Body/Interior - Difficulty Opening Front Doors
No: TSB-04-52A-004DATE: December, 2004
MODEL:
2004-05 Galant
SUBJECT:
DOOR PANEL TRIM RETENTION, REMOVAL, AND INSTALLATION
PURPOSE
This bulletin Contains information concerning door panel trim removal and installation for door panel trim retention conditions, door mirror service work, or other conditions where the trim may require removal.
BACKGROUND INFORMATION
When removing the front door panel trim for any reason, inspect to make sure it is in good condition. If it is damaged in any way, replace it with a new door panel trim. There are two types of door panel trim:
^ Early production vehicles have front door panel trim assemblies which were mounted with two different types of clips.
^ Later production vehicles have trim with the same clips and a retaining screw at the bottom rear area of the trim.
Refer to the PROCEDURES section of this bulletin for door panel trim installation information.
Symptom
Some customers may experience difficulty when opening the vehicle's front door. This condition may occur with one or both front doors.
Cause
The door panel trim assembly mounting clips may come loose allowing the door panel trim to interfere with the weatherstrip trim when the door is opened.
Remedy
If the door is stuck in the closed position, determine where the door panel is binding, shift the door panel trim in the opposite direction, then push the door open.
If the original door panel trim is not damaged, reinstall it using the information in the PROCEDURES section A of this bulletin. If the trim is damaged, replace it with new, revised front door panel trim . The new trim requires a modified clip mounting and the addition of a retaining screw, both of which are explained in PROCEDURES section B this bulletin.
AFFECTED VEHICLES
2004-05 Galant
PROCEDURES
Use the procedures in service manual Group 52A for replacement of the door panel trim assembly while addressing the added and changed procedures shown below:
A. Door Panel Trim Installation - Early-Type Trim Panel Without Retaining Screw
NOTE:
If you encounter a vehicle with door panel trim retention problems, thoroughly inspect the trim. If no damage is identified, reinstall the trim, referring to the information below If the trim is damaged, refer to section B of this bulletin and replace it with a new-style trim panel with an added retaining screw
^ Early production vehicles were originally equipped with front door panel trim assemblies attached with seven push-clips.
^ Six clips are blue, and are reusable. The other clip, located at the lower rear of the trim, is black and will be destroyed when the trim is removed, requiring a new clip when the trim is reinstalled.
^ Make sure you remove the broken pieces of the old black clip from inside the door to prevent rattles.
^ The new black clip may require slight trimming. Obtain a new special one-way door trim clip (p/n: 7259A001) then cut and trim the compression cup as shown. This will make installation easier.
^ If the door panel trim has previously come loose but suffered no damage, install additional black clips instead of blue clips in the area where it came loose to improve retention.
If the door panel trim has been removed several times, the reusable clips may lose their retention force. If the blue clips do not hold the trim securely, replace them with new blue clips.
NOTE: INSIDE BELTLINE WEATHERSTRIP:
If the inside beltline weatherstrip remains attached to the door when removing the door panel trim, remove it and then reattach the weatherstrip to the re-used or new door trim. To install the beltline molding slide it onto the door trim using either end of the door trim as a starting point.
B. Door Panel Trim Installation - Late-Type Door Panel Trim With Retaining Screw
^ If the original door panel trim is damaged, replace it with the new-style trim which has a retaining screw in the lower rear area of the door.
^ If the original trim does not have this screw, a hole must be drilled into the inner door panel sheet metal.
1. Referring to the service manual, remove the door panel trim assembly. If the original door panel trim already has the retaining screw, skip to step 4. If the damaged original trim does not have the screw, go to step 2.
2. Temporarily position the new trim over the clip mounting holes, making sure it is centered on the door. Using a proper punch, mark the location on the inner door sheet metal for drilling the new hole for the retaining screw. Use the screw hole at the lower rear of the new ,trim as a guide for marking the location for drilling.
3. Remove the trim and drill a 4 mm hole at the location marked in step 2. Use a vacuum to remove any metal particles which may have fallen into the door while drilling. To prevent any future occurrence of rust around the drilled hole, apply rust inhibitor or paint to the new hole. You may have to fold or peel back the inner door water diversion film to access the drilled area. Make sure the film is properly positioned before installing the trim.
CAUTION:
Failure to remove the door panel trim before drilling may cause damage to the new trim.
4. Obtain a new special one-way door trim clip (p/n: 7259A001) then cut and trim the compression cup as shown. This will make installation easier.
5. After trimming the black door trim clip, install the clip into the door panel trim so it is aligned with the door trim clip hole indicated in the illustration.
6. Install the blue clips (p/n: MU000637) into all the other holes in the door trim.
NOTE:
If the door panel being installed is new use all new blue clips.
If the existing door panel trim being installed has been removed several times, the reusable blue clips may loose their retention force. If the blue clips do not hold the trim panel securely replace them with new blue clips.
NOTE; INSIDE BELTLINE WEATHERSTRIP:
If the inside beltline weatherstrip remains attached to the door when removing the door panel trim remove it and then reattach the weatherstrip to the re-used or new door trim. To install the beltline molding slide it onto the door trim using either end of the door trim as a starting point.
7. Install the front door trim assembly to the door inner panel, making sure ALL trim panel clips are securely seated. Insert the M5 x 12 self-tapping screw into the hole in the door panel trim assembly and tighten.
PARTS INFORMATION
WARRANTY INFORMATION