rattle from driver's door or left dash

[dave4242]

I have a new (2004) V8 4Runner Limited which I picked up about 2 weeks ago. I absolutely love it, but I have this annoying rattle which sounds like it is coming from either the driver's door or the left dash.
It is more pronounced when the truck is cold and occurs frequently when I hit a bump in the road or especially when i travel over a very uneven surface, like our gravel driveway.
Sometimes it almost sounds like it is coming from behind me, so I'm wondering if there is the same issue as the sunroof in the previous posts. This is noticeable with the sunroof closed.
I'm wondering if anyone else has had an issue with the driver's door, and if there are instructions I can download on how to remove the door panel. I'm sure the dealership won't bother to do this.
Also, I will attempt the sunroof spacer repair as in the previous post. Thanks.
Dave

 

[Oscarz]

My driver door rattles in cold weather also. But mine is the door itself, not inside it. Apparently, it isn't adjustable to where it can close tighter, so I'm thinking maybe thicker weather strip or add some rubber material or something.

When driving, If I put a little pressure on the window/door, the noise stops. Try that and see if you have the same issue.

Otherwise, the only other things I can think of are headliner rattle (dealer will fix) or rear seat latches (wrap a piece of tape around front of metal hoop that the latch clamps onto).

 

[dave4242]

I tried to push on the door panel, but that does not seem to stop the noise.
Have people had good experiences with the dealer repairs on noises?
I don't want it to get worse if they start taking things apart.

 

[jharris2]

I've had good luck with the dealer I use -- the service manager came from a Lexus dealership so he is more concerned about noises than most people are. He's done a good job tracing the rattles and the service guys have not introduced any new noises that I have found yet.

 

[dave4242]

could anyone post the instructions on how to take the driver's door panel off?

 

[Oscarz]

Did you try pushing on window near the top? If I just press on door, it doesn't stop the noise but when I press on window it does. Just a thought before you disassemble.

 

[Nerve]

could anyone post the instructions on how to take the driver's door panel off?

implulsebrklyn has info on his site for removing the door panel. He has some pics of how he removed the panel to replace his speakers. He also posted some pdf's from the shop manuel of how to remove the panel.

Here's the link to his site
http://www.clarkson.edu/~calisec/4runner/4runner2003.htm

 

[mfjarvind69]

Rattle From door

Hello Everyone,
Looks like a lot of people are having problems with the door rattle. Well, I thought I was being paranoid about noises Anyway, everything in my 04 V8 Sport is solid except the front passenger door. Sounded like something loose inside. The dealer promptly called the factory rep who isolated the problem to one of two things:
1) Loose cables inside
2) Body cladding on the outside. When he tapped on the body classing from outside, the same tone is heard. When he held it down and tapped again, the noise disappeared.

Fixes:
1) Insulate everything on the inside.
2) Insulated the body cladding on the outside.

He mentioned that the design of the clips that hold the door may also be the problem. However, after they applied the fixes, the truck is tight again.

To me , it seems that Toyota does not test their vehicles under various temperature conditions for rattles. I wonder if rattles are something they even consider. It is true that these vehicles run like clockwork for ever, but in this day and age, testing for rattles under varying temperature conditions should be a standard procedure.

Anyway, just my 2c worth. Hope it helps some...

 

[dave4242]

I finally (after 2 trips to the dealership with no fix of the rattle), I took the door panel off. It was relatively easy to do (Took less than 10 minutes). I found that the 2 cables that go from the inside door lock and the inside handle that opens the door were tapping against the metal of the door. I wrapped some pipe insulation around them and no more noise!

 

[sauria]

wow

I finally (after 2 trips to the dealership with no fix of the rattle), I took the door panel off. It was relatively easy to do (Took less than 10 minutes). I found that the 2 cables that go from the inside door lock and the inside handle that opens the door were tapping against the metal of the door. I wrapped some pipe insulation around them and no more noise!

Great to hear I wonder if I have the same problem.
I've been breaking in a new SR-5 4x4 v-8 and have noticed a slight rattle sound in the drivers door. It occurs at low speed and sound like plastic parts rattling inside of the door. Yet, it is more pronounced on cold days (just froze) and seems diminished as the interior heats up (running heater).

Any experience with this as a past issue? How did you solve it?

I am going to try and put some armor all on the door weatherstripping and see if this has any effect.

 

[uberdog]

I have had this issue and found the fix:

In most cases the rattle noise is coming from door mechanism cables rattling against the interior door frame. In cold weather it is worse due to the stiffness of the cold plastic that surrounds the cables. In warmer weather, things expand and the plastic may be more pliable (soft).

The cables look like motorcycle brakelines and run from the door handle to the door latch. Toyota make a sound dampening kit to address this issue. You should have your dealership runthe fix under warranty rather than try and fix it yourself. I learned the hard way.

 

[sauria]

Thanks

I have had this issue and found the fix:

In most cases the rattle noise is coming from door mechanism cables rattling against the interior door frame. In cold weather it is worse due to the stiffness of the cold plastic that surrounds the cables. In warmer weather, things expand and the plastic may be more pliable (soft).

The cables look like motorcycle brakelines and run from the door handle to the door latch. Toyota make a sound dampening kit to address this issue. You should have your dealership runthe fix under warranty rather than try and fix it yourself. I learned the hard way.

Thanks, was it too hard to fix yourself? I live 180 miles from my purchasing dealer and hoped it would be a matter of insulating the cables. Is there a service bulletin for that sound dampening kit?

 

[uberdog]

It was not a big deal to fix, but it was a big deal finding the issue on my own. I also broke a few plastic pins when removing the door panel.

If you want to do it on your own (and you are mechanically inclined) it should be easy. Just be sure to wrap all the lines in foam tubing and tape it up well. My fix fell apart and then I had the dealer do it right with the Toyota kit. They had a good laugh at my expense because I did a crappy repair... :arrow:

 

[sauria]

Thanks, Kit?

It was not a big deal to fix, but it was a big deal finding the issue on my own. I also broke a few plastic pins when removing the door panel.

If you want to do it on your own (and you are mechanically inclined) it should be easy. Just be sure to wrap all the lines in foam tubing and tape it up well. My fix fell apart and then I had the dealer do it right with the Toyota kit. They had a good laugh at my expense because I did a crappy repair... :arrow:

Thanks, so the dealership actually has a repair kit? I also have the Driver's side headliner rattle -- I read that there is an '03 tsb on that. Do you have that rattle too?

 

[uberdog]

The Toyota rattle kit is generic, not part of a TSB. You may want to order one from your dealer and have them ship it to you.

The headliner issue is not something you should do yourself. It is a big freakin' deal to get the headliner down. Unfortunately it will not go backup as tight as it came from the factory.

The rattle in the headliner is the same deal as the door rattle. Electrical cable rattling between the headliner and the roof.

I am on my 2nd 2003 4Runner and both had rattle and trim issues of one kind or another. My current truck has a squeaky drivers seat, sunroof and dashboard rattles. My first Runner (wrecked) was the one with the door rattle.

Fit and finish should be better on a $40K SUV...

 

[sauria]

Thanks

The Toyota rattle kit is generic, not part of a TSB. You may want to order one from your dealer and have them ship it to you.

The headliner issue is not something you should do yourself. It is a big freakin' deal to get the headliner down. Unfortunately it will not go backup as tight as it came from the factory.

The rattle in the headliner is the same deal as the door rattle. Electrical cable rattling between the headliner and the roof.

I am on my 2nd 2003 4Runner and both had rattle and trim issues of one kind or another. My current truck has a squeaky drivers seat, sunroof and dashboard rattles. My first Runner (wrecked) was the one with the door rattle.



Fit and finish should be better on a $40K SUV...

Agreed! Thanks a bunch. I guess the kit is a bunch of insulation and foam? I called my dealer and he was not aware of a TSB on this -- so he said.
This headliner rattle is coming from the driver's side visor and is a rubbing creaking sound -- not like that in the door -- it sounds like cold plastic rubbing.

 

[uberdog]

ah, OK. I have that same headliner rattle in mine. I keep thinking it is the visor, but cannot seem to pin it down. It is worse when the weather is cold.

At the very least there seems to be a common thread to the issues people have with rattles. Same rattles in the same places. Clearly a design issue.

 

[sauria]

yes

ah, OK. I have that same headliner rattle in mine. I keep thinking it is the visor, but cannot seem to pin it down. It is worse when the weather is cold.

At the very least there seems to be a common thread to the issues people have with rattles. Same rattles in the same places. Clearly a design issue.

Yes, my sunvisor rattle can be stopped by just pressing slightly on the visor when it is in the up position. I don't have a rattle in the headliner near the sunroof. Yet?!