its amazing Toyota couldn't figure this one out. Just takes a little ingenuity like fixing that squeak that come from the rear seat latch(been driving a bunch of people nuts).

fileechino,

Glad to hear that I was able to help someone else.

WhiteSR5,

Thank you so much for the fix to this most annoying problem. I couldn't for the life of me figure out what part was rattling because mine was only doing it while the roof was closed.

I actually ended up using some 3/16" ID rubber fuel line I had laying around. Just split it down the middle and slipped it over the circular rod. No more rattle!

Thanks again,
-YZT

Since this is such a great thread (with pics too!), i am going to move this to "PROBLEMS & WARRANTY" and stick it up.

Thanks everyone for your input!:)

I have the same problem
 

I took it back to the dealer several months ago (just 1-2 months after I got the truck). They test drove the truck and they believed it's the sunroof, so they ordered a new sunroof piece. And it took them 3 days to remove the ceiling, the headliner, sunroof, all side panels inside the truck, etc.

It's quiet for 1-2 months, and now it's coming back again, and it's making two noises. One from the end of the sunroof when the truck is rolling, swinging, etc. It makes noise as if the sunroof has been squeezed. The other from the end of the sunroof on the driver side every time the truck is moving (and even when idling sometimes) on not-so-perfect roads. It sounds like a plastic panel is not screwed tight.

I had another dealer look at it, and they believed it's the rails that are making the noise. I will bring it back to the original dealer and show them a print-out of this article. Thanks guys.

Do you hear the rattling ONLY when the sunroof is closed? I've been having a small rattling and want to make sure that the sunroof is where it originates from.

It doesn't sound like it's coming from the sunroof tho. It's more like coming from the driver's door/dash. Hope it's the sunroof so I can fix it myself with the recommended method......

Thanks for the nice pics and explanation!

Thank you for the fix!

Wai, I find the rattling only happens when the sunroof is closed.

Ah ... the dreaded sunroof noise problem. I knew it well.

I took delivery of my '03 Limited V8 around July 4th weekend from Lawrence Toyota in Lawrenceville, NJ. Almost immediately, the sunroof treated me to a constant chattering noise - I'd compare it to the sound a telegraph machine makes.

Anyway, after about four trips to the delear and two attempts to utilize a supposed fix put out by Toyota, they called in the district service/factory representative to deal with this problem on my 4Runner and another customer's. I was told that this chatter problem is known to Toyota and is the result of a poorly designed sunroof.

However, there is good news. After a day with the representative, the noise disappeared permanently.

Ok, I'll bite. What did the representative do?

I have this problem and will try the easy fix from above before I let anyone rip my roof and stuff apart, but if there is an easy Toyota fix I'd try that first.

This thread rocks - thanks MUCH for the quick fix. I will try this as soon as I can swing by a hardware store!

:)

Took mine to dealer yesterday for service and had them fix it. Apparently there is a TSB out for it. They put 5" plastic tubes around the links in the picture and some more grease. Seems to have fixed it.

So it seems Toyota finally listened and followed the fix.

Great post WhiteSR5,

I put up with the rattling as long as I could but yesterday it got to me. I was up at Home Depot and found a nylon washer that has the same diameters but is not as thick as the one recommended and these are white not black. I bought 6 just in case. They were something like 3 cents each. Brought them home, and trimmed them so they would fit snuggly when attahced to the rod. Using the step ladder I clipped one washer on each side as per the instructions.

This was the easiest fix I have ever done. My 4R now rides quiet now with no rattles.

Just for info I got the nylon washers in the hardware section of Home Depot and the bin number was 418607. I think the bins numbers are the same at all Home Depots??

-TM-

I finally had my '03 4Runner at the dealership this week for it's yearly inspection. While there, I had them fix the sunroof rattle.

They fixed it on the first try!

Woohoooo!!

That rattle was driving me bonkers! So glad to have it gone!

Now if only they can eventually fix the seat!!!

Sun roof rattle
 

Hi all,

I started to hear the rattle on my 03 sport last summer. Stupid me for not brining it in while still under warranty. As it turns out, the problem is that the cables and tracks are worn (after 2 years???). Extended warranty doesn't cover it. Total damage to fix you ask?? $2,431.00. Toyota will be hearing Bout this one.

just started having a rattle on the passenger side for 1 month. i'm glad i stumbled on this fix. did it with clear plastic tubing (bendable) with 3/16 " internal diameter from lowe's. halved a small piece and placed it on it and rattle is gone!

thanks!