Body - Front Door Wind Noises Above 40 MPH
L-SB-0118-08Rev1
September 19, 2008
Front Door Wind Noise
Service Category
Vehicle Exterior
Section
Exterior Panels/Trim
Market
USA
Applicability
TSB REVISION NOTICE
October 15, 2008
^ The parts section has been updated.
Any previous printed versions of this service bulletin should be discarded.
Introduction
Some 2007-2008 model year ES 350 customers may complain of a wind noise from the front side window area when driving at speeds greater than 40 mph. Perform the inspection procedure to verify the wind noise is heard from the front lower corner of the door window and use the following repair procedure to improve this condition.
NOTE
It is important to note that this TSIB addresses unusual interior noises caused by slight variations in certain parts and by carefully following the instructions in this TSIB, these noises can be improved. Your customers must be aware that some level of wind turbulence noise, especially in cross wind conditions, is present in all vehicles.
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.
Production Change Information
This TSB applies to vehicles produced BEFORE the Production Change Effective VIN shown below.
Parts Information
Required Tools & Equipment
Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.
Inspection Procedure
Verify the wind noise is coming from the black triangle window molding (cover front door front lower frame upper) in front of the door glass by taping the joints and confirming the source of noise.
Repair Procedure
Perform this repair procedure to both sides of the vehicle.
Disassembly Procedure
1. Fully open the front door glass.
2. Using a plastic pry tool or screwdriver with the tip wrapped with protective tape disengage the 3 claws and remove the front door inside handle bezel plug.
3. Remove front door armrest base panel assembly.
A. Using a plastic pry tool or screwdriver with the tip wrapped with protective tape disengage the 5 claws and 3 clips and remove the front door armrest base panel assembly.
B. Disconnect the connector.
4. Remove courtesy light assembly.
A. Using a plastic pry tool or screwdriver with the tip wrapped with protective tape disengage the claw and remove the courtesy light assembly.
B. Disconnect the connector.
5. Remove the door armrest cover.
6. Remove front door trim board sub-assembly.
A. Remove the 5 screws.
B. Using a clip remover disengage the 9 clips.
C. Pull up the front door trim board in the direction indicated by the arrow.
D. Disengage the reference bosses from the front door panel.
E. Raise the front door trim board to disengage the 4 claws and remove the front door trim board together with the front door inner glass weatherstrip.
F. Disconnect the cables and each connector from the back side of the inside handle and remove the front door trim board subassembly.
7. Remove door frame garnish.
Using a clip remover remove the clip. Disengage the clip and remove the front door frame garnish.
8. Partially remove the upper portion of the weatherstrip on the door.
A. Peel the back upper corner of the weatherstrip and disengage the clip.
B. Remove the weatherstrip down the top edge of the door revealing the 8 rivets. Be sure to peel off the double sided tape at the front lower corner of the weatherstrip.
NOTE
After removing the upper portion of the weatherstrip, it can be left hanging.
9. Partially remove the upper front door glass run. The upper glass run can be partially removed by pulling it down from the door frame.
NOTE
This is done to prevent damage during disassembly of the outer molding.
10. Remove the front door window frame molding (Molding Front Door Window Frame Rear).
When removing the front door window frame molding heat the vehicle body and front door window frame molding using a heat light.
Do not heat the vehicle body and front door window frame molding excessively. This may cause damage to the paint and door.
A. Disengage the clip on the upper back corner of the door.
B. Using a molding remover peel off the double-sided tape and remove the front door window frame molding.
11. Put protective tape around the front door belt molding assembly.
A. Using a molding remover disengage the 5 clips and remove the front door belt molding assembly.
12. Remove the front door outside molding (Molding sub-assy Front door Outside).
A. Prepare a drill with a 4 mm (5/32 in.) bit drill.
B. Tape and cover the drill bit 5 mm from the tip. Use the tape as a drill depth guide.
C. Free the flange of head of each rivet by drilling to the 5 mm point on the bit.
D. Remove each of the 8 rivets.
E. Disengage the clip and guide and remove the front door outside molding from the door frame.
Installation Procedure
1. Install front door outside molding.
A. Engage the molding guide into the door frame.
B. Engage the clip and install the front door outside molding to the door frame.
C. Using an air riveter or hand riveter install the 8 new rivets in the order shown in Figure 18.
NOTE
^ Do not leave any space between the molding and door frame.
^ Firmly hold together the 2 items while installing the rivet.
^ Do not tilt the riveter when installing the rivet to the molding. Do not leave any space between the rivet head and molding.
D. Confirm that the rivets are seated properly against the molding.
NOTE
Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.
2. Install black triangle window molding.
When installing the black triangle window molding heat the vehicle body using a heat light.
NOTE
Do not heat the vehicle body excessively.
A. Remove the release paper from the black triangle window molding.
After removing the release paper keep the exposed adhesive free from foreign matter.
B. Engage the clip and install the black triangle window molding.
3. Install front door window frame molding.
A. Clean the vehicle body surface.
Using a heat light, heat the vehicle body.
B. Remove any residual double-sided tape from the vehicle body.
NOTE
Wipe off any tape adhesive residue with cleaner.
C. Remove the release paper from the new front door window frame molding.
NOTE
After removing the release paper; keep the exposed adhesive free from foreign matter.
D. Engage the clip and install the front door window frame molding.
E. Firmly press on the molding making sure it properly adheres to the door.
4. Install front door glass run.
Ensure that the glass run fits tightly into the door frame.
5. Install the front door upper portion of the weatherstrip.
A. Ensure that the double sided tape adheres to the lower portion of the outer molding assembly and the weatherstrip fits tightly back into position.
B. Clip in the upper back corner of the weatherstrip.
6. Install door frame garnish.
A. Engage the clip and install the door frame garnish.
B. Install the rear clip.
7. Re-Install the front door handle cables trim board sub-assembly door armrest courtesy light arm rest base panel and connector and handle bezel plug in reverse order of disassembly.
8. Install front door belt molding assembly.
A. Slide the front portion of the belt molding into the lower outside molding.
B. Firmly press down on the molding and ensure all clips snap into position.
9. Test drive the vehicle to confirm that the wind noise is reduced.