Entertainment System - Rear Seat DVD Player Rattling

TSB 04-24-1

12/13/04

RATTLE OR VIBRATION FROM REAR SEAT
ENTERTAINMENT SYSTEM DVD PLAYER - DEALER
INSTALLED UNIT

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 dealer installed DVD entertainment system, may exhibit a rattle/vibration from the rear seat entertainment system DVD player while driving over rough surfaces.

ACTION
Install a reinforcement bracket kit. Refer to the following Service Procedure.

SERVICE PROCEDURE

NOTE
EYE AND HAND PROTECTION IS RECOMMENDED 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 the four (4) center screws (flip DVD screen down for access), one (1) screw front center of DVD player, and unplug the electrical connectors.

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 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 DAMAGE.

NOTE
FOR THE REMAINDER OF THIS PROCEDURE WHEN DRILLING IS REQUIRED, USE A DRILL STOP. BEGIN BY SETTING THE DRILL STOP AT 1/2" (13 MM). 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. Prepare the TA-1 Motorcraft Metal Bonding Adhesive. Insert adhesive cartridge into the dispensing gun. Squeeze a small amount of adhesive out until each side is flowing from cartridge. This will level the plungers. Attach the mixing tip and dispense a small amount of adhesive to verify it is evenly mixed and that color is consistent.

NOTE
PERFORM STEPS 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 0.2" (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 0.2" (5 mm) beads of TA-i 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 (apply on the tangents of the reinforcement bracket so the glue will contact the moonroof bracket). (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. 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.

14. Carefully check operation of moon roof sunshade and moon roof.

15. Re-anchor DVD wire and check that all fasteners and screws are secure.

16. Reinstall headliner per Workshop Manual Section 501-01.

17. Reinstall DVD.





Parts Block

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATION DESCRIPTION TIME

042401A Install The Reinforcement 2.5 Hrs.
Bracket Kit

DEALER CODING
CONDITION
BASIC PART NO. CODE
7850244 33





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