Prius (Gen 3) :: Tailgate Panel Always Loose And Rattling


Jun 9, 2013

I recently brought my 2011 in for its final service with a laundry list of issues, one of which was the tailgate panel that was always loose and rattling. Of course the dealer told me there was no problem, and it's always been difficult to isolate the source of rattles on this car since the entire car is a symphony of rattling plastic.

I looked into the tailgate panel more closely to find that the two plastic grab handles built into the tailgate panel were loose. I pulled the panel off to discover the root for the problem. The two plastic grab handles are sonically welded (melted) to the tailgate panel, (five welds per handle). Three of the five welds on each handle were fractured, (six out of ten welds had failed).

I took the panel back to the dealership and showed it to the service manager who miraculously concluded that the panel was defective, but it wasn't like that when they looked at it the day before.

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What is strange is the rattle increases in sound volume and occurs more often the longer you drive and also if temperatures get colder.

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The video shows how bad it is : [URL] ....

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