel" in the "Doors" section of the Body/Repair Service Manual.)

14. Install front side door insulator assembly. (Refer to "Door Sound Deadener Panel-Sedan/Wagon" in the "Doors" section of the Body/Repair Service Manual.)

15. Install front door outer panel. (Refer to "Front Door Outer Panel" in the "Doors" section of the Body/Repair Service Manual.)