Dash Cowl Panel - Cracking
90isuzu02 BULLETIN NUMBER SB90-11-001ISSUE DATE March 1, 1990
GROUP BODY
I-MARK (JT) DASH COWL PANEL CRACKING
VEHICLES AFFECTED
All I-Mark (JT) models.
SERVICE INFORMATION
Individual driver habits may result in the dash cowl panel cracking in the area of the clutch cable pass-through. An improved clutch cable spacer can be affixed to the panel (Figure 1) to repair such damage and prevent further cracking.
Figure 1:
Figure 2:
SERVICE PROCEDURE
Refer to Figures 1 and 2.
1. Remove the clutch cable from the dash cowl panel.
2. Remove the existing clutch cable spacer by grinding it off.
3. Enlarge the clutch cable hole to 22 mm, without changing the center of the hole.
4. If necessary, repair the cracked panel by welding.
5. Place the patch assembly in position on the inner (engine compartment) side of the dash cowl panel.
6. The patch assembly may be secured in place by installing POP rivets, or by welding.
If using POP rivets to hold the patch assembly in place: Scribe the # 1 and # 3 holes onto the firewall, using the patch assembly as a template.
7. Install the patch assembly, using one of the following procedures:
a. Instill SD64BSLF POP rivets (available from Emhart Fastening Systems) into hole # 1 and hole # 3 of the patch assembly.
OR
b. Weld the patch assembly into place at 9 points as shown in Figure 2.
8. Apply a bead of body sealant completely around the outside edges of the patch assembly.
9. Reinstall clutch cable.
PARTS INFORMATION
Part No. Description
8-97020-429-0 Clutch Cable Patch Assembly
FLAT RATE MANUAL UPDATE INFORMATION
OPERATION
OPERATION NUMBER TASK TIME
Dash Panel Spacer 110299 Install 1.2