Rattle, Buzz and/or Clunk From the Front Door over Rough Road and/or with the Radio On #98-T-03A - (Jan 10, 2003)

For condition 1: 1996-1999 Saturn Sedans and Wagons built before and including VIN XZ124694. For condition 2: 1997 Saturn Coupes equipped with manual windows built before and including VIN VZ335593. For condition 3: 1996-1999 Saturns

Condition:

Customers may comment on one or more of the following conditions:

1. Rattle or buzz noise from the lower front door trim panel when driving over rough roads or when playing the radio at higher volumes.
2. Rattle or buzz noise from the plastic washer behind the crank handle on Coupes with manual windows when driving over rough roads.
3. Clunk or rattle type noise while driving over rough road.

Cause:

These conditions may be caused by one of the following conditions:

• Condition 1 may be caused by excessive movement at the front lower corner of the front door trim panel.
• Condition 2 may be caused by excessive movement of the plastic washer behind the window crank handle.
• Condition 3 may be caused by inadequate retention of the speaker push-pin type fasteners.

Correction:

Refer to the procedures in this bulletin.

Procedures:

Condition 1- 1996 and 1999 Sedans and Wagons

1. Remove the interior front side door trim panel on the side of the vehicle making the noise. Refer to Front Door Trim Panel in the Doors section of the appropriate year Body/Repair Service Manual.




2. Install a front side door deadener assembly P/N 21110766 on the backside of the front door trim panel.
Position the front side door deadener assembly so that an edge is located between the bottom outside of the door speaker and the front side door trim panel as shown in the illustration.
3. Install the interior front side door trim panel. Refer to Front Door Trim Panel in the Doors section of the appropriate tear Body/Repair Service Manual.
4. Verify that the condition has been repaired.

Condition 2 -- 1997 Coupes with Manual Windows built before and including VIN VZ335593

1. Remove the interior front side door trim panel on the side of the vehicle making the noise. Refer to Front Door Trim Panel in the Doors section of the 1997 Body/Repair Service Manual.




2. Install the front door window regulator handle spacer P/N 21059859 behind the front side door trim panel as shown in the illustration.
3. Install the interior front side door trim panel. Refer to Front Door Trim Panel in the Doors section of the appropriate tear Body/Repair Service Manual.
4. Verify that the condition has been repaired.

Condition 3 -- 1996-1999 Saturns

1. Remove the interior front side door trim panel on the side of the vehicle making the noise. Refer to Front Door Trim Panel in the Doors section of the 1997 Body/Repair Service Manual.
2. Remove the speaker push-pin fasteners, then remove the speaker.




3. Install the J-clip P/N 21093771 to the door where the speaker push-pins were removed at the 11:00 and 5:00 o'clock positions as shown in the illustration.
4. Install the speaker using screw P/N 11504056 in the positions where the J-clips were installed and tighten the screws.
Tighten

Tighten the screws to 2.5 N·m (22 lb in).

5. Install the push-pin fasteners in the remaining 2 locations.
6. Verify that the condition has been repaired.

Parts Requirements:

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer".  They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle.  Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely.  If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition.  See your GM dealer for information on whether your vehicle may benefit from the information.

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