Body - Rear End Door Rattles
No: 76/07/99/NASRef:
Issue: 1
Date: 04/23/99
Rear End Door Rattle
AFFECTED VEHICLE RANGE:
DISCOVERY Series II (LT) All
SITUATION:
RATTLE FROM REAR END DOOR TRIM
Customers may experience a rattle from the rear end door area. In cases where rear subwoofers are fitted, this rattle may be particularly noticeable when the radio has been set to a high bass level.
RESOLUTION:
VERIFY CORRECT INSTALLATION OF TRIM FITTINGS OR WIRING
Two potential sources for an end door rattle have been identified. When a customer complaint is addressed on vehicles with subwoofers, verify that the trim clips are properly installed. Vehicles without subwoofers may have a wire harness making contact with body components.
PARTS INFORMATION:
DKP5279L Door casing clips Qty as required
EYC101460 Center clip (female) Qty 1 if required
STC3905 Foam Tape Qty as required
WARRANTY CLAIMS:
76.28.89/52 Time 0.20 hrs.
Verify and correct trim casing clip installation
76.28.89/53 Time 0.70 hrs.
Install foam tape on wire harness or center upholstery clip Material Allowance is incorporated into the time allowance for installation
FAULT CODE: K
Normal warranty policy and procedures apply
REPAIR PROCEDURE:
VERIFY TRIM CLIP INSTALLATION
1. Verify correct engagement of the 20 trim fasteners. (Dots in Figure 1)
2. Verify correct engagement of the four fasteners located inside the rear door pocket. (Figure 1)
3. Measure across and down from the inner top of the trim panel as shown in Figure 1.
4. Feel the area to determine if a fastener is in place or if a hole exists under the fabric.
5. If a fastener is present, push home the fastener.
6. If a fastener is not present, perform replacement of center clip outlined below.
ISOLATE UNUSED WIRE HARNESS OR INSTALL CENTER FASTENER
CAUTION:
Use a well-protected trim fork to release the trim clips securing the door trim casing.
1. If the vehicle does not have a subwoofer and the rattle is still detectable or if the center upholstery clip is missing, refer to the Workshop Manual Section 76.34.09.99 and carefully remove the door casing.
2. If a center fastener is required perform the following:
^ Verify that female clip (EYC101460) is present in the door panel. Install one if required.
^ Carefully install panel clip (DKP5279L) into the hole in the upholstery panel.
3. If no subwoofer is present, place foam tape on the unused subwoofer connector.
4. Inspect all 20 trim clips and the single center clip for cracks or damage before replacing the casing.
5. Replace any damaged clips.
6. Install rear door upholstery casing.
7. Verify that no rattle is present.