T-SB-0004-15
Service Bulletin Details
Public Details for: T-SB-0004-15
Tsb: some 2014 - 2015 model year avalon and avalon hv vehicles may exhibit a condition where there is a pop/creak type noise from the lh rocker panel/bottom of the driver's door opening area. This is caused by two body panels contacting one
Models from 2015
2015 TOYOTA AVALON |
Models from 2014
2014 TOYOTA AVALON |
January 30, 2015 T-SB-0004-15 LH Rocker Panel Pop/Creak Noise Service Category Vehicle Exterior Section Body Structure Market USA Applicability YEAR(S) MODEL(S) ADDITIONAL INFORMATION 2014 – 2015 Avalon, Avalon HV Introduction Some 2014 – 2015 model year Avalon and Avalon HV vehicles may exhibit a condition where there is a pop/creak type noise from the LH rocker panel/bottom of the driver’s door opening area. This is caused by two body panels contacting one another within the rocker panel structure. Use the following Repair Procedure to address this condition. Production Change Information This bulletin applies to: • ALL 2014 model year TMMK built Avalon & Avalon HV vehicles • 2015 model year TMMK built Avalon & Avalon HV vehicles produced BEFORE the Production Change Effective VINs shown below. MODEL PLANT DRIVETRAIN Avalon TMMK Line 1 2WD Avalon HV PRODUCTION CHANGE EFFECTIVE VIN 4T1BK1EB#FU133267 4T1BD1EB#FU035563 Required Tools & Equipment REQUIRED TOOLS & MATERIAL QUANTITY Prybar (Similar to Snap-on® MPBS 11400) 1 Borescope (must be able to fit in a 15 mm diameter hole) 1 Cavity Wax (Similar to 3M® Rust Fighter-I, 08892) 1 MP (Multi-Purpose) Grease 1 © 2015 Toyota Motor Sales, USA Page 1 of 9 January 30, 2015 T-SB-0004-15 Page 2 of 9 LH Rocker Panel Pop/Creak Noise Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 BD1500 Separate Body Panels Within the Rocker Panel 1.5 57404-06140 91 43 APPLICABLE WARRANTY • This repair is covered under the Toyota Basic 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 occurrence of the specified condition described in this bulletin. Repair Procedure 1. Disassemble the vehicle. A. Remove the scuff plate garnish and the lower cowl garnish. B. Remove the driver’s side front seat assembly. Refer to the Technical Information System (TIS), applicable model and model year Repair Manual: • Avalon 2014 / 2015: Vehicle Interior – Seat – “Seat: Front Seat Assembly: Removal” • Avalon HV 2014 / 2015: Vehicle Interior – Seat – “Seat: Front Seat Assembly: Removal” C. Peel back the carpet on the driver’s side to access the rocker panel area. D. Remove the wire harness from the wire harness clips and remove the clips from the area. © 2015 Toyota Motor Sales, USA January 30, 2015 T-SB-0004-15 Page 3 of 9 LH Rocker Panel Pop/Creak Noise Repair Procedure (Continued) E. Remove the plug from the access hole on the inside of the rocker panel. NOTE Ensure to keep plug to reinstall after repair. Figure 1. Suspected Contact Area 1 2 1 Front of Vehicle 2 © 2015 Toyota Motor Sales, USA Access Hole January 30, 2015 T-SB-0004-15 Page 4 of 9 LH Rocker Panel Pop/Creak Noise Repair Procedure (Continued) Figure 2. 1 2 1 Access Hole 2 Front of Vehicle 2. Confirm and repair contact point No. 1. A. Using a borescope, navigate into the rocker panel through the access hole (from step 1E) towards the contact point No. 1. Figure 3. Contact Point No. 1 NOTE The areas of contact are internal to the rocker panel structure. 1 2 1 Contact Point No. 1 2 Access Hole © 2015 Toyota Motor Sales, USA January 30, 2015 T-SB-0004-15 Page 5 of 9 LH Rocker Panel Pop/Creak Noise Repair Procedure (Continued) B. Observe through the borescope if any part of the A-pillar reinforcement is contacting the step panel reinforcement at contact point No. 1. Figure 4. 1 2 3 5 1 Contact Point No. 1 2 Step Panel Reinforcement 3 A-pillar Reinforcement 4 Up 5 Left of the Vehicle © 2015 Toyota Motor Sales, USA 4 January 30, 2015 T-SB-0004-15 Page 6 of 9 LH Rocker Panel Pop/Creak Noise Repair Procedure (Continued) C. If contact is found in step 2B, insert a prybar through the access hole to the position of contact between the A-pillar reinforcement and the step panel reinforcement. Figure 5. Sample Tools 1 NOTICE To avoid damage to the body panel finish, please wrap the end of the tool used in electrical tape. 2 NOTE If NO contact was found in step 2C, continue to step 3. 1 Prybar 2 Drum Brake Shoe Adjustment Tool D. Using a hammer, tap the end of the pry bar until separation is created at the contact point. E. Lift the weather strip to access rocker panel flange. F. Confirm separation by shining a flashlight through the rocker panel flange towards the bulkhead and confirm with the borescope that light is coming in between the A-Pillar reinforcement and the step panel reinforcement. Figure 6. © 2015 Toyota Motor Sales, USA January 30, 2015 T-SB-0004-15 Page 7 of 9 LH Rocker Panel Pop/Creak Noise Repair Procedure (Continued) 3. Confirm and repair contact point No. 2. A. Using a borescope, navigate into the rocker panel through the access hole (from step 1E) towards contact point No. 2. Figure 7. Contact Point No. 2 1 2 1 Contact Point No. 2 2 Access Hole © 2015 Toyota Motor Sales, USA January 30, 2015 T-SB-0004-15 Page 8 of 9 LH Rocker Panel Pop/Creak Noise Repair Procedure (Continued) B. Using the borescope, observe if any part of the A-pillar reinforcement is contacting the front floor under reinforcement bracket at contact point No. 2. Figure 8. 1 2 3 5 1 Front Floor Under Reinforcement Bracket 2 Contact Point No. 2 3 A-pillar Reinforcement 4 Up 5 Left of the Vehicle C. If contact is found in step 3A, insert a pry bar through the access hole and use the tip of the pry bar to locate the contact point between the A-pillar reinforcement and the front floor under reinforcement bracket. NOTE If NO contact is found, move on to step 4. © 2015 Toyota Motor Sales, USA 4 January 30, 2015 T-SB-0004-15 Page 9 of 9 LH Rocker Panel Pop/Creak Noise Repair Procedure (Continued) D. Using a hammer, tap the pry bar three to four times to create a gap between the two panels. Figure 9. E. Use a flashlight to confirm the gap between the A-pillar reinforcement and the front floor under reinforcement bracket. 4. Reseal the area. NOTE If sheet metal was exposed during the repair, apply cavity wax to surface exposed. 5. Reassemble vehicle. A. Reinstall the access hole plug. B. Reinstall the wire harness clips (insert wire harness into clips). C. Reposition the weather strip and ensure it is fully installed. D. Replace the carpet. E. Reinstall the driver’s front seat. Refer to TIS, applicable model and model year Repair Manual: • Avalon 2014 / 2015: Vehicle Interior – Seat – “Seat: Front Seat Assembly: Installation” • Avalon HV 2014 / 2015: Vehicle Interior – Seat – “Seat: Front Seat Assembly: Installation” F. Replace the scuff plate garnish and the lower cowl garnish. 6. Confirm repair. © 2015 Toyota Motor Sales, USA