YoGeorge

This is novel...I'm sitting in the lobby of Hodges Subaru using their wireless internet, about 15 feet from Ben's office.

He showed me a copy of the Subaru TSB for the '09 Foz door panels, and underneath the door skins, there is a white waffle-textured piece of plastic that Subaru calls a "baffle" that sits in a hole in the steel inner door skin. Looks like these are press-fit or clip in pieces, but they're not tight enough to preclude rattling. The fix appears to be using double-faced tape around the perimeter of these pieces to snug 'em down and keep them from rattling. Although I had the bad rattling only in the right hand door, Ben said he'd just do both of 'em (and he just did one a couple hours ago) to head off any possible issues with my driver's door.

Definitely sounds like something that a person could do on their own, but while under warranty, I'll let my friends at Hodges take care of it.

And at 11k miles on dino oil (with two changes at 2600 and 6000 miles), I'm switching to Valvoline Synpower. I'm not expecting any more mpg's, but it should flow a bit better in the frozen Michigan Tundra.

Ben rocks....

George

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'09 FX non-premium, 5MT

 

FirstSub

Thanks for the update. I have a major rattle in the front passenger door and a minor one in the driver's door, but have delayed removing the door cards due to poor weather. Having a 'heads up' on the matter is a big help. I'll wait and do the job myself, more than likely using insulation supplies from HD, because I know that I will be more careful and thorough than the dealership. Dealership replaced the ripped-on-delivery driver's seat cover and nicked the door frame paint in the process. This is my second new car with door rattles that I have had to fix on my own. Other was a 2003 Camry and I had to open and fix 3 of 4 doors. Dealership in that case lied about removing door cards and investigating problem, as there was evidence inside of doors - i.e. innards of door were untouched - contradicting work order information.

sicko

Sweet, thanks for the info. My passenger door started rattling a little while back, I'm not really sure when it started b/c I can't hear it over the radio, but it's definitely there. I have a rattle from the back as well, but it might be all the stuff I have under the cargo floor

YoGeorge

My right door was bad enough that the radio at medium volume, if the music had any bass in it, would CAUSE the durn thing to rattle.

However, I just drove home the 18 miles from Hodges and both doors are eerily silent. I was able to hear the zipper pulls on my laptop case rattling on the front seat...

I'm guessing that Subaru *must* have started using a little of the double faced sticky on new Foresters at some point (mine was built 1/09, bought 4/09).

If this is the extent of first year design problems, and it seems like it is, I'm really happy. (The bearing shells on the early turbos were a supplier problem, and I'm glad that I don't have to deal with anything like that.)

Good luck,
George

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'09 FX non-premium, 5MT

FirstSub

YoGeorge,

Your last post is a tease...I may have to open up the door cards ASAP. I have the same problem with bass. Again, thanks for the info.

Lone Ranger

Any chance of getting a copy of the actual TSB in PDF file format? I'd prefer to do this fix myself, instead of setting up a dealer appt. Matter of convenience for me, mainly. Would be nice to have the TSB to use as a guide.

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2009 DGM 2.5X 5MT

YoGeorge

I certainly can't help ya there. I felt just fine taking mine in for an oil change, and was out the door in an hour and a half, during which time I bantered with Ben and my salesman a bit, helped sell an '09 Foz to a couple who already had an '05 and an '08 Foz, drank some free coffee, did some E-mails for work, and my post here. The mechanic who did mine had just done the same job on another Foz a few hours earlier, so he didn't "learn" on mine. I think it took him a half hour or less to do both doors.

Although I've pulled many a door card, I'd just as soon not learn the sequence of panels to pull off like puzzle pieces (the little tweeter panels, window control plates, etc.)

George

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'09 FX non-premium, 5MT

spigot

I took mine in this week for the door rattle. They said mine was the first to come back for any kind of noise. I find that hard to believe with the number of people on here with the rattles, but whatever. They had no idea what was going on. They said they saw the baffle that had fallen and the 'pins' that were broken, and they used some foam to hold it in place. It still rattles. They also scratched the door (very small, but still) taking the panel off. I bought it in September, I figured waiting until January would mean I wasn't the guinea pig, but apparently I didn't wait long enough. Probably my last trip to that place. Looks like something else I'll have to do myself.

Anybody have a diagram of how the door panel comes off? I've done a few of them, but not Subarus. I haven't purchased the factory manual yet. Didn't figure I'd need it so soon.

If anyone ever finds a PDF of the TSB, or even the TSB number, please post it here.

Lone Ranger

Maybe a dealer rep could stealth it (TSB) to someone and we could PM it amongst ourselves without public posting. Or not. Don't know if it would incur wrath from Subaru of America is the TSB was leaked.

It would at least be handy to have the TSB number, even if we can't get the text of procedure. Having the number would aide the process of having your local dealer address the rattle.

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2009 DGM 2.5X 5MT

pmpski_1

Right. I'm looking for the number so I can tell them all about it...

jwall

I took my 09 to the dealer in Seattle last Saturday to fix both front doors. Both the mechanic and service rep said they had fixed a few cars with this issue but were not aware of any TSB on it yet. When I mentioned it they looked it up and still didn't find anything.

They did fix the rattles buy removing the panels and installing foam etc... It sounded like the same issue stated on this thread. Not sure why they wouldn't admit there was one, or, that they actually couldn't find it.

suebev

YoGeorge: maybe you could call Hodges and get a copy of the TSB for the door rattle and post it on here for those of us who asked our dealers and they had no knowledge of it. Would be a big help. Thanks

MFB

From Tech Tips Nov 08, Article code 12

2009 Forester Buzzing or Rattle Noise From Front Doors

If you encounter a 2009 Forester with a customer complaint of a buzzing
or rattle-type noise from the front doors with the radio on using low bass
tones or over bumps, check for loose baffles located on the inner door skin
as shown. You can tap on the baffle and re-create the noise or play the radio
with a low bass tone and feel the baffles vibrating.


Baffle in both front doors that rattle

Remove the baffle and apply a suitable anti-rattle tape or flocked tape in the
areas shown in the picture below. Place it around the edges of the inner
door skin opening then re-install the baffle. This will tighten the fit of the
baffle against the inner door skin and keep it from rattling. Be sure to
confirm your repairs before re-installing the door trim.


Place anti-rattle tape around the door skin opening edge in the areas shown by the blue tape

Hot09XT

^^^^

Thanks for the post! I have have to refer to it to show the dealer!

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MY09 XT Limited AT
Satin White Pearl

Opie

Yeah it's not a TSB, it's a Tech Tip. TSB's are much easier to find in the Subarunet system than Tech Tips are.

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'07 Forester 2.5XT
'09 Frontier SE-V6 Crew Cab