Body - Front Door Rattles When Closed
No: 76/03/04/NASRef:
Issue: 1
Date: 27 February 2004
Front Door Rattle
AFFECTED VEHICLE RANGE:
New Range Rover (LM)
Up to 3A104762
SITUATION:
FRONT DOOR RATTLES WHEN CLOSED
The customer may complain of rattles from the front door when a door is jolted by closing or other abrupt jarring movement. A number of possible causes relating to the window mechanism and sound deadening materials may be the cause. Likely causes are:
^ Glass incorrectly fitted to glass guide channel.
^ Window regulator cable.
^ Loose window regulator.
^ Foam pad missing between the window regulator and the regulator mounting plate.
^ Clip missing or loose between the window regulator cable and the crash beam.
^ Faulty window regulator.
RESOLUTION:
INSPECT WINDOW MECHANISM FOR ROOT CAUSE AND REPAIR
By removing the door trim and inspecting various aspects of the window mechanism a cause for the rattle will be determined. Repair as indicated by the inspection
PARTS INFORMATION:
A5400 WARRANTY CLAIMS: (CANADA ONLY)
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.
Normal warranty policy and procedures apply. Material allowance is included in labor operation.
REPAIR PROCEDURE
IDENTIFY AND CORRECT DOOR RATTLE
1. Refer to RAVE Workshop Manual section 76.34.18 and remove the front door plastic sheet.
2. Lower the front door window for access to the regulator clamp Torx bolts.
3. Loosen the 2 regulator clamp Torx bolts securing the window glass (Arrowed in Figure 1).
4. Push the window glass fully rearwards into the rear glass guide channel.
5. Lightly tighten the Torx bolts.
6. Raise the window and check the glass alignment.
7. Lower the window and tighten the Torx bolts to 10 Nm (88.5 lbf.in).
8. Secure the regulator cables with a cable tie at the point where the regulator cables cross ("A" in Figure 2).
9. Trim the excess material from the cable tie.
10. Verify the bolt securing the regulator to the crash beam is tightened to 9 Nm (80 lbf.in) ("B" in Figure 2).
11. Verify that a foam pad has been fitted between the regulator and the regulator mounting plate (Arrowed in Figure 3).
12. If the foam pad is missing, install a new foam pad between the regulator and the regulator mounting plate.
13. Verify that the regulator is secure.
14. Check the integrity of the clip securing the regulator cable to the crash beam (Arrowed in Figure 4).
15. If the clip is loose, push the clip fully onto the crash beam.
16. If the clip is missing, secure the regulator cable to the crash beam with a cable tie. And trim the excess material from the cable tie.
17. Refer to RAVE Workshop Manual section 76.34.18 and install the front door plastic sheet.
18. Open and close the front door, listening for rattles with the window glass in the open and closed positions.
19. If rattles are still present, refer to the RAVE Workshop Manual section 76.31.45 and replace the front door regulator assembly.