Body - A-Pillar/Roof Bar Cracking Noises
51 08 032012964/3
November 26, 2008.
Supersedes Technical Service Bulletin Group 51 number 08-01 dated June 12, 2008 for reasons listed below.
51 A-pillar and roof bar make cracking noises
Condition
Cracking noises come from the left or right body between the A-pillar and the roof frame when driving on uneven roads.
Technical Background
Figure 1:
The bonding of the front left or right fender support is not correct. The bonder is positioned too far back.
Figure 2:
The welding point (Figure 2, C) of the fender support to the A-pillar cracks on the left and right sides.
Production Solution
- Improved automated bonder application under the fender supports.
- Optimized welding.
Service
Two different repairs are specified below as a service solution. Both repairs may or may not need to be performed depending on the VIN of the vehicle.
- Up to VIN 4F 5N045000, both repairs will be necessary. Apply bonder to and additionally rivet the fender support.
- From VIN 4F 5N045001 on, only the rivet solution will need to be performed.
Up to VIN 4F 5N045000: Bond the fender support
Figure 3:
1. Bend the fender support (A) off the A-pillar (B) with a plastic wedge or another suitable tool.
2. Reseal the upper and lower PVC seal on the fender support with sealer. Restore the paint structure with a touch-up pencil and spray protective wax on the area, including the fender supports and A-pillar.
The fender does not have to be removed.
All VINs: Rivet the fender support
Figure 4:
1. Rivet the fender support as follows:
Rivet the fender support, as shown in Figure 4, with three 4.8 mm blind rivets, part number N 905 344 03.
2. Drill 5.0 mm holes in the fender support and A-pillar.
3. Before the riveting, apply 2K Epoxid bonder AS 001 730 A1 with mixture nozzle D 001001 in the gap between the fender support and A-pillar.
4. Seal off the blind rivet with sealer.
5. Restore the anti-corrosion treatment.
Warranty
When procedure applies to vehicles under warranty, use the following:
Required Parts and Tools
Additional Information
All parts and service references provided in this TSB are subject to change and/or removal. Always check with your Parts Department and service manuals for the latest information.