NHTSA Complaint #10137542 — 2005 TOYOTA MATRIX

WE OWN A 2005 TOYOTA MATRIX AWD XR WITH A FACTORY INSTALLED MOON ROOF. IT HAS BEEN TO THE DEALER 2 TIMES FOR A RATTLE IN THE ROOF. 1ST DIAGNOSIS: FOUND ROOF SUPPORT TO BE SLIGHTLY LOOSE DUE TO LACK OF SPOT WELD, BENT LIP OF SUPPORT DOWN AND APPLIED FOAM TO ALL POINTS OF CONTACT. 2ND DIAGNOSIS: SUPPORT BRACES ARE LACKING INSULATION AND SEALER, CAUSING THEM TO BE NOISY OVER BUMPS. VEHICLE IS BACK FROM THE 2ND REPAIR AND STILL HAS THE RATTLE NOISE. WE ARE CONCERNED THAT THE ROOF SUPPORTS NOT BEING CORRECT IN THE MANUFACTURING PROCESS MAY MAKE THE CAR LESS STRUCTURALLY SOUND NOW OR IN THE FUTURE AS THE INSULATION WEARS DOWN. THE SERVICE MANAGER SAID THIS LACK OF INSULATION A PROBLEM THEY HAVE BEEN SEEING IN THE CARS. *JB