This post will be spread over three pages
Well, after about a year of driving my used 2003 G35 sedan (7/02 build date) that was bought in January of this year, I finally pinpointed numerous rattle locations. Since my dealership is clueless and chooses to put "could not replicate problem" on nearly every issue I've brought up with the car, I gathered up the guts to tear into my G35's interior. Since I'm taking about 10 days off for work, this seemed like the best time.
The good news is most of the rattles are easily fixable assuming you're careful. I take no responsibility for you breaking your car. Light duty adhesive-backed felt tape and black foam rubber water pipe insulation with adhesive inner edges and a 1/2"-3/4" internal inner diameter served as the rattle fixes. Both of these parts are available at Home Depot for less than $12 total.
I've determined three major areas of rattles in most 03/04 G35s, especially ones with the titanium trim console. The three areas are the center console
, all four door panels
, and the rear deck area
. I noted that nearly all the rattles were simply bad engineering choices. Marginally secured hard plastic on plastic will rattle, NISSAN!!!
1) Upper edge of center console. This is the entire edge where the upper trim attaches down to the lower console plastic.
2) Upper console cupholder bin contacting lower console plastic support.
3) Rear portion of lower console contacting metal support which is mounted to chassis.
4) Black air duct (runs through lower center console) contacts chassis bolts located underneath duct.
5) Shifter plate
6) Cupholder housing
To make the fix, you'll need to remove the entire upper console. Remove the shift ****, pull the shifter back to D, lift up on the rear of the front upper console portion (the console part that houses the shifter, ashtray, etc) and it will pop up and out. Finally disconnect the harnesses to the ashtry light, hazard button, etc. Remove front upper console.
For the rear upper console, lift the armrest and pry out the plastic vent plate located between the support arms for the armrest. With the plate removed, you'll see for screws holding in the armrest. Remove the screws and remove armrest. The rear upper console can now be removed. The accessory outlet harness will have to be disconnected. Peer down into the lower console cavity and you'll see two bolts holding the rear of the air duct to the chassis. Remove the bolts. Push the seats forward and remove the screw s(both sides) on the rear of the lower console.
For issue #1, I took felt and placed it in the areas where the upper console ribs sit in the lower console when the two pieces are assembled. I also added some felt along the upper outside edge of the lower console. There were probably 16+ points I added felt to. See the attached pic for felt locations (white and green felt). See pic #1.
For issue #2, I added felt to the lower console support. See pic #1 and note to two large peices of green felt in the middle of the pic.
For issue #3, I lifted up on the rear of the lower console and added felt to uppor portion of the metal support lessening the impact between the plastic of the console and the metal support. See pic #2 and note the brown felt.
For issue #4, I added felt to the areas of the front and middle underside areas of the duct that were hitting chassis points. You'll have to experiment to find them. Simply push down on the duct to simulate road impact and figure out where the contact is coming from and then pull out the duct. It runs from the rear of the lower console all the way to the front of the console. Add felt as necessary. In pic #1, you'll see the black duct running along the interior passenger side of the lower console.
For issue #5, I disassembled the shifter plate assembly and added felt to lower side of the chassis plate.
For issue #6, I disassembled the cupholded assembly and added to points that contacted plastic to plastic.
Pic #2 view from rear ashtray (removed)