Body - Liftgate/Glass Hard To Open/CHMSL Hits Roof
TSB SB05-11-S005Liftgate or Liftgate Glass Binds, Does Not Open Completely, CHMSL Hits Roof
Light Duty ASCENDER 2003 Bulletin BODY 04/01/05
Light Duty ASCENDER 2004 Bulletin BODY 04/01/05
Light Duty ASCENDER 2005 Bulletin BODY 04/01/05
ISSUE DATE: MARCH 2005
Affected Vehicles
2003-2005 Isuzu Ascender (UT).
Service Information
Condition:
Some customers may comment that the liftgate or liftgate glass binds when opening or does not open all the way.
Possible Cause:
This condition is caused by the Center High Mounted Stop Lamp (CHMSL) applique' hitting the roof of the vehicle.
Correction:
Verify that the CHMSL applique' is not loose or broken off one or more of its mounting points. If the applique' is broken, it will need to be replaced.
Important:
It should not be necessary to replace the liftgate glass. All measurements and alterations should take place prior to paint finish. It is necessary to install any replacement parts in order to measure and determine if further modification is required.
Service Procedure
FIGURE before modifications (Figure 1)
To achieve the proper clearance, modification to the applique' is required using the following procedure:
1. Measure (with applique' installed) the area of interference in order to determine the material to be removed.
The top surface (height) of the applique' should line up approximately 1 mm (0.039 in) below the top surface of the roof.
A gap of 6-8 mm (0.236-0.315 in) should exist between the roof and the applique' to allow for adequate clearance while opening the liftgate.
2. Mask off the desired amount of material to be removed.
3. Open the liftgate glass.
Notice:
Do not damage the applique' or the liftgate glass when removing the applique' from the liftgate glass.
4. Remove the screws that retain the applique' to the liftgate glass.
5. With a flat-bladed tool, carefully remove the applique' from the liftgate glass.
6. Remove the CHMSL harness grommet from the roof panel.
7. Disconnect the CHMSL harness connector and remove CHMSL applique' from the vehicle.
8. Using a 1/4" die grinder and Scotch-Brite(R) Disc, 3M(R) P/N 07481, remove excess material from the applique'.
FIGURE After Modification
9. Paint the applique' to match.
Important:
If the original part is used, it is important to seal (clear coat) the edge to protect the clear coat from lifting.
10. Remove the old adhesive from the underside of the applique'.
11. Clean the application area of the CHMSL applique' with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984, or equivalent, and dry thoroughly using a clean low lint towel or towelette.
12. Apply double-sided adhesive tape, 3M(R) P/N 06397, or equivalent, to the underside of the CHMSL applique.
13. Remove the old adhesive from the liftgate glass.
Important:
The installation area of the liftgate glass must be clean and dry. Any airborne dust, oils, etc., may contaminate the glass or the applique' adhesive, and reduce the bond of the tape. DO NOT use commercial glass or surface cleaners. These may contain petroleum. The glass surface temperature should be no lower than 21°C (70°F) and not exceed 38°C (100°F).
14. Clean the application area of the liftgate glass with Isopropyl Alcohol (rubbing alcohol), 3M(R) P/N 08984, or equivalent, and dry thoroughly using a clean low lint towel or towelette.
15. Apply adhesive promoter, P/N 8-12378-555-0 to the liftgate glass surface, completely wetting the applique' application area.
Important:
Use a clean low lint towel or towelette and wipe the glass, only removing the excess adhesive promoter from the liftgate glass. Do not wipe the glass dry. Allow the liftgate glass to air dry completely. The applique' must be installed within 30 minutes following the use of the promoter.
16. Allow the adhesive promoter to remain on the glass surface for a minimum of 10-seconds.
17. Attach the CHMSL wire to the connector and install the grommet.
18. Slide the liftgate glass on the hinge pins to the left in order to allow clearance for the locating hooks.
19. Remove the protective liner from the tape on the applique.
20. Attach the locating hooks on the applique' to the hinge pins.
21. Apply the applique' to the liftgate glass.
22. With the heel of your hand, and starting from center of the applique' and working outward towards each outer edge, apply even and consistent pressure ensuring complete contact of the adhesive strip to the glass.
23. Install the screws that retain the applique' to the liftgate glass
Tighten
Tighten the screws to 5 Nm (44 lb in).
Important:
The vehicle must be kept dry and at 21°C (70°F) to 43°C (110°F) for no less than 4 hours to ensure proper adhesive cure time.
24. Clean the liftgate glass and applique' area.
Parts Information
Warranty Claim Information
Use the labor operation table.
Disclaimer