0104-nv00602r-dashrattle

Toyota Supports ASE Certification of 6

NV

006-02

Title:

DASH PAD RATTLE REPAIR TIPSModels:

’01 – ’04 TacomaTechnical Service

BULLETINMay 17, 2002

TSB REVISION NOTICE:January 28, 2004: 2003 and 2004 model years have been added; Production ChangeInformation has been removed; Parts Information has been updated; Figure 3 hasbeen updated; TIS Repair Manual references have been added throughout the bulletin.Previous versions of this TSB should be discarded.

Some customers may experience rattles from the dash area. The following procedureswere developed to reduce noise from the dash area.

� 2001 – 2004 model year Tacoma vehicles.

OP CODE DESCRIPTION TIME OFP T1 T2

BD1042 Instrument Panel Sub–Assembly 4.0 55301–04020–## 91 57

Applicable Warranty*:This repair is covered under the Toyota Comprehensive Warranty. This warranty is ineffect for 36 months or 36, 000 miles, whichever occurs first, from the vehicle’sin-service date.

* Warranty application is limited to correction of a problem based upon a customer’s specific complaint.

NV

H

Introduction

ApplicableVehicles

WarrantyInformation

DASH PAD RATTLE REPAIR TIPS – NV006-02 Revised May 17, 2002

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PART NUMBER PART NAME QTY

08231–00810 Wind Noise Kit (EPT Sealer)* 108231–00801 Noise Kit (Felt Insulation)* 155950–04020 Defroster Nozzle (’01 – ’02 model year only) 190249–04057 Dash Pin (replace as needed) As Needed90467–15024 Clip (replace as needed) As Needed

* There is enough material in these kits to repair numerous vehicles.

TOOLS & MATERIALS PART NUMBER QUANTITY

3M Squeak Reduction Tape* 3M 06356 13M Window Weld* 3M 08611 1

* There is enough material to repair several vehicles.

Test drive and locate the source of the noise by using the palm of your hand to applypressure on the suspect area or by grasping and holding onto the suspected source.When disassembling the dash, it is suggested that all of the identified noise reducingcountermeasures be performed, as shown below.

Noise Located at Defroster Duct for 2001 – 2002 Model Year Tacoma Only

1. Remove instrument panel. Refer to the Technical Information System (TIS):2002 model year Tacoma Repair Manual: Body (Mechanical) Instrument Panel.

2. Remove plastic defroster nozzle assembly and discard.

3. Add EPT sealer to the inlet and outlet surfaces of a new defroster nozzle assembly.

4. Install the new defroster nozzle assembly.

PartsInformation

RequiredTools &Material

RepairProcedure


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5. Insulate all clips, pins and connectors used.

NOTE:� Strips found in referenced Wind Noise Kit are pre–cut (290 x 5 x 4 mm) for this

application.� One Wind Noise Kit supplies enough material to repair approximately 10 vehicles.

Figure 1

Add EPT Sealer to Duct Outlet:4 pieces at 290 x 5 x 4 mm2 pieces at 230 x 5 x 4 mm

Add EPT Sealer to Duct Inlet:2 pieces at 100 x 5 x 4 mm2 pieces at 105 x 5 x 4 mm

RepairProcedure(Continued)


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Noise Located at Duct Mounting Pins

1. Inspect locating pins of defroster nozzle and add 3M Squeak Reduction Tape (P/N 3M 06356) to locating pins as shown in Figure 2.

2. Add 3M Window Weld (P/N 3M 08611) to each of the four defroster nozzle assemblymounting points on the body.

Figure 2

Add 3M Squeak ReductionTape to Pins

Add 3M Window Weld toEach of the Four NozzleMounting Locations onEngine Wall

Noise Coming From Broken Dash Mounting Clips

1. Remove broken clips and pins (see Figure 3) and discard.

2. Install new clips and pins where needed.

3. Apply 3M Squeak Reduction tape (P/N 3M 06356) to pins as shown below.

Figure 3

Replace Clips if Broken

Replace Pins if Broken andadd 3M Squeak ReductionTape (P/N 3M 06356)

3M Squeak Reduction Tape(P/N 3M 06356)

Pin



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Noise Located at Airbag Assembly

Loosen airbag, reposition and retighten bolts to specified torque. Please refer to theTechnical Information System (TIS): 2004 model year Tacoma Repair Manual: Body(Mechanical) Instrument Panel.

Noise Located at ECM

Remove ECM and apply EPT sealer (P/N 08231–00810) to insulate the bracket from the ECM.

Figure 4ECM

ECM Connector

Glove Compartment

Lower No. 2 Finish Panel

Noise Located at Reinforcement Bar

1. It will be necessary to unbolt the junction block, lower steering column, and unfastenECM (Figure 4) to complete this operation.

2. Loosen No. 1 brace by removing 2 top bolts (see Figure 5).

3. Loosen No. 2 brace by removing top bolt.

4. Loosen reinforcement bar by removing 4 nuts and 3 bolts that hold it in place.

5. Place felt insulation from Noise Kit (P/N 08231–00801) at each end of thereinforcement bar to eliminate the source of the noise.

6. Reinstall reinforcement bar, junction block, steering column and ECM. For assemblyinstructions, please refer to the Technical Information System (TIS): 2004 model yearTacoma Repair Manual: Body (Mechanical) Instrument Panel.

For torque specifications, please refer to TIS: 2004 model year Tacoma RepairManual: Service Specifications: Body.

No. 1 Brace No. 2 Brace

Instrument Panel ReinforcementRemove Bolts and Nuts as Shown Circled

Figure 5



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Noise From Wiring

1. Wrap any wiring that appears to rub on the underside of the I/P with foam from Wind Noise Kit (P/N 08231–00810).

2. Use foam to insulate all plastic connectors on wiring harness that may be potentialsources of noise from Wind Noise Kit (P/N 08231–00810).

Noise From HVAC Cables

1. Make sure cables are properly secured to the mounting brackets.

2. Wrap cables with foam from Wind Noise Kit (P/N 08231–00810).

Noise From Radio Bezel

Wrap the radio bezel clips with 3M Squeak Reduction Tape (P/N 3M 06356).

Noise From “A” Pillar

Wrap the “A” pillar clips with 3M Squeak Reduction Tape (P/N 3M 06356).


0104-nv00602r-dashrattle

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