Body - Tailgate Rattles
No: 76/02/98/NASRef: WSM Section 76
Issue: 1
Date: 03/06/98
PRIDE VI 6-18
Rear End Door Dovetail Rattle
AFFECTED VEHICLE RANGE:
DISCOVERY (U) UP TO 98MY
SITUATION:
REAR END DOOR RATTLES AT DOVETAIL.
While traveling over rough or bumpy roads, the rear end door may rattle causing customer complaint.
RESOLUTION:
INSTALL REVISED REAR END DOOR DOVETAIL
A revised dovetail, with softer contact areas, is available to eliminate rattles from the dovetail area. After a road test has confirmed the source of the rattle as the dovetail, follow the procedures outlined below to replace the dovetail and properly adjust the rear end door.
NOTE:
The repairs outlined in this TIB are to be performed to resolve customer complaint of the symptoms described.
PARTS INFORMATION:
ASR1516 Male Dovetail Qty 1
ASR1515 Female Dovetail Qty 1
LRN92125A242 M6x25, 4 mm Hex Head Qty 2
WARRANTY CLAIMS:
76.37.56 Time 0.30 hrs.
Replace dovetail
76.37.89/34 Time 0.80 hrs.
Replace dovetail and rear end door adjustment
FAULT CODE: W
Normal warranty policy and procedures apply
REPAIR PROCEDURE:
INSTALLATION OF REVISED DOVETAIL
1. Remove current male and female dovetails from rear end door and E-post.
NOTE:
Retain the two existing fasteners from the male dovetail for reuse when installing new male dovetail.
NOTE:
If a shim is found beneath the female dovetail, retain and reuse with new dovetail.
2. Install revised male dovetail on rear end door using retained fasteners. Use the two rearmost fastening points.
3. Tighten fasteners to 8-10 Nm (6-7.5 lbf.ft.).
NOTE:
Four fasteners attach the original female dovetail. The new dovetail is attached with only two.
4. Install new female dovetail on E-post using new bolts (do not tighten fasteners completely to allow for adjustment).
5. Adjust female dovetail to center the male dovetail roller (Figure 1).
NOTE:
If clearance is less then 2 mm, it will be necessary to adjust the door to obtain the proper clearance.
6. Check for a minimum clearance of 2 mm (0.080 in.) between the roller element on the male dovetail and the female dovetail (Figure 2).
7. If clearance is less than 2 mm, adjust the door away from the dovetail to obtain the proper clearance.
8. After rear end door adjustment, close door firmly.
8. Carefully open door to avoid altering the position of the female dovetail achieved by closing the door.
9. Tighten the female dovetail fasteners to 8-10 Nm (6-7.5 lbf.ft.).
10. Close all other doors and windows and test for closing effort required to close the rear end door. If closing effort is not satisfactory (exceeds effort required to close other doors), proceed with door adjustment procedure below.
REAR END DOOR ADJUSTMENT PROCEDURE
1. Remove six rear end door panel studs and two grommets by door hinges for access to the hinge bolts.
2. Loosen, but do not remove, four hinge bolts.
3. Adjust rear end door to create 2 mm (0.080 in.) clearance at the dovetails.
NOTE:
This clearance measurement is in the horizontal plane. Increase clearance by moving door away from door opening. Decrease clearance by moving door closer to doorframe.
4. Tighten hinge bolts to 30-34 Nm (22-25 lbf. ft.).
5. Close door to check closing effort.