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I wanted to post my findings on my wife’s 2003 9-5 Linear 2.3 that had a right side front window rattle in the glass when the window was down and the door was then shut. The procedure for fixing it is as follows.
1. Remove the plate in the outside mirror adjustment that would be there on a RHD car in the passenger door.
2. Carefully pull using the hole to unsnap the triangular shaped black plate and then proceed to unclip the entire black window trim around the top of the window glass and down the side.
3. Using a very sharp point fine instrument (I used a dental tool) to remove the black cover plate in the inside door release lever to expose the torx screw.
4. Remove the two color coded plugs in the door close handle to expose the torx screws.
5. Remove all 3 torx screws. Pull out and remove the entire door release lever on the inside by pulling the front of it toward you and hinges out at the back. Watch out for the aluminum washer under the bolt. It will fall out.
6. Use a small flat blade to remove the lower door light in the bottom of the door and unplug the harness and set aside. You do not need to remove the black pop in keeper in the bottom of the door.
7. Using a small pry bar from the right lower corner start prying the door panel off to release the pop in keepers. I did not break any of them. They were made better than the GM door panels that I have dealt with in the past.
8. After the all the door pop in clips are released work the door panel up to release it against the glass with an upward motion and remove the panel.
9. Using a 10 mm socket (3 bolts) remove the speaker and disconnect the wiring.
10. Carefully start prying lose the glue on the weather sheet of foam that keep moisture and sound out of the door panel from the lower right corner and release ¾ of the way up and to the speaker on the bottom. Do not tear this part you will need to re-glue it back.
11. Now pull up the door cover and using a small piece of tape, tape it out of you way by lifting it up toward the outside mirror diagonally.
12. Now look in the door cavity and remove the approx 1 foot piece of rubber that is laying in the bottom of the door that is approx 2 -3 inches wide. This is the piece that has fell out of one or the other tracks. Mine was the side away from the speaker. You could look at the track and it was just bear metal. The rubber piece is directional and I looked at the speaker side to see which side of the fat and skinny side went which way. The flat piece forms a U shape with a flat guild at the back of the piece. Hard to describe look at the other one in the track for reference. I did use 3M black weather stripping adhesive to glue mine back in(there is debate on the board to glue or not to glue, I did not want to do it again. I cleaned the track and rubber with alcohol. I glued the piece but hind sight and picking glue off my fingers all night I might should have applied it to the track before inserting the piece. The speaker side track piece was also loose at the bottom. I did not take it out due to the limited space but I did glue the bottom. I thought the way these things get out is the bottom comes loose and then falls out since the top always has a part of the window in it.
13. I rolled the window down and checked the operation and then left the widow down to hold the track in it natural position while drying. Do not get glue in the rubber track the window travels in!!
14. I used 3M to glue back the acoustic and moisture barrier. Make sure you have the light harness in the door lead back through the hole in the acoustic barrier.
15. Assemble the door panel back on like you took it off. Feed the door lock manual knob through the hole at the top of the door and install the door panel from the top first. I found the window being down makes this easier than taking it off. Make sure you hinge back in the inside door handle and check operation before putting in the bolt.
16. Let glue dry.
17. You should be fixed for a little elbow grease and a little glue.
posted by 69.34.15...
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