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RESTRICTED Member
2004 Forester XS 5 speed manual
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661 Posts
Discussion Starter · #1 ·
This is should be the LAST gusset fix ever needed on subaruforester.org!!
It fixes the problem 100% of the time with no tape, no rubber hoses, no glue, only results.

Just follow these steps and cautions and you should not need to replace those obnoxiously annoying and expensive gussets. Let me know your results!
1) Roll down window
2) Remove interior plastic gusset cover
3) Unplug mirror
4) Remove mirror
5) Get a rag/towel and a pair of flat bill vice grips like these:
http://www.sears.com/vise-grip-8-in-pliers-metal-working-locking/p-00920702000P
6) Find where the rubber window channel on the gusset turns to a metal core

7) Place the rag over the gusset to protect from marring the surface
8) Using the vice grips, adjust the metal core in small increments. Between adjustments, roll window up to check fitment between seal and glass.
CAUTION: Be gentle when crimping gusset, if you are not far enough on the metal core the vice grips can slip off and can tear the rubber seal. You can also crimp too much
 

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RESTRICTED Member
2004 Forester XS 5 speed manual
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661 Posts
Discussion Starter · #3 ·
I figured it would be pretty straight forward seeing as I mentioned using flat bill vice grips, but what I mean is squeeze the vice grips to bend the metal core of the gusset inward. This will make it so the rubber is tighter around the window.
 

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Registered
2003 Forester X 5 speed
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37 Posts
I did this mod/fix last year. Completely gets rid of the wind noise. My drivers side started making noise again so Ill have to recrimp it. I took off the mirror cover, unbolted the 3 nuts and moved the mirror over a bit without unplugging it and squashed it a bit.
 

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Registered
04 Forester XT manually powered assisted
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370 Posts
I'm going to give this a shot on my days off which are coming up tue/wed and shall post results. Seems as if this particular place gets out of balance over time from shutting the door. Now, just so everyone is clear on this I would like to ask...am I crimping and adjusting in a foward motion or back?
 

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RESTRICTED Member
2004 Forester XS 5 speed manual
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661 Posts
Discussion Starter · #9 ·
there is no forward or backward to bending the metal core, the vice grips will bend both sides fairly evenly. the noise is caused over time due to stretching of the rubber seal on the gusset because it is a frameless window design and the window has a fair amount of slop. this method makes it so the rubber is forced to have more pressure on the glass which in turn means a better seal.
 

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Registered
2004 Forester XTi STi 6 speed w/ DCCD
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45 Posts
I will attest to this working with amazing results as well. Reduced wind noise was shocking.
 

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Just a member
03 XS AUTO
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847 Posts
I missed this thread. I did basically the same thing, but I removed the gusset and clamped it in a vice. I couldn't find my wide bill Visegrips and I didn't think about using a c-clamp and wood untill I was already into the second one.

I was amazed at what a difference it made. Amazed. Not surprised, amazed. I also added a strip of double sided tape to the leadind edge of where the mirror mounts.

After you do this fix, be sure to shut the door, by the door. Don't push on the glass when shutting the door. I think using the glass to close the door, over time, is what causes this problem.
 

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Registered
04 Forester XT 5spd
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254 Posts
I did the same last year along with the rubber tubing behind the weather striping and the noise went away. The driver's side is starting to make a little noise again, so I need to adjust it again. I roll that window down more than the passenger, so that could be the cause of it.
 

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Registered
2005 Forester XT Auto
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1,086 Posts
This fix has helped mine, but the very top tips of the gussets are split. Does anyone have a good fix for this besides plain electric tape? I believe someone used liquid electrical tape? how would i seal the splits (about an inch long) with a nice permanent solution?

edit: looked up liquid electrical tape - think i have my answer, will give it a shot. More edit: got the liquid tape from hardware store. Worked great, awesome stuff. subaruforester.org strikes again. Thanks OP for the post on gussets.
 

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Registered
2004 Forester XT 4EAT
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9 Posts
Just tried this on my forester and it worked like a charm! No more dreaded wind noise!

I also had to use some liquid electrical tape to seal where there were rips at the top of the gussets. Let's hope that it holds up!

Thanks for the advice! :icon_biggrin:
 

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Premium Member
2004 Forester XT 5 speed
Joined
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1,042 Posts
This fix has helped mine, but the very top tips of the gussets are split. Does anyone have a good fix for this besides plain electric tape? I believe someone used liquid electrical tape? how would i seal the splits (about an inch long) with a nice permanent solution?
Just buy a new gusset. Is $60 really that much? In making this adjustment, you've already done 90% of the work.
 

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Registered
2005 Forester XT Auto
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1,086 Posts
I also had to use some liquid electrical tape to seal where there were rips at the top of the gussets. Let's hope that it holds up!
So far so good on mine...only been 10 days though! But seems solid. I put a couple coats on there, per the instructions. Stuff dries nicely actually, made my craftsmanship look better than it is!
 

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Just a member
03 XS AUTO
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847 Posts
Just buy a new gusset. Is $60 really that much? In making this adjustment, you've already done 90% of the work.
Is that each? It took me longer to remove one gusset than it took to pull both panels, so I wouldn't say 90% of the work has been done. Plus, some people just like doing things themselves.
 

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Registered
2005 Forester XT Auto
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1,086 Posts
Is that each? It took me longer to remove one gusset than it took to pull both panels, so I wouldn't say 90% of the work has been done. Plus, some people just like doing things themselves.
Yeah they are like $70 each from what ive seen. You have to take off door panels. For my car, that money goes toward keeping it running., ill spend a little bit to make it look nice and interior stuff, but its not going to ever see new gussets unless they disintegrate or something. Plus, the fix works well enough.
 

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Member
2005 Forester X Manual
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189 Posts
Dumb question prob. Does the whole door panel have to come off? Not just the little gusset correct?
 
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