Interior - Tonneau Cover Bar Locating Pegs Loose/Sheared

NUMBER
XT501-0262
*(Issue 2)*

DATE
14 Nov 2006

MODEL
X-TYPE

ISSUE '2'CHANGES ARE HIGHLIGHTED WITH GREY BACKGROUND AND ASTERISKS

SECTION:
501-05 - INTERIOR TRIM AND ORNAMENTATION

Tonneau Cover Bar - Locating Pegs Loose/Sheared

AFFECTED VEHICLE RANGE:
X-TYPE (Wagon models only)

VIN:
D77509 onwards

Model Year:
2004 onwards

CONDITION SUMMARY:

TONNEAU COVER BAR LOCATING PEGS COMING LOOSE OR SHEARING

Situation:
A customer may report a concern of the tonneau cover bar locating pegs coming loose or breaking off.

Action:
Should a customer report this concern, refer to the Repair Procedure detailed in this bulletin to replace the tonneau cover bar pegs and install peg support brackets where necessary.





PARTS:





WARRANTY:

NOTE:
Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only. Always refer to DDW to obtain the latest repair time.

DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.

Normal warranty policy and procedures apply.

REPAIR PROCEDURE

REPLACE TONNEAU COVER BAR PEGS





NOTE:
Vehicles currently having the new level bar pegs will require replacement with latest level bar pegs. New level bar pegs already have peg support brackets assembled. New level bar pegs can be identified by an elongated leg as illustrated in Figure 1.

Vehicles currently having old level bar pegs will need to have peg support brackets (C2S 43272) installed in addition to latest level bar pegs. Old level bar pegs do not have an elongated leg illustrated in Figure 1.

1. Open the liftgate.

2. Operate tonneau cover assembly latches and remove tonneau cover assembly from the vehicle.

3. Place tonneau cover assembly inverted on a suitable surface.

4. Remove the end pegs from the tonneau cover bar.

5. Install and fully seat the new tonneau cover pegs into the tonneau cover bar.

NOTE:
To aid in marking and protect areas that will be drilled, a piece of masking tape must be applied at each end of the tonneau cover.





6. Apply a piece of masking tape at each end of the tonneau cover, covering the areas to be marked for drilling. (Figure 2)

7. Measure and mark positions of each of the four pilot holes (two each end) as illustrated in Figure 2 as follows:

^ Measure and mark a point 10 mm (0.4 in) inboard from each end of the tonneau cover.

^ Measure and mark a point 20 mm (0.8 in) inboard from the 10 mm point marked above.

CAUTION:
When drilling pilot holes, care must be taken not to drill all the way through the bar.

8. Drill a 3.0 mm (0.1 in) diameter pilot hole at each of the four drill points marked in Step 7.

9. Remove and discard the masking tape from each end of the ton neau cover.

10. Remove any fillings or shavings remaining around each pilot hole.

11. Install each of the four new screws (C2S 43224) and tighten to secure the new pegs to the ton neau cover bar. (Figure 2)

INSTALL TONNEAU COVER SUPPORT BRACKETS

NOTE:
Only vehicles currently having old level bar pegs will need to have peg support brackets (C25 43272) installed. Old level bar pegs do not have an elongated leg illustrated in Figure 1.

NOTE:
To aid in marking and protect areas that will be drilled, a piece of masking tape must be applied at each end of the tonneau cover.





1. Apply a piece of masking tape at each end of the tonneau cover, covering the areas to be marked for drilling. (Figure 3)

2. Measure and mark positions of each of the four pilot holes (two each end) as illustrated in Figure 3 as follows:

^ Measure and mark a point 33.5 mm (1.3 in) inboard from the end of the tonneau cover and 18 mm (0.7 in) below the end of the tonneau cover.

^ Measure and mark a point 33.5 mm (1.3 in) inboard from the end of the tonneau cover and 21 mm (0.8 in) below the 18 mm point marked above.

CAUTION:
When drilling pilot holes, care must be taken not to drill all the way through the bar.

3. Drill a 3.0 mm (0.1 in) diameter pilot hole at each of the four drill points marked in Step 13.

4. Remove and discard the masking tape from each end of the tonneau cover.

5. Remove any fillings or shavings remaining around each pilot hole.





6. Install each of the four new screws (C2S 43224) and tighten to secure the new pegs to the tonneau cover bar. (Figure 4)

7. Install and fully seat the tonneau cover assembly to the vehicle.

8. Close the liftgate.





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