Body - Pop or Rattle From Rear Door Area
NUMBER: 12-148-13DATE: 03/27/13
APPLICABILITY:
2012MY Impreza
SUBJECT:
"Rattle" or "Popping" Sound From
Rear Door Area
INTRODUCTION
This bulletin provides a repair procedure to address a customer concern of a "rattle" or "popping"sound which could come from either of the rear door opening areas. The sound may occur over small bumps or when a twisting motion is introduced into the vehicle body at low speeds. The cause is an insufficient gap between multiple layers of the body structure where they are spot-welded together as shown in the illustrations.
SERVICE PROCEDURE / INFORMATION
1. Remove the rear seat cushion and the door sill trim panel to access the affected area shown following the procedures outlined in the applicable Service Manual. Once the seat cushion and trim are removed, road test the vehicle again to confirm the area circled in the photo is the source of the sound.
2. Remove the sealer from the seam "A" areas shown in the photo above using a scraper.
3. Next, using a pick tool as shown in the photo, remove the sealer from between the layers of sheet metal.
4. Once the sealer has been removed, using a flat-blade screw driver, carefully work it in between the layers of sheet metal and increase the gap in the areas between the spot-welds in the two "A" sections shown first. Only spread the layers enough to allow the spray grease to penetrate (Step 7).
5. Next, road test the vehicle again to confirm whether or not the sound has been eliminated.
6. If the sound persists, repeat Steps 2 - 5 on the "B" sections shown.
7. Once the sound has been eliminated, apply the spray grease into the gaps created between the layers of sheet metal.
8. Clean off any excess spray grease from outside the gaps using a clean shop cloth with solvent or brake cleaner applied.
9. Once the area is clean and dry, apply body sealer to seal the gaps made between the spot-welds.
10. Reinstall the trim panels and the rear seat cushion to complete the repair.
WARRANTY / CLAIM INFORMATION
For vehicles within the Basic New Car Limited Warranty period, this repair may be claimed using the information shown.
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