Audio System - Distorted Sound/Door Panel Buzzes/Rattles
NUMBER: 23-024-02GROUP: Body
DATE: June 17, 2002
THIS BULLETIN IS BEING PROVIDED EN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL JULY 1, 2002.
SUBJECT:
Distorted Audio System Bass Sound and/or Door Trim Panel Buzz/Rattle
OVERVIEW:
This bulletin involves installing two foam blocks, a screw, washer and tube behind the front door speaker grille, checking the torque on the door trim and speaker fasteners, replacing the door pull cup screw as well as cutting a small hole in the water shield on both doors.
MODELS:
2001 - 2002 (JR) Sebring Convertible
SYMPTOM/CONDITION:
Distorted audio system bass sound and/or door trim panel buzz/rattle may be experienced during higher volume and bass output levels. This condition is caused by loose door trim and/or speaker fasteners, and/or fluttering water shield and/or movement of the lower front corner of the door trim panel. Audio system components, speakers in particular, have been found to have no causal effect for this condition and therefore speaker replacement should be avoided.
DIAGNOSIS:
Play the audio system at a high volume and full bass setting, if a buzz/rattle noise is heard, perform the Repair Procedure.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
1. Use a trim stick to pry the front edge of speaker grille from the door trim panel. Remove and set the grille aside.
2. Remove the front door speaker fasteners and remove the speaker from the opening. It may be necessary to use a trim stick to pry the speaker out, use care to prevent damaging the speaker. Disconnect the speaker wiring connector and set the speaker aside.
3. Install a foam block so the 2 in. thickness is between the top of the speaker mounting bracket and the water shield, (Fig. 1) Item 1. Insert the outboard surface (against speaker bracket) of the block first, then rotate the inboard surface (against water shield) up and work the foam block into position so it will not obstruct the installation of the speaker.
4. Install a foam block so the 2 in. thickness is between the door trim panel and the water shield at the front of the speaker opening, (Fig. 1) Item 2. Position the block so its bottom edge is horizontal and above the speaker locator hole as well as forward of the speaker mounting bracket screw boss
5. Referring to (Fig. 2) use a sharp knife to cut an opening in the water shield. Be careful to make sure the opening does NOT extend past the horizontal area of the water shield surface, otherwise water may leak into the passenger compartment.
6. Check the tightness of the 4 speaker bracket to door inner panel mounting screws, they should be torqued to 1.5-2.5 Nm (13-22 in. lbs.).
7. Replace the screw in the door pull cup with screw p/n 00153634. Torque the screw to 1.5-2.5 Nm (13-22 in. lbs.).
8. Check the tightness of the remaining 6 door trim panel mounting screws, they should be torqued to 1.5-2.5 Nm (13-22 in. lbs.). The access cover on the front of door trim panel must be removed to gain access to the forward fastener. The cover is removed by prying at the rear edge The correct torque on this fastener is "critical" to eliminate trim panel rattle. The red courtesy reflector at the rear of the door must be removed to gain access to the rear trim panel fastener. Care must be taken to avoid breaking the reflector. The reflector can be removed by prying at the screwdriver notch at the bottom of the reflector.
9. Check the tightness of the 3 door trim panel to speaker bracket mounting screws, they should be torqued to 1.5-2.5 Nm (13-22 in. lbs.).
10. Referring to (Fig. 3), measure from the speaker grille locator hole, 20 mm rearward and 57 mm downward, and place a mark.
11. Drill a 5/32 in. (4 mm) hole through the door trim panel and through the door inner sheet metal at the marked location, (drill as straight and level as possible).
12. Drill a 3/8 in. (9.5 mm) through the door TRIM panel, using the 5/32" hole as a pilot. Do NOT drill through the door sheet metal.
13. Slide the washer, p/n 06100874, onto the screw, p/n 00154811, followed by the tube, p/n 05101756M.
14. Insert the screw, washer, and tube assembly into the hole drilled in the door trim panel and start the screw into the pilot hole in the sheet metal of the door.
15. Torque the screw to 2.8-3.4 Nm (25-30 in. lbs.).
16. Install the door speaker. Torque the mounting screws to 4.5-5.5 Nm (40-48 in. lbs.).
17. Install the speaker grille.
18. Repeat steps 1 through 17 on the other door.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: