Wind Noise Or Excessive Gap At Front Door A Pillar Molding - keywords adjust air alignment appearance body clearance door fit front gap leak left molding noise pillar right roof w/s weatherstrip wind

This PI is being superseded to update measurement from 9mm to 7mm and update Models. Please discard PIT4172.

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Some owners may comment of a wind noise or excessive gap between the front door and "A" pillar molding. This concern could be noticed at either the left or right front door.

1. Measure the gap between the reveal molding and the edge of the door, 25 mm down from the top of the reveal molding (see picture).



2. If the gap is greater than 7 mm then proceed with the following repairs.
3. Replace and secure all door side bolts with service bolt part # 11609733 (one bolt at a time). These are the bolts attaching the hinge to the door.
4. Loosen the upper hinge bolts and pull the top of the front door header in towards the cab while tightening the top hinge bolts. Close the front door and recheck the gap as per step 1 and if the gap is still 7 mm or greater continue to the next step.
5. Support the door, loosen all door side bolts and lower the door by 1mm and pull the door header inboard while pushing the bottom outboard. While holding the door in this position have someone else tighten the hinge bolts. Close the front door and recheck the gap as per step 1 and if the gap is still 7mm or greater continue to the next step.
6. Remove the reveal molding and install nylon washers behind the reveal up against body in the area shown below. This will space the molding closer to the door edge, but still have at least a 2 to 3 mm overlap of the glass.



7. An additional item that can be completed is to install foam between the body and weather strip as shown below.

Note:  View to ensure it looks good from a front view with the door closed.

Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.