Canada - Interior - Rear Package Tray Noise Repair Tips

Bulletin
1269

Issue Date
2003-09-09

Reference
BC-03-020

Model
Corolla

Year Range
2003

Market
Canada


Component
BC

Subject:
REAR PACKAGE TRAY NOISE REPAIR TIPS

Some customers may experience a clicking, squeaking, or itching noise from the rear package tray. The following procedures were developed to reduce noises in the rear package tray area.

APPLICABLE VEHICLES: 2003 model year Corolla vehicles.







REQUIRED TOOLS AND MATERIALS:

REPAIR PROCEDURE 1:

1. Carefully lower headliner along the top edge of the back glass.







2. Locate the two plastic clips approximately 25 cm in from the left and right side.







3. Carefully, remove these clips using a screwdriver.
4. Test drive the vehicle to confirm that noise is gone. If noise is still present, go to step 5.
5. Remove rear seat back assembly (fixed type rear seat only).
6. Fold rear seats forward (separated type rear seat only).
7. Remove roof side garnish inner.
8. Remove rear package tray trim panel assembly.
9. Remove rear seat belt assembly outer (retractor side).
10. Open Trunk.
11. Remove trunk door liner and right/left side carpet.







12. Locate seat belt anchor brackets on package tray reinforcement.







13. Carefully drill 2 holes (10-12 mm in diameter) 15-25 mm straight above current spot-welds just through the bracket panel. Plug weld (MIG) bracket panel to inner panel.

NOTE:
Keep welds cool! Use proper rust prevention methods/coating after welding.

14. Reassemble in reverse order. Rear seat belt assembly outer (retractor side) torque specification:

41.2 N-m (420 Kgf-cm, 30 ft-lbs)

15. Test drive vehicle to confirm that the noise is gone.

"Click" noise from rear of vehicle while turning.
1. Open trunk.
2. Remove all trunk liner mats.







3. Locate the wheel house and the front portion of the package tray.







4. Carefully drill 2 holes (10-12 mm in diameter) 25 mm apart (refer to black dots in illustration) in the first panel (package tray). Plug weld (MIG) the package tray to the wheelhouse.

NOTE:
Keep welds cool! User proper rust prevention methods/coating after welding.

5. Using 7 - 10 mm tack welds (thick black line in illustration) weld the package tray to the wheelhouse.

6. Reassemble and test drive vehicle.

REPAIR PROCEDURE 3:

"Squeaking" or "Itch" noise from the rear of the vehicle.







1. Remove rear package tray. Refer to ETAS Library for 2003 MY Corolla Repair Manual:
Section: Exterior/Interior Trim; Sub-section: Roof Headlining Assembly.







2. Insert foam blocks (50mm x 50mm) into 4 locations (2 behind each speaker).

NOTE:
If foam blocks are placed too far back against window, they may be visible after package tray is reinstalled. Be sure to use a foam block that has no memory and is not hard enough to create a bow in the assembled package tray.

3. Reassemble in reverse order and confirm that the noise is gone.

WARRANTY INFORMATION:







Clicking Noise from Rear of Vehicle







Clicking Noise While Turning







Squeaking or Itching Noise

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.