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| Subject:
RATTLE NOISE FROM FRONT DOOR GLASS | Bulletin No: 09-038/16 |
| Last Issued: 06/09/2016 |
BULLETIN NOTE
This bulletin supersedes the previously issued bulletin(s) listed below. The changes are noted in Red beside the change bars.
| Previous TSBs: | Date(s) Issued: |
| 09-016/15 | 05/18/15 |
| 09-017/14 | 08/29/14, 03/05/14 and 08/18/14 |
| 09-011/13 | 04/17/13 |
APPLICABLE MODEL(S)/VINS
2014-2016 Mazda6
2014-2016 Mazda3
DESCRIPTION
Some vehicles may experience a rattle noise from the front door glass when driving with the window open approx. 1/2 to 4 inches (1 – 10 cm).
The rattle noise may be caused by insufficient holding force of the glass run channel. To increase the holding force, the shape of glass run channel has been changed and non-woven pads have been attached to the glass run channel.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
- Verify the customer concern. The rattle noise should go away when holding the slightly opened window by hand or when the window is completely closed.
- If the noise goes away, proceed to the next step to attach non-woven pads to Positions A and/or B of the glass run channel as shown below.
NOTE: Depending on vehicle type, a non-woven pad or resin foam may have already been attached to Position A. In this case, it is not necessary to attach additional non-woven pads to this position.
- If the noise does not go away, this service bulletin does not apply. Troubleshoot the noise according to section 09 (Body and Accessories) of the MS3 online instructions or the Workshop Manual.
(O = Outer, F = Front, J = Molded Joint Line, R = Rear)
- Obtain the 0.25mm thick pad from the Noise Parts Set and cut pads to size for the position(s) according to vehicle type listed in the tables below.
Mazda3 (Japan Built)
| Vehicle Type | Production Date | VIN Range | Position and Size (T x W x L mm) | ||
| Position A | Position B | ||||
| A | On or before 7/1/14 | JM3BM****** | 100001 to 218352 | O (1 x 7 x 50) | O (1 x 7 x 40) |
| B | On or after 7/2/14 | JM3BM****** | 218353 to 999999 | X | O (1 x 7 x 40) |
Mazda3 (Mexico Built)
| Vehicle Type | Production Date | VIN Range | Position and Size (T x W x L mm) | ||
| Position A | Position B | ||||
| A | On or before 6/2/14 | 3MZBM****** | 100001 to 117653 | O (1 x 7 x 50) | O (1 x 7 x 40) |
| B | On or after 6/3/14 | 3MZBM****** | 117654 to 999999 | X | O (1 x 7 x 40) |
Mazda6
| Vehicle Type | Production Date | VIN Range | Position and Size (T x W x L mm) | ||
| Position A | Position B | ||||
| B | All | JM1GJ****** | 100001 to 999999 | X | O (1 x 7 x 40) |
O: Attach the specified size of non-woven pad.
X: A non-woven pad or a resin foam has already been attached to this position, so it is not necessary to attach another one.
- Using a straight-edge and sharp knife, cut the pad into the sizes necessary for the vehicle repair, then stack the 4 pieces on top of one another to create a 1mm thick pad.
- Open the door glass fully and pull the glass run channel off of the door frame (right side glass run channel shown below).
- Degrease the glass run channel where the pads for Positions A and/or B will be attached to the glass run channel.
NOTE: Depending on the vehicle type, degreasing is not necessary for Position C or Positions C and A if a non-woven pad or a resin foam has already been attached there.
- Apply an adhesion promoter (one that is suitable for use on plastic) to the locations where the pads will be attached.
NOTE:
- Obtain adhesion promoter locally.
- Recommended adhesion promoter: 3M K-540NT, K500 or 4298UV. If these products cannot be obtained, any adhesion promoter suitable for plastic can be used.
- According to the vehicle type, attach the non-woven pads to the glass run channel as shown below.
POSITION A: Attach 50mm pad (A) BELOW the molded joint line (J) as shown below.
| Vehicle: Mazda3 – Type A | Pad Size: 1 x 7 x 50mm |
 |  |
| (O = Outer, F = Front, G = Glass Run Channel (RH), J = Molded Joint Line, R = Rear) | |
POSITION B: Attach 40mm pad (A) right ABOVE the molded joint line (J) as shown below.
NOTE: The images below are of a perspective view. Attach the 40mm pad along the uneven line of the back-side of the lip.
| Vehicle: Mazda3 and Mazda6 – Type B | Pad Size: 1 x 7 x 40mm |
|  |
| (O = Outer, F = Front, G = Glass Run Channel (RH), J = Molded Joint Line, R = Rear) | |
- Reinstall the glass run channel back to the original position.
- Operate the door glass up and down to verify proper operation.
- Repeat the repair on the glass run channel on the other side if necessary.
PART(S) INFORMATION
| Description | Qty. | Notes | Part Number |
| Noise Parts Set | 1 | Use non-woven of 0.25 mm thickness.
(One sheet can repair 5 to 12 vehicles, depending on the vehicle type) | TA01-76-100 |
WARRANTY INFORMATION
NOTE:
- This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair.
- This repair will be covered under Mazda
’s New Vehicle Limited Warranty term. - Additional diagnostic time cannot be claimed for this repair.
| Warranty Type | A | |
| Symptom Code | 82 | |
| Damage Code | 97 | |
| Part Number Main Cause | ****-59-605* / ****-58-605*
NOTE: Check the GEPC for the part number of the glass run channel applicable to the VIN of the repaired vehicle. | |
| Quantity | 0 | |
| Operation Number / Labor Hours | Attach sheet to Position B only | XXL41XRX / 0.2 Hrs. (one side) XXL42XRX / 0.3 Hrs. (both sides) |
| Attach sheet to Positions A and B | XXJ5CXRX / 0.3 Hrs. (one side) XXJ5DXRX / 0.4 Hrs. (both sides) | |
NOTE: Do not claim the noise parts set (P/N TA01-76-100) as a related part. The amount of pad and adhesion promotor used for this repair is included in the labor allowance.
09-038/16
06/09/2016
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09-016/15
05/18/2015
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