Sunroof - Rattles on Rough Roads: Overview

No: 76/16/97/NAS

Ref: WSM Section 76

* Replaces TIB 76/95/97/NAS

Issue: 4 *

Date: 01/16/98

Pride V 6-16

Revisions are shown by asterisks.

* Sunroof Open Position Rattle or Jam *

AFFECTED VEHICLE RANGE:

DISCOVERY (U) Up to VA746176

SITUATION;

SUNROOF RATTLES IN TILT OR FULLY OPEN POSITION

Owners may experience raffles from the sunroof area when driving on rough pavement or uneven surfaces. The cause may be the sunroof mechanism or a loose sunroof glass. Possible flexing of the roof panel stiffeners may contribute to the sunroof rattle.
* Some early sunroofs may also experience jamming during tilt operations. *

RESOLUTION:

DETERMINE SOURCE OF RATTLE AND CORRECT, REPAIR JAMMED MECHANISM

NOTE:
Only the sunroof diagnosed with a rattle during a test drive should be repaired. It is not necessary to rework both sunroofs in all cases.

To resolve an owner complaint of sunroof rattle, inspect sunroof area and perform test drive to determine source of rattles. When rattle source has been identified, perform corrective procedure.

* Sunroofs which jam during the tilting operation may be repaired using the guide rails announced in this bulletin. *

PARTS INFORMATION:

* CAUTION:
It is important to identify the clamping/lower frame assembly installed in the vehicle to ensure that only the latest configuration is used with the new guide rails. *

EGM 100190 Sunroof guide rail kit (Includes LH and RH rail
for one sunroof assembly)

* STC 1686 Lower Frame Assembly (Required for clearance when rails are
replaced on original sunroof assembly used up to VINs
TA188273 and TA519024) *

Locally sourced:

^ Polyurethane Sealer (Example: Sikaflex 221 or Betafill 10215)

WARRANTY CLAIMS:

76.82.89/35 4.15 hrs.
Apply sealer to roof stiffeners and fit one guide rail kit.

COMP CODE 9D5K for front sunroof
9S5K for rear sunroof

76.82.89/38 4.65 hrs.
Apply sealer to roof stiffeners and fit two guide rail kits.

COMP CODE 9D5K

* Normal warranty policy and procedures apply (See Policy Statement which follows.) *

* POLICY STATEMENT:
THIS TIB SUPERSEDED AND REPLACES ALL PREVIOUSLY PUBLISHED TIBS RELATING TO DISCOVERY SUNROOF JAMMING OR RATTLE.

^ Only the sunroof diagnosed as jammed or exhibiting a rattle during a test drive is to be repaired. It is not necessary to rework both sunroofs in all cases.

^ Sunroof replacement is no longer authorized as a sunroof rattle or jamming repair.

^ Warranty claims for replacement of sunroofs to correct jammed or rattling conditions will be denied if the repair date is after 17 November 1997.

^ Vehicles prior to VINs TA188273 and TA519024 may still be equipped with the original specification sunroof clamping/lower fram assembly (without relief impressions for the rails). The replacement of the clamping/lower frame assembly is authorized to replace the early design in conjunction with the fitting of the side rail kit. *