Interior - Dash Pad Rattles
NVH
NV006-02
REVISED

May 17, 2002

Title
DASH PAD RATTLE REPAIR TIPS

Models
'01 - '04 Tacoma

TSB REVISION NOTICE:

January 28, 2004: 2003 and 2004 model years have been added; Production Change Information has been removed; Parts Information has been updated; Figure 3 has been updated; TIS Repair Manual references have been added throughout the bulletin.

Previous versions of this TSB should be discarded.

Introduction

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

Applicable Vehicles^ 2001 - 2004 model year Tacoma vehicles.

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.

Parts Information

Required Tools & Material

Repair Procedure

Test drive and locate the source of the noise by using the palm of your hand to apply pressure 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 reducing countermeasures 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.

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.

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 assembly mounting points on the body.

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.

Noise Located at Airbag Assembly

Loosen airbag, reposition and retighten bolts to specified torque. Please refer to the Technical 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.

Noise Located at Reinforcement Bar

1. It will be necessary to unbolt the junction block, lower steering column, and unfasten ECM (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 the reinforcement bar to eliminate the source of the noise.

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

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

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 potential sources 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).