TSB: 09-039/06 MULTI-MODEL - WIND NOISE AROUND DOORS NOTE: This bulletin replaces S-018/98. Please update your records accordingly. BULLETIN NOTE This bulletin supersedes the previous bulletin S-018/98, issued on 07/29/98. The APPLICABLE MODELS has been revised. APPLICABLE MODEL(S)/VINS 1995-2007 B-Series 1997-2003 Protege 1997-2002 626 1997-2002 Millenia 1997-2006 MPV 2001-2006 Tribute 2003-2007 Mazda6 2004-2007 Mazda3 2004-2007 RX-8 2006-2007 Mazda5 2007 CX-7 DESCRIPTION Wind noise around doors may occur with some vehicles. This may be caused by the door weather-strip seal. Customers having this concern should have their vehicle repaired using the following repair procedure. REPAIR PROCEDURE 1. Verify customer concern. 2. Examine weather-strip for the following conditions: ^ Rips, tears, cuts ^ Loose or falling off ^ Excessive deterioration If the weather-strip has any of the above conditions, replace it and verify repair. If weather-strip does not have any of the above conditions, but wind noise still exists, proceed to the "Card Test." Card Test 3. Open the door and insert a business card (0.2 mm thickness) between the door and the weatherstrip at the base of the A-pillar. Close the door. 4. Slide the business card up along the A-pillar. ^ If the card slides easily at any location along the A-pillar, the sealing contact between the door is insufficient and requires adjustment. Proceed to Door Adjustment. ^ If there is consistent resistance, proceed to the "White Grease Test". NOTE: The Card Test only be used to evaluate the A-pillar sealing contact. Use the following "White Grease Test" to evaluate the rest of the weather-strip. White Grease Test 5. Roll down windows and adequately cover all interior surfaces to prevent contact with grease. 6. Thoroughly and evenly spray the sheet metal surface of the body that seals against the weatherstrip on the door. Do not spray the weather-strip. NOTE: It is recommended that you use Permatex Product # 81981 "Multi-purpose white lithium grease (aerosol spray)" or equivalent. 7. Using only the door handle, very gently close the door. This will prevent over-slam which could result in an inaccurate reading. 8. Open the door and measure the width of the grease pattern that is left along the length of the weather-strip (check for any unevenness in width). ^ If 4 mm or more, sealing contact is adequate if door closing effort is acceptable. Clean grease from vehicle. ^ If 3 mm or less, sealing contact is insufficient. Clean grease from vehicle and proceed to "Door Adjustment". The door should be adjusted to obtain the proper seal compression while maintaining proper door alignment. The hinges control the in/out location of the door at the front as well as overall tip or tilt of the door when viewed from the front or rear. The door striker controls the in/out location of the door at the rear latch. CAUTION: Do not pry or force the door into alignment. In addition to Workshop Manual procedures for door alignment, the following information tips are provided: ^ As a guideline, if the weather-strip contact is insufficient, the door hinge(s) should be adjusted 2-4 mm inward. Determine the amount of movement by outlining the hinge mount area before door adjustment and after. ^ Adjusting one hinge at a time will prevent any extreme door movement. This is done by loosening the hinge bolts and moving the door with a padded pry bar just enough to permit movement of the door. ^ Hinges should be adjusted first, followed by the striker. ^ Adjustment to the rear door(s), if applicable, may require adjustments to the front door and possibly to the front fender to maintain alignment. ^ Door closing effort should be checked to ensure that it remains acceptable after adjustments are completed. If any doors are too difficult to close, the seal compression may be excessive and adjustment will need to be repeated. ^ After completing adjustments, verify seal compression by using the "Card Test" and "White Grease Test".