Body - Convertible Top Wind Noise

NVH
NV009-04

Title:
CONVERTIBLE TOP WIND
NOISE IMPROVEMENT

Models:
'04 Solara Convertible

September 20, 2004

Introduction
Some customers may experience abnormal wind noise while driving at highway speeds. The tarpaulin rail cables have been modified to improve this condition. Please follow the repair procedure to properly install new tarpaulin rail cables.

Applicable Vehicles

^ 2004 model year Solara convertible vehicles produced BEFORE the Production Change Effective VIN shown below.





Production Change Information





Parts Information





Required Tools & Material





Warranty Information

Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 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

NOTE:

^ Before proceeding with this TSB, please confirm the root cause of the wind noise. If the tarpaulin top cover has approximately 30 to 40 mm (1.2 to 1.6 in.) of up and down movement on either side, as shown below, please proceed with this TSB.

^ The LH and RH cables should be replaced at the same time.

^ Be careful not to damage convertible top when performing this procedure. Also, be careful not to drop any fasteners into rear quarter panels.





1. With convertible top down, remove front window weatherstrip by releasing the retaining clip on each end.





2. Remove the front window weatherstrip retaining rail by loosening four T25 screws.

NOTE:
There will be shims behind the rail. These shims should be attached to the rail with adhesive. Be careful not to dislodge shims. If shims become dislodged, note the locations for reassembly.





3. Remove the two T25 screws in the front of the convertible top.





4. Carefully peel back the convertible top to expose the cable retaining tab.

5. Carefully close top to the half-way position (full vertical).





6. Drill out the two 1/8" retaining rivets.

NOTE:

^ Place a cloth or towel below the rivets to catch the metal filings.

^ Be careful not to allow drill chuck to contact cloth top.





7. Close top and remove the right rear window weatherstrip by releasing three clips (one in front, two in rear).





8. Remove the four T25 screws from weatherstrip retaining rail.





9. Remove the six T25 screws, releasing cloth/convertible top from weatherstrip/cover rail.

10. Carefully peel convertible top away from cover railing to expose cable.





11. Remove T25 cable anchoring screw.





12. Tie string onto end of broken cable and pull cable out.

13. Tie the new cable to the string and pull cable back through run.





14. Install two 1/8" inch rivets to the front cable retaining tab to secure new cable to convertible top.

NOTE:
File any burrs on rivets to prevent damage to the cloth top during installation and/or normal operation.





15. Drill out rivet holding the cable guide clip. Slide over new cable and install with new 1/8" rivet.





16. Flip plastic mesh boot upside down and place it around end of cable. Fasten cable to cover railing.

NOTE:
Plastic mesh boot should be flush with spring end.

17. Reassemble top in reverse order.

18. Confirm convertible top operation and test drive vehicle to ensure abnormal wind noise is resolved.