January 30, 2015

T-SB-0004-15

LH Rocker Panel Pop/Creak Noise
Service
Category

Vehicle Exterior

Section

Body Structure

Market

USA

Applicability
YEAR(S)

MODEL(S)

ADDITIONAL INFORMATION

2014 – 2015

Avalon, Avalon HV

Introduction

Some 2014 – 2015 model year Avalon and Avalon HV vehicles may exhibit a condition where there
is a pop/creak type noise from the LH rocker panel/bottom of the driver’s door opening area. This
is caused by two body panels contacting one another within the rocker panel structure. Use the
following Repair Procedure to address this condition.
Production Change Information

This bulletin applies to:
• ALL 2014 model year TMMK built Avalon & Avalon HV vehicles
•

2015 model year TMMK built Avalon & Avalon HV vehicles produced BEFORE the Production
Change Effective VINs shown below.
MODEL

PLANT

DRIVETRAIN

Avalon

TMMK
Line 1

2WD

Avalon HV

PRODUCTION CHANGE EFFECTIVE VIN

4T1BK1EB#FU133267
4T1BD1EB#FU035563

Required Tools & Equipment
REQUIRED TOOLS & MATERIAL

QUANTITY

Prybar (Similar to Snap-on® MPBS 11400)

1

Borescope (must be able to fit in a 15 mm diameter hole)

1

Cavity Wax (Similar to 3M® Rust Fighter-I, 08892)

1

MP (Multi-Purpose) Grease

1

© 2015 Toyota Motor Sales, USA

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LH Rocker Panel Pop/Creak Noise

Warranty Information
OP CODE

DESCRIPTION

TIME

OFP

T1

T2

BD1500

Separate Body Panels Within the Rocker Panel

1.5

57404-06140

91

43

APPLICABLE WARRANTY
• This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months
or 36,000 miles, whichever occurs first, from the vehicle’s in-service date.
• Warranty application is limited to occurrence of the specified condition described in this
bulletin.

Repair Procedure

1. Disassemble the vehicle.
A. Remove the scuff plate garnish and the lower cowl garnish.
B. Remove the driver’s side front seat assembly.
Refer to the Technical Information System (TIS), applicable model and model year Repair
Manual:
• Avalon 2014 / 2015:
Vehicle Interior – Seat – “Seat: Front Seat Assembly: Removal”
• Avalon HV 2014 / 2015:
Vehicle Interior – Seat – “Seat: Front Seat Assembly: Removal”
C. Peel back the carpet on the driver’s side to access the rocker panel area.
D. Remove the wire harness from the wire harness clips and remove the clips from the area.

© 2015 Toyota Motor Sales, USA

January 30, 2015

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LH Rocker Panel Pop/Creak Noise

Repair Procedure (Continued)

E. Remove the plug from the access hole on the inside of the rocker panel.
NOTE
Ensure to keep plug to reinstall after repair.
Figure 1. Suspected Contact Area

1

2

1

Front of Vehicle

2

© 2015 Toyota Motor Sales, USA

Access Hole

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LH Rocker Panel Pop/Creak Noise

Repair Procedure (Continued)
Figure 2.

1

2

1

Access Hole

2

Front of Vehicle

2. Confirm and repair contact point No. 1.
A. Using a borescope, navigate into the rocker
panel through the access hole (from step 1E)
towards the contact point No. 1.

Figure 3. Contact Point No. 1

NOTE
The areas of contact are internal to the
rocker panel structure.

1

2

1

Contact Point No. 1

2

Access Hole

© 2015 Toyota Motor Sales, USA

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LH Rocker Panel Pop/Creak Noise

Repair Procedure (Continued)

B. Observe through the borescope if any part of
the A-pillar reinforcement is contacting the step
panel reinforcement at contact point No. 1.

Figure 4.

1

2

3

5

1

Contact Point No. 1

2

Step Panel Reinforcement

3

A-pillar Reinforcement

4

Up

5

Left of the Vehicle

© 2015 Toyota Motor Sales, USA

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LH Rocker Panel Pop/Creak Noise

Repair Procedure (Continued)

C. If contact is found in step 2B, insert a prybar
through the access hole to the position of
contact between the A-pillar reinforcement and
the step panel reinforcement.

Figure 5. Sample Tools
1

NOTICE
To avoid damage to the body panel finish,
please wrap the end of the tool used in
electrical tape.
2

NOTE
If NO contact was found in step 2C, continue
to step 3.

1

Prybar

2

Drum Brake Shoe Adjustment Tool

D. Using a hammer, tap the end of the pry bar until separation is created at the contact point.
E. Lift the weather strip to access rocker panel flange.
F. Confirm separation by shining a flashlight
through the rocker panel flange towards
the bulkhead and confirm with the
borescope that light is coming in between
the A-Pillar reinforcement and the step
panel reinforcement.

Figure 6.

© 2015 Toyota Motor Sales, USA

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LH Rocker Panel Pop/Creak Noise

Repair Procedure (Continued)

3. Confirm and repair contact point No. 2.
A. Using a borescope, navigate into the rocker
panel through the access hole (from step 1E)
towards contact point No. 2.

Figure 7. Contact Point No. 2

1

2

1

Contact Point No. 2

2

Access Hole

© 2015 Toyota Motor Sales, USA

January 30, 2015

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LH Rocker Panel Pop/Creak Noise

Repair Procedure (Continued)

B. Using the borescope, observe if any part of the
A-pillar reinforcement is contacting the front
floor under reinforcement bracket at contact
point No. 2.

Figure 8.

1

2

3

5

1

Front Floor Under Reinforcement Bracket

2

Contact Point No. 2

3

A-pillar Reinforcement

4

Up

5

Left of the Vehicle

C. If contact is found in step 3A, insert a pry bar through the access hole and use the tip
of the pry bar to locate the contact point between the A-pillar reinforcement and the front
floor under reinforcement bracket.
NOTE
If NO contact is found, move on to step 4.

© 2015 Toyota Motor Sales, USA

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LH Rocker Panel Pop/Creak Noise

Repair Procedure (Continued)

D. Using a hammer, tap the pry bar three to four
times to create a gap between the two panels.

Figure 9.

E. Use a flashlight to confirm the gap between the A-pillar reinforcement and the front floor
under reinforcement bracket.
4. Reseal the area.
NOTE
If sheet metal was exposed during the repair, apply cavity wax to surface exposed.

5. Reassemble vehicle.
A. Reinstall the access hole plug.
B. Reinstall the wire harness clips (insert wire harness into clips).
C. Reposition the weather strip and ensure it is fully installed.
D. Replace the carpet.
E. Reinstall the driver’s front seat.
Refer to TIS, applicable model and model year Repair Manual:
• Avalon 2014 / 2015:
Vehicle Interior – Seat – “Seat: Front Seat Assembly: Installation”
• Avalon HV 2014 / 2015:
Vehicle Interior – Seat – “Seat: Front Seat Assembly: Installation”
F. Replace the scuff plate garnish and the lower cowl garnish.
6. Confirm repair.

© 2015 Toyota Motor Sales, USA