Body - Tailgate Pops/Scrapes Upon Opening
03-060September 23, 2003
Applies To:
2003 Pilot - From VIN 2HKYF18..3H500001 thru 2HKYF18..3H562075
Scraping or Popping When Opening the Tailgate
SYMPTOM
The tailgate makes a loud scraping or popping noise as it nears its fully open position. This problem usually happens in hot weather.
PROBABLE CAUSE
The front edge of the tailgate spoiler trim is too high, and the T-bolts on each side of the spoiler trim stick in their tracks.
CORRECTIVE ACTION
Replace the foam under the tailgate spoiler trim with 3M Scotchfoam tape. Remove any plastic flashing from the T-bolt tracks so the bolts move freely.
PARTS INFORMATION
Rear Spoiler Clip A (Tailgate Spoiler Trim Clip) (two required):
P/N 91505-S0X-000, H/C 6031033
REQUIRED MATERIALS
3M Scotchfoam Black Vinyl Foam Tape:
3M P/N: 06370
Tape Number: 4504
Size: 3/4-inch wide by 1/4-inch thick
(Each roll repairs about five vehicles.)
(Available at automotive paint supply stores.)
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
Operation Number: 823006
Flat Rate Time: 0.5 hour
Failed Part: P/N 74900-S9V-A01ZA
H/C 7034648
Defect Code: 042
Contention Code: B07
Template ID: 03-060A
Skill Level: Repair Technician
Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.
REPAIR PROCEDURE
1. Inspect the roof area near the tailgate spoiler trim for dents and paint damage. Repair any damage (refer to the 2003 Pilot Body Repair Manual).
2. Close the tailgate. Check the spoiler trim for delamination by pulling on the front edge of the spoiler trim at the corners. The spoiler trim is two pieces bonded together and the bond may have broken. If the spoiler trim top plate separates from the base, replace the spoiler trim.
3. Open the tailgate.
4. Remove the access plug, then remove the tailgate spoiler trim mounting nuts (three total).
5. Gently close the tailgate, then lift up on the spoiler trim to release its two clips.
6. Remove the high mount brake light bulb socket from its housing in the spoiler trim. Unclip the high mount brake light wire harness from the spoiler trim (five places). Note which clip goes with which colored tape location on the harness.
7. Disconnect the rear window washer tube.
8. Remove the spoiler trim, and turn it upside down.
9. Peel off the weatherstrip rings from the T-bolts on each end. Make sure the T-bolts slide freely. If necessary, use a utility knife to trim any flashing from the slots. Replace the two clips.
10. Remove the foam strip that runs across the entire back edge of the spoiler trim.
11. Use a clean shop towel to wipe any dirt from the top edge of the rear window glass and the tailgate. Then use alcohol wipes to clean an area 25 mm above and below the top edge of the glass across its entire width.
12. Starting 15 mm in from the side edge of the rear window glass, apply foam tape across the width of the glass. Position the tape with the upper 2/3 of the tape above the glass and the lower 1/3 on the glass. Carefully cut the tape 15 mm in from the edge of the glass.
13. Use your hands to press the tape firmly against the glass, then peel off the paper backing.
14. Apply a second layer of tape in the area of the high mount brake light. Using the tailgate's indent for the high mount brake light as a guide, position the end of the tape roll on top of the tape you just applied, starting at one end of the indent. Apply the tape, and cut it when you reach the other end of the indent.
15. Press the tape firmly against the other tape, then peel off the paper backing.
16. Reconnect the rear window washer tube.
17. Reinstall the high mount brake light bulb socket. Reinstall the wire harness, making sure you match the colored tape locations on the harness with the appropriate spoiler trim clips.
18. Position the spoiler trim on the tailgate, then snap it into place.
19. Open the tailgate.
20. Reinstall the spoiler trim mounting nuts, starting with the center nut. Torque the nuts to 9.8 N.m (7.2 lb-ft). Reinstall the access cap.
21. Close the tailgate, and measure the height difference between the roof and the front edge of the spoiler trim. The spoiler trim must be at least 5 mm lower than the roof. If the spoiler trim is too high, remove the spoiler trim, and add a second piece of tape over the piece you applied under the high mount brake light.
22. Check that the high mount brake light and the rear window washer work properly.
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