T-SB-0059-12 March 28, 2012

Rattle/Knock Noise from Roof

ServiceCategory Vehicle Interior

Section Interior Panels/Trim Market USA

Applicability

YEAR(S) MODEL(S) ADDITIONAL INFORMATION

2008 – 2011 Sequoia

Introduction

Some 2008 – 2011 Model Year Sequoia vehicles may exhibit a condition where there is a rattle orknocking noise occurring from the roof structure while driving. Follow the steps listed in this bulletinto address this condition.

Production Change Information

This bulletin applies to vehicles produced BEFORE the Production Change Effective VINs shownbelow.

ENGINE DRIVETRAIN PRODUCTION CHANGE EFFECTIVE VIN

5TDZM5G1BS#0031922WD

5TDKM5G1BS#003192

5TDBM5G1BS#0015111UR-FE

4WD5TDJM5G1BS#001511

5TDZY5G1BS#036412

5TDKY5G1BS#0364122WD

5TDYY5G1BS#036412

5TDBY5G1BS#052850

5TDJY5G1BS#052850

3UR-FE

4WD

5TDDY5G1BS#052850

5TDBW5G1BS#052850

5TDJW5G1BS#0528503UR-FBE 4WD

5TDDW5G1BS#052850

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Rattle/Knock Noise from Roof

Warranty Information

OP CODE DESCRIPTION TIME OFP T1 T2

63111-OC901 (Roof Panel Assy)BD1206 NVH Bonding Procedure 4.1

63111-OC160 (Roof Panel Assy)91 38

APPLICABLE WARRANTY• This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for

36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.

• Warranty application is limited to occurrence of the specified condition described in thisbulletin.

Required Tools & Equipment

REQUIRED EQUIPMENT PART NUMBER QTY

3M™ Duramix™ NVH Dampening Material 04274 1

3M™ Manual 200 mL Cartridge Applicator Gun 08571 1

3M™ Automix™ Mixing Nozzle 08193 1

3M™ General Purpose Adhesive Cleaner 08984 or 08987 1

Repair Procedure

1. Remove the headliner assembly per the repairmanual.

Refer to the Technical Information System (TIS),applicable model and model year Repair Manual:

• 2008 / 2009 / 2010 / 2011 / 2012 Sequoia:Vehicle Interior – Interior Panels/Trim – “Roofheadlining: Removal”

Figure 1. Overview.

2

1

1 Roof Panel

2 Reinforcements

© 2012 Toyota Motor Sales, USA

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Rattle/Knock Noise from Roof

Repair Procedure (Continued)

2. Inspect NVH dampening bonds between roofreinforcements and roof panel for separation.

Figure 2. Sealer Separation.

1

32

1 Roof Panel

2 Reinforcements

3 Sealer Separation

3. If NVH dampening bonds are NOT separated,STOP. This TSB does NOT apply. Furtherdiagnosis may be required.

Figure 3. Sealer Intact Condition.

1

2

3

1 Roof Panel

2 Reinforcements

3 No Sealer Separation

4. In locations where dampening bond separation is identified, clean the mating surfaces of theroof sheet metal and the roof reinforcement. Use 3M General Purpose Adhesive Cleaner,following the instructions on the container.

5. Apply the 3M™ Duramix™ NVH Dampening Material between the roof sheet metal and the roofreinforcement, following the instructions on the container.

6. Allow the 3M™ Duramix™ NVH Dampening Material to cure as instructed on the container.

© 2012 Toyota Motor Sales, USA

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Rattle/Knock Noise from Roof

Repair Procedure (Continued)

7. Prior to reassembly, road test the vehicle to verify the repair.

8. Reinstall the headliner assembly, following the procedure specified in the repair manual.

Refer to TIS, applicable model and model year Repair Manual:

• 2008 / 2009 / 2010 / 2011 / 2012 Sequoia:Vehicle Interior – Interior Panels/Trim – “Roof headlining: Installation”

© 2012 Toyota Motor Sales, USA