Hi Mount Brake Light - Replacement
Section3
Group
35
No
0009
Year
99
Month
11
Cars
S80
1999-
Brake light, replacement
Background
This service bulletin describes how to replace the high-level brake light. The brake light design has been changed and has been introduced into production. Only the new brake light design is available as a spare part.
Brake light version 1 is available for chassis number 000001-003335. Brake light version 2 is available for chassis number 003336-.
Model Factory Chassis No.
S80 1 000001-003335
Material
Description Quantity Part No.
Connector JAE, 5-pin 1 978305
Brake light 1 9483350
Replacement of the brake light Special tools: 951 2636
Removing the brake light
1
Use clean gloves
Caution!
To avoid customer complaints, the following should be adhered to:
- Use gloves that leave no traces.
- Any visible areas, where the brake light may cover the rear window, should be kept stainless and flawless.
- Any visible areas on the brake light should be kept stainless and flawless.
2
Preparatory work
Remove:
- three rear clips (1) in headlining, turn a quarter turn and pull out.
- rear interior lighting (2). The attachment is made of curved plate springs.
- foam plastic (3) from the upper side of the headlining. Do this with care, since it will be used again.
Note!
Make a note of the position of the foam plastic.
- Lower seat back for fast access to brake light assembly.
- connector (4) from brake light.
- wires to brake light. Pull them out through the hole for the rear interior lighting.
3
Removing brake light bulb
Warning
Carefully remove the rear light from the headliner. If not, the headliner may be damaged.
Use a pressure tool to cut as close to the brake light tape as possible. This protects the headlining.
Start with the two pieces of tape on the part directed forwards, and then the two pieces on the part closest to the rear window.
Work on one corner at a time.
Identification
4
Identifying the brake light
If a car is equipped with a version 1 brake light, it can be checked as follows:
- part number (1), embossed on the left side of the brake light housing, is 9154503.
- connector (1) on the brake light is turned with its smooth side down, and has a collar.
If a car is equipped with a version 2 brake light, it can be checked as follows:
- part number (2), embossed on the left side of the brake light housing, is 9483132.
- connector (2) on the brake light is turned with its smooth side up.
5
Removing loose paper
Take away all the loose paper from the inside of the headlining, where the brake light was.
Note!
Do not damage the headlining.
6
Replacing brakelight with the same model
If the brake light that is to be replaced is of the same model as the new one, no changes have to be made. Continue with; 13 - 16.
7
Replacing the brake light from version 1 to version 2
If the brake light to be replaced is version 1, and the new one is version 2 (see 4), the wires should switch places (terminal reversal), as described in 8 - 12.
Reversing wire terminals
8
Use a thin screwdriver, 3-4 mm (0.11"-0.16") wide.
Carefully release the latches of the secondary locking.
9
Removing wire
Push the wire terminal into the cavity.
Insert removal tool 951 2636 from terminal side in the upper cavity row, by the wire terminal. The bevelled part of the tool should point sideways.
Remove wire terminal.
Repeat for each wire.
10
Checking the wire terminal
Check that the wire terminal latches have not been compressed or damaged during removal.
11
Installing wire
Hint:
The number of each slot is marked on the back side of the connector.
Use a new connector, part number 978305.
Install the yellow-red wire in position 1.
Install the brown wire in position 5.
When the wire terminal is inserted into its cavity, a clicking sound can mostly be heard when the primary locking engages.
Try to pull the wire slightly to check that the wire terminal stays in the cavity.
12
Closing the secondary locking
When the secondary locking engages, a clicking sound can mostly be heard.
It the secondary locking is difficult to close, this could be caused by the wire terminal not being properly inserted into the cavity.
Installing components
13
Testing the brake light
Connect a new brake light.
Check the function.
Disconnect.
14
Removing the protective paper
Remove the protective paper (1) from the double-sided tape on the brake light.
15
Installing the brake light
Put the brake light on the headlining, with the inner part(1) towards the heading not allowing the doublesided tape to touch the headlining.
Note!
To avoid any noise problems (grinding sounds) it is very important to position the brake light properly on the headlining.
Align light assembly with the headlining.
Press the brake light against the headlining.
16
Completing work
Install connector (1) to brake light.
Tape (2) the brake light wires to the headlining, to avoid any possible noise sources.
Install foam plastic (3), right behind the hole for the rear interior lighting. Use contact adhesive, for example 1161434, if there is not enough adhesive left on the foam plastic to make it stick.
Install clips (4) in the headlining by pressing straight upwards and turning a quarter of a turn.
Making sure the rubber seal is up in place.
Install the interior lighting (5) by pressing straight upwards.
Function test
17
Checking the brake light
Check that the brake light works properly with dipped beam on, and direction indicator activated.
Check the function of the interior lighting.
Clean rear window inside.
WARRANTY STATEMENT: Claims may be submitted under the New Car Warranty when there is a documented customer complaint, using claim type 01.
Operation No. Labor description Time allowance
35919-3 Reversing wire terminal and replacing connector 0.1 hr
35617-2 Replacing extra brake light 0.2 hr