For 1990-2009 cars

# Squeaks and Rattles Coming From the Upper I/P Area

Subject: | Squeaks and Rattles Coming from the Upper Instrument Panel Area -- Install Rocker Cover Panel Outer Molding

Models: | 1995 Sedans, Coupes and wagons, and 1996 Coupes

### Condition:

The customer may comment about squeaks and rattles coming from the top or top corners of the instrument panel area.

### Cause:

Squeaks in the top of the instrument panel may be caused by the paper sound deadener material on the modular dash assembly curling up, allowing the I/P upper trim panel to rub against the modular dash assembly.

Rattles in the top of the instrument panel may be caused by the I/P upper trim pad and/or panel retainers, also called Dual-Locks, located on each end of the I/P upper trim panel assembly and I/P upper trim panel outer corner filler assemblies, not being engaged from the plant, or having their engagement released due to high humidity. Also, the I/P upper trim pad and/or panel retainers may loose adhesion to either the I/P upper trim panel assembly, I/P upper trim panel outer corner filler assemblies, or the modular dash assembly.

### Correction:

Refer to the procedures in this bulletin and remove the I/P trim pad assembly and the I/P upper trim panel outer corner filler assemblies. To prevent squeaks, install a rocker cover panel outer molding along the forward edge of the I/P upper trim panel assembly. Also, remove any paper sound deadener material found curled up along the modular dash assembly or on the passenger side of the I/P upper trim Panel assembly.

To prevent rattles, inspect the I/P upper trim pad and/or panel retainers on both sides of the modular dash and on the bottom of the I/P upper trim panel assembly, and I/P upper trim panel outer corner filler assemblies to ensure that they are firmly attached. Re-attach any retainers found not firmly attached.

### Procedures

1. Remove the I/P upper trim panel outer corner filler assemblies by carefully lifting up at the clip locations, starting at the rear.
2. Remove the I/P upper trim panel assembly screw caps by carefully prying them with a small flat head screwdriver.
3. Remove the screws.
4. Lift the I/P upper trim panel assembly at the clip locations no the rear edge to disengage the clips.
5. Pull the panel rearward out of the clips at the bottom of the windshield.
6. Remove the I/P upper trim panel assembly.
7. Remove any curled up paper sound deadener material along the modular dash assembly, or on the passenger side of the I/P upper trim panel assembly.
8. Inspect the I/P upper trim pad retainers to ensure that they are tightly stuck to the modular dash assembly. Replace any that are not tightly stuck to the modular dash assembly.
9. Inspect the I/P upper trim panel retainers to ensure that they are tightly stuck to the bottom of the I/P upper trim panel and the I/P upper trim panel outer corner filler assemblies. Replace any that are not tightly stuck to either the I/P upper trim panel or the I/P upper trim panel outer corner filler assemblies.
10. Cut a length of rocker cover panel outer molding to exactly fit from one end of the I/P upper trim panel to the other end.

Important: The rocker cover panel outer molding is available in two different part numbers: 21096610 -- right and 21096611 -- left. Either part can be used for this application.

11. Install the rocker cover panel outer molding along the forward edge of the I/P upper trim panel. Ensure that the lip is installed on the top side of the upper trim panel.
12. Install the I/P upper trim panel into the clips at the base of the windshield.

Important: After installing the I/P upper trim panel, press firmly at the retainers to ensure that they are tightly secured.

13. Lower the I/P upper trim panel down at the locations to secure.

Notice: Fastener Notice

14. Install and tighten the screws
15. Install the I/P upper trim panel assembly screw caps.

Important: After installing the upper trim panel outer corner filler assemblies, press firmly at the I/P upper trim panel retainers to ensure that they are tightly secured.

16. Install the I/P upper Trim Panel outer corner filler assemblies.

Parts Requirement

Part Number | Description
--- | ---
Only one of the following is required per vehicle, either left or right can be used:
21096610 | Molding -- Rocker Cover Panel Outer -- Right
21096611 | Molding -- Rocker Cover Panel Outer -- Left
Use the following as required:
21040477 | Retainer -- I/P Upper Trim Pad
21040478 | Retainer -- I/P Upper Trim Panel
21040476 | Retainer -- I/P Upper Trim Panel

CLAIM INFORMATION | To receive credit for this repair, submit a claim through the Saturn Dealer System as follows:
--- | ---
-- | Case Type | Description | Labor Operation Code | Time
-- | VW | Install Rocker Cover Panel Outer Molding | T9703 | 0.40 hrs