Interior - Rattle From Instrument Panel on Rough Roads
NVHNV008-07
Title:
INSTRUMENT PANEL RATTLE NOISE
Models:
'07 ES 350
June 14, 2007
Introduction
Some 2007 model year ES 350 vehicle customers may complain of a rattle noise from the instrument panel when driving on rough roads. The condition may also be worse when the weather is cold. Use the repair procedure below to improve this condition.
Applicable Vehicles
^ 2007 model year ES 350 vehicles.
Required Tools & Material
Warranty Information
Applicable Warranty*:
This repair is covered under the Lexus Comprehensive Warranty. This warranty is in effect for 48 months or 50,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific complaint.
Repair Procedure
1. Record the radio station presets.
2. Remove the instrument panel sub-assembly.
Refer to the Technical Information System (TIS), 2007 model year ES 350 Repair Manual, Vehicle Interior - Interior Panels/Trim - "Instrument Panel: Instrument Panel Safety Pad: Removal".
3. Flip the instrument panel sub-assembly upside down and place on a clean blanket to protect the surface of the instrument panel.
4. Perform the 5 repairs (A through E) as shown in the overview picture below. Each repair is described in detail in the following steps.
A. Add felt to the panel behind the gauge cluster.
Cut two pieces of 1 mm (0.04 in.) thick felt from the Interior Noise Kit to the following dimensions:
Length: 45 mm (1.78 in.)
Width: 20 mm (0.79 in.)
Thickness: 1 mm (0.04 in.)
Place the felt so as to cover the two small ribs on the back of the panel.
B. Add felt to the speaker grilles.
The felt is placed BETWEEN the metal mesh and the plastic base. Cut felt from the Interior Noise Kit to the following dimensions:
Length: 20 mm (0.79 in.)
Width: 10 mm (0.40 in.)
Thickness: 0.5 mm ([0.20 in.] thinnest sheet felt in the Interior Noise Kit)
a. Using a small screwdriver, fold back the metal mesh.
b. Place the felt between the metal mesh and the plastic base as shown.
c. Stick the felt down, following the contours of the plastic base.
d. Bend the metal mesh down.
e. Repeat on each metal mesh tab that is folded over the edge.
C. Add felt to the top of the defroster duct.
Remove the center defroster duct by removing the 5 screws. Turn the defroster duct over to insulate the duct to instrument panel interface. Add felt to top of the defroster duct. Cut twelve pieces of 1 mm (0.04 in.) thick felt from the Interior Noise Kit to the following dimensions:
Length: 20 mm (0.79 in.)
Width: 12 mm (0.48 in.)
Thickness: 1 mm (0.04 in.)
Place the felt as shown.
D. Add thicker felt to the instrument panel locating clips.
a. Remove the 5 clips from the dash and cowl.
b. Remove the original 0.5 mm (0.02 in.) thick felt from the 5 clips.
NOTE:
The last 12 mm (0.47 in.) of the felt does NOT have any adhesive on it.
c. Using 1 mm (0.04 in.) thick felt from the Interior Noise Kit (P/N 08231-00801), make 5 NEW felt pieces.
NOTE:
^ Use the old felt pieces from the clips as a template.
^ The hole does NOT have to be cut out on the new felt.
d. Using a felt tip pen, draw an outline of the felt on the back of the new 1 mm (0.04 in.) felt sheet.
NOTE:
Draw a line where the adhesive stops on the old felt.
e. Cut out the outline of the NEW felt piece.
f. Cut the backing paper at the line where the adhesive stops on the original felt.
CAUTION
Make sure to cut the backing paper ONLY. Do NOT cut the felt at this line.
g. Take OFF the backing paper on the NEW felt piece, except for the area that did NOT have adhesive on the original felt.
h. Apply the NEW felt starting at the top of the clip, making sure NOT to overhang the edge of the clip.
CAUTION
Make sure that the felt does NOT overhang the edge of the clip on the top side.
NOTE:
Flip the felt (with the backing paper still attached) over into the middle of the clip.
i. Install the clips to the cowl panel.
CAUTION
The tab on the clip is located on the TOP of the clip.
E. Add felt to shifter trim.
Cut two pieces of 0.5 mm (0.02 in.) thick felt from the Interior Noise Kit to the following dimensions:
Length: 23 mm (0.91 in.)
Width: 10 mm (0.40 in.)
Thickness: 0.5 mm (0.02 in.)
Place the felt over the ribs that stick up perpendicular to the locking tab as shown below. Apply the felt to the two outer clips ONLY.
5. Remove the register ducts from the instrument panel by removing the 7 screws to gain access to the speaker wiring harness. Wrap the center speaker wiring harness with foam. Cut a piece of foam from the Interior Noise Kit to the following dimensions:
Length: 60 mm (2.40 in.)
Width: 45 mm (1.80 in)
Thickness: 5.0 mm (0.20 in.)
Wrap the wiring harness starting 20 mm (0.79 in.) away from the connector (as shown).
6. If the fold-down mirror switch connector is NOT used, wrap it with foam from the Interior Noise Kit to prevent noise (as shown in the illustration).
7. Install the instrument panel sub-assembly.
Refer to the Technical Information System (TIS), 2007 model year ES 350 Repair Manual, Vehicle Interior - Interior Panels/Trim - "Instrument Panel: Instrument Panel Safety Pad: Installation".
8. Reset the radio presets and clock.