Canada - Body - Back Glass Ticking Noise

Bulletin
TSB2693

Issue Date
December 21, 2006

Market
Canada

Title
CREAKING OR TICKING NOISE FROM BASE OF REAR WINDOW

Component
BODY COMPONENT

Models
'05 - '06 Avalon

INTRODUCTION:







Some 2005 - 2006 model year Avalon vehicles may experience a creaking or ticking noise from the base of the rear window. This repair procedure adds a spot weld to both sides of the lower corner of the rear window opening flange. Use the information and repair procedure in this TSB to improve this condition.

APPLICABLE VEHICLES:
- 2005 - 2006 model year Avalon vehicles produced BEFORE the Production Change Effective VIN shown below.






PRODUCTION CHANGE INFORMATION:






WARRANTY INFORMATION:






RECOMMENDED EQUIPMENT:






REQUIRED TOOLS & MATERIAL:

DIAGNOSTIC PROCEDURE:







1. Use ChassisEAR(TM) to confirm that the noise is coming from the metal panels in the specific area shown in the picture.
2. Remove the package tray trim panel assembly.
Refer to ETAS:
- 2005 model year Avalon Repair Manual, Vehicle Exterior -- Window/Glass -- "Back Window Glass: Replacement".
- 2006 model year Avalon Repair Manual, Vehicle Exterior -- Window/Glass -- "Windshield / Window glass: Back Window Glass: Removal".

3. Place the ChassisEAR(TM) clamp on the flange with the hole in the lower corner of the back window glass opening.
If the noise is coming from this area of the metal panels, then go to the Repair Procedure.

REPAIR PROCEDURE:







1. Remove the back window glass.
Refer to the ETAS:
- 2005 model year Avalon Repair Manual, Vehicle Exterior -- Window/Glass -- "Back Window Glass: Replacement".
- 2005 model year Avalon Repair Manual, Vehicle Exterior -- Window/Glass -- "Back Window Glass: Replacement".

2. Remove all glass adhesive from the metal flange area.







3. Check the two existing spot welds in the lower corner of the back window opening (see illustration) to make sure the welds are good (NOT separating or incomplete).
- If the existing spot welds are good, go to step 4.
- If the existing spot welds are NOT good, drill a hole through the top layer of the sheet metal using a spot weld drill bit (10 to 12 mm in diameter; 3/8 inch to 15/32 inch) and Plug Weld (MIG) the hole.

4. Add a NEW spot weld between the 2 existing spot welds.
5. Carefully drill 2 holes in the top layer of the sheet metal at the spot weld using a spot weld drill bit (10 to 12 mm in diameter; 3/8 inch to 15/32 inch), one on each side of the vehicle, between the two existing spot welds (as shown in the illustration).
6. Plug Weld (MIG) the holes.
7. Reinstall the rear window glass and package tray trim panel assembly.

NOTE:
- Make sure to keep the area of the welds cool. Add a heat dam and weld the holes slowly to keep the temperature of the area low.
- Protect the painted outer panels from incidental damage from the drilling and welding process.
- Apply a rust preventative paint over the area of the Plug Welds to prevent corrosion. (The area of the spot welds is NOT visible when glass and trim is reinstalled. No finish painting should be required.)