Body - Tailgate Spoiler Foam Strip Hangs Down
04-003January 16, 2008
*Applies To:
2003-05 Pilot - ALL*
Tailgate Spoiler Foam Strip Hangs Down
(Supersedes 04-003, dated February 13, 2004, to update the information marked by asterisks)
SYMPTOM
The foam strip under the tailgate spoiler comes loose and hangs down over the rear window.
PROBABLE CAUSE
The foam strip has lost its adhesion.
CORRECTIVE ACTION
Replace the foam strip under the tailgate spoiler with 3M Scotchfoam tape.
PARTS INFORMATION
Rear Spoiler Clip A (Tailgate Spoiler Clip)
(two required):
P/N 91505-SOX-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 part supply stores.)
WARRANTY CLAIM INFORMATION
In warranty:
The normal warranty applies.
Operation Number: 823304
Flat Rate Time: 0.5 hour
Failed Part: P/N 74900-59V-A11ZA
H/C 7034655
Defect Code: 02502
Symptom Code: 00101
Template ID: 04-003A
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. With the tailgate closed, check the tailgate spoiler for delamination by pulling on the front edge of the spoiler at the corners. (The spoiler has two pieces bonded together and the bond may have broken.) If the spoiler top plate separates from the base, replace the spoiler.
2. Open the tailgate.
3. Remove the access plug, then remove the tailgate spoiler mounting nuts (three total).
4. Gently close the tailgate, then lift up on the spoiler to release its two clips.
5. Remove the high mount brake light bulb socket from its housing in the spoiler. Unclip the high mount brake light wire harness from the spoiler (five places). Note which clip goes with which colored tape location on the harness.
6. Disconnect the rear window washer tube.
7. Remove the spoiler, and turn it upside down. Check for broken plastic weld points. If any of the weld points are broken, replace the spoiler.
8. Peel off the weatherstrip rings from the I-bolts on each end. Make sure the I-bolts slide freely. If necessary, use a utility knife to trim any flashing from the slots. Replace the two clips.
9. Remove the foam strip that runs across the entire back edge of the spoiler.
10. 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.
11. 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.
NOTE:
For best results, apply the foam tape in a work area where the ambient temperature is at least 50° F.
12. Use your hands to press the tape firmly against the glass, then peel off the paper backing.
13. Reconnect the rear window washer tube.
14. 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 clips.
15. Position the spoiler on the tailgate, then snap it into place.
16. Open the tailgate.
17. Reinstall the spoiler mounting nuts. Starting with the middle nut, torque the nuts to 9.8 N.m (7.2 lb-ft). Reinstall the access plug.
18. Close the tailgate, and measure the height difference between the roof and the front edge of the spoiler. The spoiler must be at least 5 mm lower than the roof. If the spoiler is too high, remove it, and add a layer of foam tape over the tape under the high mount brake light. Cut the tape the same length as the high mount brake light indent. Reinstall the spoiler, and remeasure.
19. Check that the high mount brake light and the rear window washer work properly.
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