Entertainment System - Rear Seat DVD Player Rattles
TSB 04-17-309/06/04
RATTLE FROM REAR SEAT ENTERTAINMENT
SYSTEM (RES) DVD PLAYER
FORD:
2003-2005 Explorer
LINCOLN:
2003-2005 Aviator
MERCURY:
2003-2005 Mountaineer
ISSUE
Some 2003-2005 Explorer 4dr/Mountaineer and Aviator vehicles equipped with a moon roof and DVD entertainment system, may exhibit a rattle noise from the rear seat entertainment system (RES) DVD player while driving over rough surfaces.
ACTION
To service, install a Reinforcement Bracket Kit. Refer to the following Service Procedure.
PARTS BLOCK
SERVICE PROCEDURE
NOTE
EYE AND HAND PROTECTION IS SUGGESTED WHEN PERFORMING THIS PROCEDURE.
NOTE
BE SURE TO PROTECT THE INTERIOR OF THE VEHICLE DURING THIS PROCEDURE.
NOTE
THE RIVETS PROVIDED IN THE REINFORCEMENT KIT MUST BE USED. DO NOT SUBSTITUTE WITH DIFFERENT SIZES OR STYLES AS THIS WILL RESULT IN INTERFERENCE WHEN OPERATING THE MOON ROOF SUNSHADE.
NOTE
KEEP THE SUNSHADE IN THE FULL FORWARD POSITION THROUGHOUT THE ENTIRE PROCEDURE TO AVOID DAMAGE.
1. Close the moon roof slide sunshade (full forward position).
2. Remove DVD unit from headliner by removing two (2) center screws (flip DVD screen down for access), one (1) screw LH side (open storage door to access), and detaching three (3) clips (1-LH, 2-RH side). Unplug electrical connector. Refer to Workshop Manual Section 415-00.
3. Remove headliner per Workshop Manual Section 501-01.
4. Remove DVD mounting bracket from moon roof assembly by disengaging the DVD wire anchors. Remove the two (2) screws on each side, two (2) screws at rear and then slide the bracket rearward to disengage the three (3) tabs at the front.
5. Place the moon roof cross member reinforcement bracket from the Kit onto the moon roof cross member, center and retain with clamps (Figures 1 and 2).
NOTE
DO NOT CLAMP ON THE MOON ROOF PANEL OR SUNSHADE PANEL ALUMINUM TRACKS AS THIS CAN CAUSE DEFORMATION AND/OR DAMAGED.
NOTE
FOR THE REMAINDER OF THIS PROCEDURE WHEN DRILLING IS REQUIRED, BEGIN BY SETTING THE DRILL STOP AT 13 MM (1/2"). THE DRILL STOP CAN BE ADJUSTED TO DRILL SLIGHTLY DEEPER IF NEEDED. DAMAGE TO THE ROOF COULD OCCUR IF DRILLED TOO DEEP.
6. Using a 1/8" drill bit with stop, drill through the moon roof cross member using the rivet holes in the reinforcement bracket as a guide (Figure 2).
7. Preparation of TA-1 Motorcraft Metal Bonding Adhesive.
a. Insert adhesive cartridge into the dispensing gun.
b. Squeeze a small amount of adhesive out until each side is flowing from cartridge. This will level the plungers.
c. Attach the mixing tip and dispense a small amount of adhesive to verify it is evenly mixed and that color is consistent.
NOTE
PERFORM STEP 8 AND 9 ON ONE SIDE AT A TIME.
8. Remove the three (3) screws that secure the side bracket to the body side roof rail and moon roof track (Figure 3). Retrieve the corresponding side bracket from the Kit. Apply 5 mm beads of TA-1 adhesive to the Kit bracket (Figure 4) and place against the existing side bracket. Secure by reinstalling the three (3) screws (Figure 5).
9. Using a 1/8" drill bit with stop, drill through all rivet holes in side reinforcement into the body side rail (Figure 6). Install rivets from Kit (Figure 7). Repeat on opposite side.
10. Un-clamp and remove reinforcement bracket and remove metal chips. Apply 5 mm beads of TA-1 adhesive to the moon roof cross member. Do not apply adhesive over the slots in the cross member (Figure 8).
11. Place the reinforcement bracket back onto the cross member. Align pre-drilled holes and clamp in place. Secure the reinforcement bracket with rivets from Kit (Figures 9 and 10).
12. Check to ensure that none of the rivets are protruding up into the path of the sunshade travel. If necessary flatten rivets on the sunshade side.
13. Take the DVD mounting bracket and place on a work bench. Using the measurements provided in (Figure 11), accurately lay out the rivet holes to be drilled. Drill holes using a 1/8" drill bit.
14. Reinstall DVD mounting bracket being sure to locate the stops of the three (3) tabs against the edge of the cross member slots, it may be necessary to slightly pry the center front edge. Secure with all screws.
15. Using the rivet holes drilled into the DVD mounting bracket as a guide, drill through both the reinforcement bracket and cross member (Figure 12). Clean out chips and secure with rivets from Kit (Figure 13).
16. Check again that none of the rivets are protruding into the path of the sunshade travel. If necessary, flatten rivets on sunshade side.
17. Carefully check operation of moon roof sunshade and moon roof.
18. Re-anchor DVD wire and check that all fasteners and screws are secure.
19. Reinstall headliner per Workshop Manual Section 501-01.
20. Reinstall DVD.
WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
041703A Install The 2.5 Hr.
Reinforcement
Bracket Kit:
2003-2005
Explorer/
Mountaineer/
Aviator
DEALER CODING
CONDITION
BASIC PART NO. CODE
7850244 33
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