Interior - Instrument Panel Rattle on Rough Roads
L-SB-0017-08April 4, 2008
Instrument Panel Rattle
Service Category
Vehicle Interior
Section
Interior Panels/Trim
Market
USA
Applicability
Introduction
Some 2007 - 2008 model year ES 350 owners may complain of a rattle noise from the instrument panel when driving on rough roads. The condition may be worse in low ambient temperatures. Use the repair procedure below to improve this condition.
Required Tools & Equipment
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.
Parts Information
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"
^ 2008 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 following repairs (A through E) on the instrument panel 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 on the two small ribs on the back of the panel. Make sure the ribs are covered.
B. Add felt to the speaker grilles between the metal mesh tabs 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)
(1) Using a small screwdriver fold back the metal mesh tab.
(2) Place the felt between the metal mesh and the plastic base as shown.
(3) Stick the felt down following the contours of the plastic base.
(4) Bend the metal mesh tab down
(5) Repeat on each metal mesh tab.
C. Add felt to the 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.)
(1) Remove the center defroster duct by removing the 5 screws.
(2) Turn the defroster duct over to insulate the duct to instrument panel interface.
(3) Add felt to top of the defroster duct as shown.
D. Replace the 3 stays and 2 clips with NEW improved parts.
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 felt to the two outer clips ONLY.
5. Add foam to the speaker wiring harness. 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.)
A. Remove the 7 screws to gain access to the speaker wiring harness.
B. Wrap the center speaker wiring harness with foam.
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.
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".
^ 2008 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.
9. Confirm Repair.