Interior - Various Squeaks and Rattles
No: 76/20/03/NASRef:
Issue: 1
Date: 10/31/03
Interior Squeaks and Rattles
AFFECTED VEHICLE RANGE:
Discovery Series II (LT) See individual repair applicability
SITUATION:
INTERIOR SQUEAKS AND RATTLES
A customer may complain of a variety of interior noises that can be hard to diagnose. Some may be the result of friction between various upholstery and trim parts and others may result from loosened components or fasteners.
RESOLUTION:
TROUBLESHOOT AND REPAIR SUSPECT AREAS
Use the troubleshooting guidelines and repairs outlined in this TIB, investigate the various squeaks and rattles. Once the noise ha been confirmed, perform the specific repair for the problem.
PARTS INFORMATION:
STC4006 Anti-Vibration Kit Qty 1
STC3937 Velour Pads Qty as required
STC3118K Anti-creak tape Qty as required
LRN100050S Krytox spray Krytox also in Kit STC4006
HAK000010 Seat Vibration Kit Qty 1
Locally Sourced:
Electrical tape
AS400 WARRANTY CLAIMS:
For each repair select Fault Code and only claim against the SROs from the table. Times claimed should reflect the work carried out and the R.0. should be endorsed with the repair procedure reference. A separate claim line will be required for each Fault Code used.
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
For each repair procedure select SROs from the table. Times claimed should reflect the work carried out and the R.0. should be endorsed with the repair procedure reference. A separate claim line will be required for each repair
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
PROCEDURE 1 - CORRECT CREAKING NOISE COMING FROM THE CORNER OF THE FASCIA AND THE BOTTOM OF THE "A" POST TRIM.
1. Release three clips securing the upper trim to the "A" post and disconnect tweeter multi-plug.
2. Remove the "A" post upper trim.
3. Open glove box, align stops with cutouts in fascia and remove glove box.
NOTE:
It may be necessary to loosen the fascia to free the cable,
4. Holding both ends of the trapped tweeter or coaxial cable, work the cable towards the "A" post until it is free.
5. If loosened, tighten bolts securing fascia to body to 26 Nm (19 lbf.ft.).
6. Raise glove box, align stops with cut outs in fascia and close glove box.
7. Install the "A" post upper trim.
PROCEDURE 2 - TAPPING NOISE FROM THE "A" POST.
1. Release three clips securing the upper trim to the "A" post and disconnect tweeter multi-plug.
2. Remove the "A" post upper trim.
3. If not fitted, fit foam pad available in kit STC4006 to the tweeter multi-plug.
4. Cut off excess from cable tie.
5. Position coaxial cable to body clips.
6. Push body clips fully into recess in the "A" post.
7. Fit the "A" post upper trim.
PROCEDURE 3 - TAPPING NOISE FROM THE GLOVEBOX
1. Open the glove box, align stops with cutouts in fascia and remove the glove box.
2. Ensure the light harness clip is fitted to appropriate hole in fascia frame (Arrowed in Figure 1).
3. Ensure the aerial coaxial lead is fitted as shown (A in Figure 2).
4. Ensure the airbag harness is fitted in the "Y" frame (B in Figure 2).
5. Raise the glove box, align stops with cut outs in fascia and close the glove box.
PROCEDURE 4 - CORRECT CONSTANT OR INTERMITTENT CREAKING FROM THE FORWARD EDGE OF CENTRE CONSOLE.
1. Release clips securing the transfer box lever gaiter to the centre console and remove knob and gaiter from the gear lever.
2. Remove the foam pad.
3. Move selector lever to the "D" position.
4. Release clips securing selector lever panel and raise the panel.
5. Open the rear console lid.
6. Remove two screws securing the rear of the console.
7. Remove two bolts securing the front of the console.
8. Move console rearwards approximately 15-20 mm (1/2 to 3/4 inch).
9. Fit velour pads (STC3937) to recesses in fascia (B in Figure 3) and then move pad into position (A in Figure 3).
10. Align console and install and tighten screws and bolts.
11. Close the rear console lid.
12. Secure selector panel and move selector lever to the "P" position.
13. Install foam pad.
14. Install transfer box lever gaiter and knob, secure gaiter.
PROCEDURE 5 - THIRD ROW SEATS RATTLES AND CREAKS
1. Release the 3rd row seat from the stowed position.
2. Remove the rubber buffer and refit in reversed position (from "A" to "B" in Figure 4)
3. Remove backing from tape (STC3118K) and fit pad to the top and the underside of the hook on seat frame (See Figure 5).
4. Fully deploy the seat and apply Krytox to seat piping (Arrowed in Figure 6).
5. Stow seat.
6. Repeat procedure for the other side.
PROCEDURE 6 - SECOND ROW SEATS RATTLES AND CREAKS
1. Fold the LH and RH rear seat squabs forward.
2. Apply Krytox to the upper area on the LH side of the LH rear seat squab.
3. Cut two velour pads (STC3118K) to the dimensions detailed in Figure 7.
4. Remove backing from the velour pads and install one pad to the LH seat cam (A in Figure 8) and one pad to the RH seat cam (B Figure 8).
5. Secure seat squab into fixed position.
6. Lower center armrest and apply Krytox to areas between armrest and seat bolsters (Figure 9).
7. Fold center armrest back into position.
PROCEDURE 7 - RATTLE FROM BEHIND THE SECOND ROW SEATS.
1. Release the load space roller blind from the seat back.
2. Remove backing from the foam pad (Available in kit STC4006) and insert into the female press-stud.
3. Secure the load space roller blind to the seat back.
PROCEDURE 8. CREAKING NOISE FROM REAR LEFT HAND CORNER OF VEHICLE
1. Check for slight discoloration on the rear quarter trim (A in Figure 9).
2. Carefully push on the bottom of the rear quarter trim (B in Figure 9) to create a clearance gap between the subwoofer and the rear quarter trim.
3. Release six clips securing the tail door aperture upper trim casing and remove the upper trim casing.
4. Remove the backing from the tape (STC3118K).
5. Install the tape to both ends of the trim casing. (Arrowed in Figure 10)
6. Remove two trim studs (A in Figure 11) from "D" post upper trim casing and ease casing away from the glass.
7. Remove backing from velour pad (Available in kit STC4006).
8. Install pad to edge of trim casing (B in Figure 11).
9. Install studs to trim casing and secure casing.
10. Install and secure the tail door aperture upper trim casing.
PROCEDURE 9 - TAPPING NOISE FROM IN-BETWEEN THE ALPINE GLASS AND THE REAR BODY SIDE GLASS.
1. Refer to RAVE section 76.13.73 and remove the "D" post trim casing.
2. Tape any loose wires to the main harness and secure harness in the body clips.
3. Install the "D" post-trim casing.
PROCEDURE 10 - CREAK FROM REAR SEAT AREA THAT IS HARD TO TRACE.
1. Ease the wheel arch away from the chassis outrigger to create a 2-3 mm gap (Arrowed in Figure 12).
2. Apply underbody sealer to the damaged area.
PROCEDURE 11 - TAPPING NOISE FROM THE CENTRE OF THE HEADLINING.
1. Remove the lens from interior lamp.
2. Remove two nuts securing interior lamp to roof.
3. Release the interior lamp from the headlining and locate the unused loose connectors (Figure 13).
4. Wrap all connectors and harnesses with foam tape available in kit STC4006.
5. Position connectors behind the headlining and under the other harness running along the headlining.
6. Install the interior lamp and lens.
7. Tap the headlining to verify noise has been eliminated.
PROCEDURE 12 - TAPPING NOISE FROM HEADLINING ABOVE LH SIDE "B" POST.
1. Remove the blanking panel from headlining,
2. Locate the unused alarm ultrasonic sensor connector (Arrowed in Figure 14).
3. Wrap foam tape available in kit STC4006 around the connector.
4. Position the connector behind the headlining.
5. Install the blanking panel.
PROCEDURE 13 - NOISE FROM FRONT CROSS MEMBER
1. Slide seat fully forward.
2. Apply non silicone based grease available in kit HAK000010 to the mating surfaces of the cross member and outboard plinth bracket. (Arrowed in Figure 15)
3. Return seat to original position.
PROCEDURE 14 - METAL TO METAL NOISE FROM REAR TRACK END-STOP WHEN SEAT IS FULLY REARWARD.
1. Switch ignition to the on position.
2. Slide seat fully forward and apply grease available in kit HAK000010 to both slide end-stops. (Arrowed in Figure 16)
3. Return seat to original position.
4. Switch off ignition.
PROCEDURE 15 - NOISE FROM SEAT BELT PRETENSIONER
1. Trim and fit velour strips (STC3118K) to the seat belt stalks. (Arrowed in Figure 17)
PROCEDURE 16 - CORRECTION OF VARIOUS NOISES WITHIN SEATS:
^ NOISE FROM THE SUSPENSION MAT AREA FROM CONTACT WITH REAR TUBE
^ CREAK FROM SLIDE LATCH CONTACTING FRAME WHEN SEAT OCCUPIED.
^ CORNER BRACKET CREAK FROM REAR OF FRONT SEAT.
^ NOISE FROM THE HEIGHT-ADJUST CROSS-TUBES.
^ NOISE FROM CUSHION SIDE CHANNEL.
^ A CONSTANT HIGH PITCHED SQUEAKING NOISE FROM THE UPPER PART OF THE FRONT SEAT SQUAB FROM TRIM WIRE CONTACT WITH THE RETURN
2. Refer to RAVE section 78.30.01/81 and remove the front seat cushion.
3. Remove the cable tie securing the recline motor harness.
4. Release four springs and two clips securing the suspension mat to the frame.
5. Remove the seat cushion suspension mat.
6. Install spacers from the service kit (HAK000010) to the new suspension mat.
7. Position the suspension mat and secure with two clips and four springs.
8. Secure the recline motor harness with a cable tie.
9. Hold the release catch fully open and apply grease to the teeth on both latches (arrowed in Figure 18).
10. Drill out the rivet and open out hole to fit an M6 bolt (arrowed in Figure 19).
11. Insert a new bolt (supplied in kit HAK000010) with the head of the bolt on the outside of the seat frame, apply a thread lock compound and torque to 14 Nm (124.3 lbf.in.).
12. Apply grease to both mating surfaces of the rear cross-tube and wipe off excess. (Arrowed in Figure 20)
13. Replace nut and washer (supplied in kit HAK000010), and torque to 19 Nm.
14. Remove any weld spikes from the bearing surfaces.
15. Using a flat-bladed screwdriver, create a 2-3 mm (1/8 inch) gap between the side channel and slide reinforcing bar. (Arrowed in Figure 21)
16. Refer to RAVE section 78.30.01/81 and remove the front seat squab cover.
17. Inspect the seat frame for evidence of paint removal caused by the trim wire contacting the seat frame. (A in Figure 22)
18. Apply rattle tape to cover the marks on the seat frame or the area identified as B in Figure 22 as follows:
^ Measure and cut a piece of tape to cover the area.
^ Clean the area on the seat frame for fitting the rattle tape.
^ Remove backing from the rattle tape and install on the area identified as B in Figure 22.
19. Install the front seat squab cover.
20. Install the front seat.