Some Info on Cabin Noise
The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.
Condition/Concern
Some owners may comment of a wind buffeting/droan noise or body/pressure booming (the feeling of pressure in the ears) while driving. The body booming issue may be more noticeable when the engine is in V4 mode. In some cases, they may also notice a water leak from the headliner area, if equipped with a sunroof. These concerns could be caused by the roof sheet metal no longer being attached to the roof bows (1). On trucks with a sunroof, it may be noticed that the rear edge of the sunroof glass is considerably lower than the roof (2). This is due to the roof sheet metal being detached from the roof bow directly behind the sunroof opening (3).
To correct this concern, apply panel vibration control material between the roof bow and roof sheet metal, along with foam shim material when necessary.
Remove the headliner to access the underside of the roof. Inspect all 4 roof bows for insufficient bonding to the roof sheet metal (4). Any roof bow that is not bonded to the sheet metal will need to be repaired.
Use the following repair for all 4 bows on trucks without a sunroof, and for the 3 rear bows on trucks with a sunroof:
Use a plastic scraper or similar tool to remove the old foam. Measure the gap between the top of the roof bow and bottom of the roof sheet metal. If the gap is 5/16 (8mm) or greater, use a combination of 3/4" wide by 5/16" or 7/16" thick foam shim material (as listed below) to fill the gap between the roof bow and the sheet metal. Care should be taken to add only the correct thickness of foam to fill the gap so it does not push up on the roof. Cut the foam into 5 inch lengths and place in three spots along the roof bow, one piece in the middle and one at each outer edge. With the foam shim material in place, or if the gap is less than 5/16" (8mm), use the panel control vibration material (as listed below) to fill the voids between the roof bow and sheet metal. In some cases, it may take a couple layers of material to fill the void.
Repair for 1st bow on trucks with a sunroof:
Use a plastic scraper or similar tool remove the old foam. Use the panel control vibration material (listed below) and apply along the top of the 1st roof bow. Obtain two 2x4 pieces of wood cut long enough to span the opening of the sunroof. Wrap one of the 2x4's with a cloth to protect the roof paint and place it on top and the other one on the bottom. Then clamp together using three C-clamp as shown below (5 & 6). The clamps will need to stay in place until the panel control vibration material is dry.
Part Number
Description
Qty
Material Allowance
SEM 39977
*Panel Control Vibration Material
2 Tubes
$80.00
P46500
**Kent Industries 3/4 X 5/16 in. Adhesive Back Foam Shim Stock
As Required
$20.00
P46505
**Kent Industries 3/4 X 7/16 in. Adhesive Back Foam Shim Stock
As Required
$20.00
* For panel control vibration material ordering information, call SEM at 1-866-327-7829. SEM products are also available at local automotive paint supply stores.
** Contact Kent Automotive at 1-888-937-5368 or
www.kent-automotive.com to order Kent Industries Adhesive Back Foam Shim Stock.
Warranty Information
For vehicles repaired under warranty use:
Labor Operation
Description
Labor Time
1480348*
Install Foam Shim Material To Roof Bows And Refoam
2.5 hr
Add
For Vehicles With Sunroofs
0.5 hr
