Canada - Body - Moonroof Rattling Noises
Bulletin
1312
Issue Date
2003-11-03
Reference
BC-03-026
Model
4Runner
Year Range
2003
Market
Canada
Component
BC
Subject:
MOONROOF (SLIDING ROOF) RATTLE NOISE (REVISION)
TSB REVISION NOTICE:
- June 03, 2004: "Notice" added.
- November 20 2003: The Parts Information Table has been updated since the Sliding Roof Housing Sub Assembly is not required for the repair procedure.Previous versions of this TSB should be discarded.
Previous versions of this TSB should be discarded.
Customers may experience a persistent rattle noise from the moonroof (also known as a sliding roof.) The following procedure has been developed to improve this condition.
APPLICABLE VEHICLES:
- 2003 model year 4Runner vehicles produced BEFORE the Production Change Effective VINs shown.
PRODUCTION CHANGE INFORMATION:
PARTS INFORMATION:
WARRANTY INFORMATION:
REPAIR PROCEDURE:
There are eight field fix methods covered. One or all of these methods may be used depending on the source of the noise being addressed on a particular vehicle. The main source of rattle noise is the moonroof wind deflector rods (field fix section one.) It is highly recommended to re-test for the customer complaint after each section. Section 3 requires removal of the moonroof housing sub-assembly. Perform this section only after all other measures have failed.
SECTION 1:
1. Add a piece of hose included in kit P/N 63207-35040 to moonroof wind deflector rod (both sides.)
a) Open the moonroof to the full open position by pressing the rocker switch.
NOTE:
The moonroof must be opened fully to ensure proper operation after the field fix is complete.
b) Remove the wind deflector by pressing down on the guide block release lever using a small screwdriver.
NOTICE:
To prevent breakage of the guide block release lever when the outside temperature is below 40_F, use a heat gun to raise the temperature of the guide block and surrounding aluminum housing to a temperature of at least 65_F. Be careful not to damage components or paint with the heat gun.
c) Pull back on the moonroof wind deflector guide block.
d) Slide the moonroof wind deflector toward the front of the moonroof.
e) Insert a small screwdriver between the moonroof wind deflector rod and the aluminum moonroof track and twist. The rod will snap free of the moonroof guide rail holder.
f) Replace the moonroof wind deflector guide rail holder with new service part included in moonroof rattle field kit P/N 63207-35040 and apply grease supplied with kit.
g) Add piece of hose included in kit P/N 63207-35040 to the moonroof wind deflector rod (both sides.)
Sliding roof wind deflector rod hose:
L: 150mm
Internal diameter: 5mm
External diameter: 8mm
NOTE:
Using larger diameter hose may result in moonroof operation malfunction.
H. Reinstall the moonroof wind deflector rod and wind deflector.
NOTE:
Ensure that the moonroof wind deflector rod is installed securely in the guide block's forward most position.
2. Apply grease included in the kit P/N 63207-35040 to moonroof wind deflector rod clamp.
NOTE:
The moonroof wind deflector rod clamp is located at the rear of the moonroof opening (both sides.)
a) Ensure the moonroof is in the full open position.
b) Apply grease to the rod behind the clamp.
c) Partially close the moonroof then reopen. The moonroof wind deflector rod will have moved forward carrying grease inside the clamp.
HINT:
Ensure grease gets between the rod and clamp surfaces.
d) Re-test vehicle for customer complaint. Stop here if customer complaint resolved. If rattle noise still present, continue on to Section 2.
SECTION 2:
1. Apply felt squares to the guide rail garnish and the moonroof side garnish.
a) Remove the moonroof side garnish and moonroof guide rail garnish.
b) Apply three pieces of felt to the moonroof side garnish.
"A" Felt Dimensions:
Length: 10mm
Width: 10mm
Thickness: 1.0mm
"B" Felt Dimensions:
Length: 15mm
Width: 12mm
Thickness: 1.0mm
c) Apply nine felt pieces to the moonroof side rail garnish. Please see the table for felt sizes and locations.
d) Reinstall the moonroof guide rail garnish and moonroof side garnish.
2. Fit a piece of felt to the front side bottom of the moonroof garnish as shown in the illustration.
3. Reinstall the moonroof garnish.
4. Apply Grease to Drive Cable Pin. Using a brush, apply Body Grease W, (P/N 08887-02007) to the housing drive cable pin as shown in the shaded area.
a) Tilt moonroof up.
b) Remove moonroof side garnish.
c) Apply grease to the pin as shown in the shaded area in the illustration.
d) Reinstall moonroof side garnish.
5. Apply Grease to Drive Cable Lifter Pin. Using a brush, apply Body Grease W, (P/N 08887-02007) to the housing drive cable lifter pin surface as shown in the shaded area.
a) Tilt moonroof up.
b) Remove moonroof side garnish.
c) Apply grease to the pin as shown in the shaded area in the illustration.
d) Reinstall moonroof side garnish.
e) Apply grease to drive cable pin.
f) Apply grease to drive cable lifter pin.
6. Fit three pieces of felt to the moonroof housing wind deflector tray.
a) Remove the original pieces of felt.
b) Apply one piece of felt to the center of the moonroof housing wind deflector tray.
c) Apply one piece each at the right and left corners of the moonroof housing wind deflector tray.
NOTE:
If 4mm thick felt is not available, multiple pieces may be layered in order to obtain the desired thickness.
NOISE FROM MOONROOF SUNSHADE:
7. Fit Felt and Clear Tape to Moonroof Center Reinforcement. Fit a piece of clear tape (P/N 3M SJ6595) and felt (2 mm thick from Noise Kit, P/N 08231-00801) to the center moonroof reinforcement.
8. Remove the interior light.
a) For the interior light with rear seat audio system, refer to the 2003 4Runner Repair Manual on ETAS.
Section: Interior/Exterior Trim;
Subsection: Roof Headlining;
Page: Replacement
b) For the interior light without rear seat audio system, disengage the 4 clips shown in the illustration.
9. Disconnect the four hooks and loop fasteners located behind the sunshade that secures the roof headlining to the roof.
NOTE:
It is not necessary to remove the headliner to complete this operation.
10. Measure and cut the tape and felt.
a) Cut clear tape (P/N 3M SJ6595) and felt (2 mm thick from Noise Kit, P/N 08231-00801) to the sizes shown in the illustration.
b) Remove release paper from tape.
NOTE:
Do not remove the release paper from the felt.
c) Superimpose the felt onto the tape, and make four slits as shown in the illustration.
NOTE:
Slits allow for air evacuation.
11. Lift up sunshade trim, position the tape and felt to the center upper surface of the center moonroof reinforcement (black metal painted parts) which is located rearward of the sunshade trim handle. Attach the tape securely to the reinforcement as shown in the illustration.
12. Reconnect the four hooks and loop fasteners located behind the sunshade that secure the roof headliner to the roof.
13. Reinstall the interior light.
14. Re-test for customer complaint. Stop here if customer complaint resolved. If customer complaint still present, continue on to step 10.
SECTION 3:
NOISE FROM MOONROOF HOUSING CENTER REINFORCEMENT
1. Apply two pieces of felt to the center moonroof housing reinforcement and two pieces of urethane sponge to the right and left drive cable housing.
a) Remove the moonroof housing from the vehicle (refer to 2003 4Runner Repair manual on ETAS.
Section: Sliding Roof/Convertible;
Subsection: Sliding Roof;
Page: Replacement
b) Cut felt to size indicated below and slide under the edge of the center moonroof housing reinforcement.
NOTE:
Do not remove the release paper until the felt is properly positioned under the center moonroof housing reinforcement.
c) After removing the release paper, fold the felt over the top of the center moonroof housing reinforcement.
d) Complete steps "B" and "C" for both driver's and passenger's sides.
e) Wrap drive cables with urethane sponge at each corner.
NOTE:
The location of the sponge should be where the cable housings cross at both right and left corners.
f) Re-install moonroof housing.
NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.