Recall Repair of Right Front Door Latch (All Vehicles In Range)
A. Recall Inspection and Repair1. Verify that Recall D456 repair has not been previously performed by inspection for a recall label on the front cross member.
2. Remove and discard upper latch retention screw on right front door latch.
3. Install a new latch screw (STC3763) and washer (AFU1069) in the upper mounting hole (figure 1).
4. Tighten new screw to 4-5 Nm. (36-45 lbf. in.).
B. Right Front Door Latch Inspection
1. Open RH front door and raise the window.
2. Perform the following inspection using first the exterior door handle and then the interior door handle:
^ Lock and then unlock the door using the sill button. This step places the latch paw in the fully seated position.
^ Observe the latch pawl (figure 2) and pull the release handle to its stop.
NOTE:
During the following operation check that the pawl does NOT stick or move sluggishly and that it returns to the fully seated position.
^ Continue to observe the pawl, and slowly return the handle to its rest position.
^ Repeat all latch inspection steps using the interior release handle.
3. Lower the door window fully and repeat step 2.
4. Close the door several times and verify that there is no "bounce" off of the door seal and that the latch works correctly.
5. If the pawl operated freely during the inspections in step 2 and no door bounce is observed in step 4, go to "Left Front Door Inspection and Repair" and inspect the left front door.
6. If the pawl was sticking or sluggish during inspections in step 2 or if door bounce is experience in step 4, replace the latch as described in Section C.
C. Right Front Door Latch Replacement
1. Refer to the Workshop Manual, Section 76 and remove the defective front door latch.
NOTE:
On some vehicles, the inboard latch bolt may have a spacer between the door and latch. This spacer must be saved and installed during installation of the new latch. (figure 4)
2. When the latch has been removed:
^ Drill out the inboard latch mounting hole using a 12 mm. (15/32") drill bit.
^ Remove any sharp edges from around the hole.
NOTE:
The following parts must be used in the assembly process. The upper screw must be replaced with a new screw because of the onetime-use thread locking compound:
^ A new recall extended length screw (STC3763) (figure 3).
^ Washer (AFU1069) in the upper mounting hole (figure 3).
^ Washer (AFU1069) under the inboard mounting bolt (figure 4).
^ Spacer if originally installed (figure 4)
3. Refer to Workshop Manual, Section 76. Apply a new gasket to the replacement latch and install.
4. Torque the upper and lower screws on the door case edge to 4-5 Nm. (36-45 lbf.in.) and then torque the interior mounting screw to 4-5 Nm. (36-45 lbf.in.) also.
5. Before installing the door trim panel verify the following:
^ Refer to the Workshop Manual, Section 76 and to TIB 76/01/97/US. Ensure that the door lock actuator is adjusted properly.
^ Refer to TIB 76/02/97/US. Ensure the front door handle link rod adjustment is correct.
^ Ensure proper alignment of the door glass frame to the door seal to prevent water leaks and wind noise.
^ Ensure that the water curtain is sealed fully around the perimeter. Seal any small tears using waterproof tape.
D. Final Right Front Door Functional Check
1. Open the right front door and raise the window.
2. Perform the following inspection using first the exterior door handle and then the interior door handle to ensure that the latch pawl operates freely:
^ Lock and then unlock the door using the sill button. This step places the latch pawl in the fully seated position.
^ Observe the latch paw (figure 5) and pull the release handle to its stop.
NOTE:
During the following operation check that the pawl does NOT stick or move sluggishly and that it returns to the fully seated position.
^ Continue to observe the pawl, and slowly return the handle to its rest position.
^ Repeat all latch inspection steps using the interior release handle.
3. Lower the door window fully and repeat step 2.
4. Check operation of door sill button with central door lock remote and with vehicle key.
5. Close the door several times and verify that there is no "bounce" off of the door seal and that the latch works correctly.
6. Perform a final check of power window operation.
7. If any problems are encountered with the latch mechanism during this final check, contact the Land Rover Technical Help Line (800) 562-5824.