09-009/05 2004-2005 MAZDA3 - FRONT DOOR RATTLE

APPLICABLE MODEL(S)/VINS

2004 -) 2005 Mazda3 with VINs lower than JMZ BK**** ** 275577 ( produced before January 14, 2005)

DESCRIPTION

When driving over bumps or rough road surfaces, a rattle type noise may be heard from either of the front doors. The noise may be due to a loose clip(s) from the front pad mounted in the door panel.

Customers having this concern should have their vehicles repaired using the following repair procedure.

REPAIR PROCEDURE

NOTE: Obtain the following fasteners (purchased locally) before proceeding.

Description	Detail	Qty
Bolt	M6 x 10mm	2
Washer	Flat -) (6mm I.D.)	2
Nut	M6 thread size	2

1. Verify concern.

2. Ensure window is in the "closed" position.

3. Remove front door unit according to Workshop Manual (section 09-11 FRONT DOOR UNIT REMOVAL/INSTALLATION)

   NOTE: While removing the front door unit, hold the window so that it does not drop. Once the front door unit is removed, allow the window rail to rest on the bottom of the door panel.

4. Zip-tie the regulator spool to prevent it from coming apart.
   • If the spool separates from the housing, the regulator assembly will need to be replaced.

     

5. Remove two (2) plastic clips securing the front pad bracket.

   

   

   

6. Re-install front pad using the bolt, washer, and nut (purchased locally) to secure to door body. Use loctite #)242 (or equivalent) to prevent nut loosening.

   NOTE: Place washers between bracket and door body to prevent crushing of the bracket's channel shape.

   

   

7. Cut the zip-tie holding window regulator spool.

8. Reassemble front door unit in the reverse order.

9. Verify repair.

WARRANTY INFORMATION

NOTE:

• This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair. Refer to the SRT microfiche for warranty term information.
• Additional diagnostic time cannot be claimed for this repair.