Squeak Noise from Front Inner Door Armrest/Pull Handle (Replace Front Inner Door Pull Handle Pushnuts)

This bulletin has been revised to update model year and part number information. Please discard Saturn Bulletin 02-T-61 (Corporate Bulletin Number 02-08-64-019 [Section 08 -- Body & Accessories]).

Some customers may comment on a squeak noise coming from the front inner door pull handle area. This noise may be present when the door is being closed or when there is enough weight placed on the armrest either vertically or horizontally.

This condition may be caused by the armrest pushnut (installed in the door structure) retention tabs, which may be spread out when a customer pulls the front inner door pull handle. This action may cause the pushnut to move inside the door structure, causing metal-to-metal contact between the pushnut and the door even when the retaining bolt is tight.

To correct this condition, refer to procedure in this bulletin to replace the two pushnuts in the door structure of each affected door.

1. Put window in full up position.
2. Remove retaining screw from center of inside handle pocket.
3. Slide door handle forward and pull outward to expose lock rods.
4. Using a thin bladed screwdriver, disengage lock rods from retaining clips.
5. If equipped with power door locks, disconnect electrical connector from switch by depressing retaining tabs.



6. Gently pull at top end of door speaker cover to disengage attaching clips.
7. Lift door speaker cover out from behind door trim panel.
8. While holding door speaker cover, disengage speaker wiring harness from speaker, then remove door speaker cover.
9. Remove the door trim panel screw located behind the speaker cover.



10. On non-power windows, remove window crank handle.



11. Remove inside door pull handle escutcheon by disengaging retaining tab at bottom of escutcheon with a small flat bladed tool.
12. Remove door trim panel fasteners located behind door pull handle escutcheon.
13. Remove door trim panel fasteners at bottom of door.
14. Pull up on the door trim panel to disengage trim panel hooks from the sheet metal.
15. Carefully remove part of inner door water deflector to gain access to both pushnuts.




Important: Passenger's door shown, driver's door similar.

Important: Pushnuts to be replaced are the ones for the upper and lower door pull handle.

16. Using 90° needle nose pliers, enter access hole near each pushnut to be replaced. Depress tabs on pushnut from inside door structure and remove pushnut. Discard old pushnuts.
17. Install new pushnut, P/N 11518162, into door structure by pushing them into door frame opening (tabs should be on left and right of opening).

Important: Repeat step 17 for other pushnut.

18. Reinstall inner door water deflector making sure there are no gaps in the sealer.
19. Position door trim panel over top of door hooks structure.



20. Push downward to engage door trim panel hooks to structure.
21. Install fastener located at the bottom of door trim panel.

Tighten
Tighten Door Trim Panel Lower Fastener to 2.5 N·m (22 in-lbs).

22. Install fasteners located behind door trim pull handle.

Tighten
Tighten Door Trim Panel Fasteners to 2.5 N·m (22 in-lbs)

23. Snap inside door pull handle escutcheon into place.



24. On non-power windows, install window crank handle.
25. Install the door trim panel fastener located behind the speaker cover.

Tighten
Tighten Door Trim Panel Fastener to 2.5 N·m (22 in-lbs)




26. Connect speaker wiring harness to speaker.
27. Position door speaker cover over door trim panel with speaker cover mounting tabs behind door trim panel.
28. Gently push on door speaker cover to engage attaching clip.
29. If equipped with power door locks, connect electrical connector to power door lock switch.
30. Position inside handle to door trim and partially seat the rear tangs.
31. Lift lock rods into retaining clips, secure rods into handle by latching clips over rods.
32. Push handle into trim panel and slide rearward to fully engage tangs. Ensure the rods clear the water deflector.
33. Install inside handle retaining screw in handle.

Tighten
Tighten Inside Handle Retaining Screw to 2.5 N·m (22 in-lbs)

34. Verify correct installation of lock rods by checking for smooth movement of lock button and inside handle.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for C3240 (Handle, Front Door Inside Pull, Right - R&R or Replace) or C3241 (Handle, Front Door Inside Pull, Left - R&R or Replace). An "add time" condition is provided to replace the door handle push nut.