Body - Hollow Sound When Closing Front Doors

Bulletin No: 09-003/09

Last Issued: 01/22/2009

Subject:
HOLLOW SOUND WHEN CLOSING FRONT DOOR(S)

APPLICABLE MODEL(S) / VINS
2009 MAZDA6

DESCRIPTION

Some vehicles may experience a hollow sound when closing the front door(s). This may be caused by the sealer beads between the impact bar and the outer door sheet metal becoming detached.

Customers having this concern should have their vehicle inspected and/or repaired using the following repair procedure.

REPAIR PROCEDURE

NOTE: This repair should be performed by a qualified body shop.

1. Verify customer concern.

2. Record customer's pre-set radio stations.

3. Disconnect negative battery cable.





4. Tape window of affected door to hold window in place before removing door trim.

5. Remove front door trim according to Workshop Manual (section 09-17 FRONT DOOR TRIM REMOVAL/ INSTALLATION).





6. Using a fiber stick and a 3 x 5 card (or equivalent piece of paper), slide the card between each sealer bead and inner door sheet metal noting which sealer beads are detached.





7. Apply 3M General Adhesive Cleaner (08984) to cotton swab or equivalent.





8. Thoroughly clean the areas where new sealer bead(s) will be applied.

NOTE:
Only apply a new sealer bead next to a sealer bead that is detached.

9. Obtain locally:








^ Duramix NVH Dampening Material (04274)

^ Automix Mixing Nozzle (08193)

^ Mixpac Applicator Gun (08117) OR 3M Cartridge Applicator Gun (08571)

NOTE: DO NOT use any other products for this repair, such a panel bonding glue. Panel bonding glue is so strong it will pull the door sheet metal into the impact bar and cause a poor appearance concern on the outer side of the door.





10. Insert Duramix NVH Dampening Material (04274) into applicator gun and remove cap.





11. Begin squeezing applicator gun trigger until clear dampening material starts to come out of one side.





12. Continue squeezing trigger until both sides (dampener material and hardener) come out equally.

NOTE:
This ensures dampener material and hardener are correctly mixed and will harden properly.

13. Screw Automix Mixing Nozzle (08193) onto Duramix NVH Dampening Material (04274).





14. Squeeze trigger until a small amount of material comes out.





15. Begin applying material to affected areas between originally detached sealer beads.

NOTE:
Apply material in the same size as the original sealer bead.





16. Repeat repair for other side front door as necessary.

17. Allow material to dry for twenty-four (24) hours leaving the door(s) slightly open during drying time.

NOTE:
^ DO NOT press on the outer side of the door while material is drying.

^ DO NOT slam door closed while material is drying. This may break the bond.

18. Reinstall front door trim according to Workshop Manual (section 09-17 FRONT DOOR TRIM REMOVAL/ INSTALLATION).

19. Reconnect negative battery cable.

20. Re-enter customer's pre-set radio stations.

21. Perform "Power Window Reinitialization Procedure".

22. Verify repair.





PART(S) INFORMATION





WARRANTY INFORMATION