Body - Doors Hard To Open From Inside/Outside
No: 76/15/05/NASFGN LM501-03
Ref: 76/15/03/NAS
*Issue: 2*
Date: 05 June 2006
Door Latch Mechanism Function
CHANGES MADE FOR ISSUE "2" ARE HIGHLIGHTED WITH GREY BACKGROUND AND ASTERISKS
AFFECTED VEHICLE RANGE:
New Range Rover (LM)
*3A101029 onwards*
SITUATION:
*DOOR IS DIFFICULT TO OPEN*
A condition can occur where a door *may be extremely difficult to open from both* the interior and exterior handles, despite the locking mechanism functioning correctly when using a key or the remote (as indicated by expected door lock-button movement). *A riveting process in the manufacture of the latch assembly may cause an internal lever to bind.*
RESOLUTION:
RELEASE AND REPLACE LATCH MECHANISM
Should a customer express concern regarding the above, refer to the Service Procedure detailed in this bulletin to release the affected door. Following manual release of a latch, the door latch must be replaced. In cases where the door opens, but from only one of the handles, follow the trouble shooting guide detailed in TIB 76/15/03/NAS (Issue 2) "Troubleshooting Problems with Handles, Locks and Latches.
PARTS INFORMATION:
*CAUTION:
Correct replacement door latches must have a date code of 28155 or later. Door latches supplied with a date code prior to 28155 must be rejected and returned to Caterpillar by normal return process, referencing this bulletin. Refer to Repair Procedure titled "Verify Door Latch Date Code and Replace Affected Door Latch" for date code identification.*
DDW WARRANTY CLAIMS:
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
RELEASE AND REPLACE FRONT DOOR LATCH
1. Unlock all doors.
2. Verify that all door lock-buttons are in the UP position indicating an unlocked condition.
3. Partially open the rear door behind the affected front door. (Figure 1)
CAUTION:
Protection in the area of the front-edge of the rear door and the rear-edge of the front door is required to prevent paint damage.
4. Place tape or other suitable protection on the front-edge of the rear door and the rear-edge of the front door. (Figure 1 and Figure 2)
5. Identify the grommet covering the latch adjustment screw of the front door latch. (Figure 1)
6. Remove the grommet covering the latch adjustment screw. (Figure 2)
7. Using a suitable implement (bent wire or similar), locate and hook the adjustment screw. (Figure 3)
NOTE:
An audible click will be heard as the mechanism is released.
8. Release the mechanism using one of the following methods:
^ Move the adjuster screw up and down providing the small amount of movement that may release the mechanism.
^ Pull the screw in the upward direction using modest force.
9. When the lock mechanism releases, open the door using the door handle.
10. Go to section "Replace Affected Door Latch."
RELEASE AND REPLACE REAR DOOR LATCH
1. Unlock all doors.
2. Verify that all door lock-buttons are in the UP position indicating an unlocked condition.
3. Fully open the window on the affected rear door.
4. Carefully remove the window-glass outer waist seal. (Figure 4)
5. Look through the space between door glass and exterior door panel and locate the exterior release- lever of the door latch inside the door cavity.
CAUTION:
Protection is required in the area of the forward glass-runner to prevent paint damage.
6. Place suitable protection in the area of the forward glass-runner to prevent paint damage. (Figure 5)
7. Using a slender implement with notched end, locate and hook the lever. (Figure 5)
NOTE:
A click will be heard as the mechanism is released.
8. Pull lever in a rearward/upward direction.
9. When the mechanism has been released open the door using the door handle.
10. Go to section "Replace Affected Door Latch."
VERIFY DOOR LATCH DATE CODE AND REPLACE AFFECTED DOOR LATCH
* CAUTION:
Only door latches with a date code of28155 or later are to be installed.
NOTE:
Door latch manufacturing date is stamped on the assembly and coded by values and digit positions. The first correct latch assembly date code is used as an example (Figure 6):
^ First and Second digit = Week of manufacture (e.g. 28 = Week 28)
^ Third and Fourth digit = Day of Month in Week (e.g. 15 = 15th day of month in which Week no. falls)
^ Fifth digit = Year of manufacture (e.g. 5 = 2005)
1. Verify an acceptable date code is stamped on the new latch assembly as follows:
^ Verify the week of manufacture, identified by the first and second digit of the date code, is 28 or higher. (Figure 6)
^ Verify the day of month, identified by the third and forth digit of the date code, is 15 or higher. (Figure 6)
^ Verify the year of manufacture, identified by the fifth digit, is 5 or higher. (Figure 6)*
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ LM - Range Rover/2003 > Workshop Manuals > Service Procedures > Bookmark "76-1 - DOORS" link "76.37.12 Latch - front door"
The same procedure applies to front and rear door latch replacement.
2. Refer to GTR Workshop Manual section 76.37.12 and replace the affected door latch assembly.
3. If extra effort is required to open the door after replacing the door latch, perform the following:
^ Check for preload on the interior or exterior release handles.
^ Verify that both handles return fully
4. Adjust door latch adjuster screws if required as follows:
^ Open affected front or rear door.
^ If installed, remove grommet from the affected door (Figure 7 and Figure 8) for access to the door lock adjuster screw.
NOTE:
The door lock adjuster screws rotate counter-clockwise on LH doors, clockwise on RH doors to release tension.
^ Release the door lock adjuster screw two turns.
^ Tighten the door lock adjuster screws to 4 Nm (3 lbf ft).
5. Install the door lock adjuster screw grommet.
6. Close front and rear doors.
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