Noise Related
Application:VIN Breakpoints: NL200310
CONDITION:
The following three conditions may exist causing squeak and rattle in the number one bow area.
(1) Rattle between the number one bow and the side rails.
(2) Squeak between number one bow and number one bow garnish molding.
(3) Rattle between number one bow boss and number two bow pivot link.
CORRECTION:
Perform all the following corresponding corrections.
CORRECTION FOR CONDITION (1):
Add a wave washer P/N 12520633 and *Loctite Removable Threadlocker # 242 to provide tighter fit of number one bow and side rails.
1. Lower the top halfway. Refer to 1992 Service Manual Section 10-8 for removal of the number one bow garnish molding and remove.
2. Refer to Figure 1, left side view shown, right side similar. Remove Allen drive bolt, one per side, attaching side rails to number one bow.
NOTICE:
Do not remove both Allen drive bolts at the same time. Reinstallation would be more difficult.
3. Add one washer P/N 12520633 to each bolt and apply Loctite Removable Threadlocker # 242 to the threads.
4. Reinstall bolts with washers and Loctite.
CORRECTION FOR CONDITION (2):
Replace foam tape on the top cover retainer with loop portion of *3M # 06480 Scotchmate Hook and Loop Fastening System. Cut strip in half and install a strip inboard of each latch location. (Refer to Figure 2).
1. Remove old foam tape from garnish molding.
2. Refer to Figure 2 which shows an exploded assembly, but only the garnish molding needs to be removed to access the old tape. Cut loop portion, of 3M # 6480 Hook and Loop Fastening System, in half and install a strip inboard of each latch location along the length of the top cover retainer.
3. Trim away any excess "loop" material.
CORRECTION FOR CONDITION (3):
Saw or grind off boss. File any burrs and paint cut area.
NOTICE:
Protect top cover, backlite and any exposed surfaces from metal filings. Use cardboard and tape, paint drop cover, etc. to protect exposed surfaces.
1. Refer to Figure 3. Locate bosses at the rear outboard sides of number one bow. Use a small air body saw or 90 degree grinder to remove the bosses. Cut flush to the number one bow surface.
2. File any burrs or rough areas. Use black exterior touch-up paint P/N 1050335 on the cut/ground areas. Follow paint instructions for drying time.
3. Install garnish molding.
4. Raise and latch the top.
LABOR OPERATION:
T1869
TIME ALLOWANCE:
1.3 HRS. Total Time
NOISE RELATED (II)
Application:
1991
CONDITION:
Squeak at header inner trim garnish molding.
CORRECTION:
Add 546 mm (21.5") of 3M # 5430 Squeak Reduction tape to garnish molding.
1. Refer to Figure 4. Remove sunshade screws and sunshade.
2. Remove header inner trim garnish molding screw.
NOTICE:
Use care to prevent cracking or marring of garnish molding during removal and reinstallation.
3. Loosen "A" pillar inner garnish molding upper screw (left and right side).
4. Carefully shift header garnish molding rearward and out of the latch plate. Then slide header garnish molding up and out of the "A" pillar inner garnish molding.
5. Note Figure 4, View B. Apply 546 mm (21.5") of 3M # 5430 tape to header garnish molding inner face between the latch plate locations.
6. Trim any tape protruding from the molding flange. Reinstall the header inner trim garnish molding.
7. Install and tighten "A" pillar inner garnish molding screws. Carefully shift edges of header garnish molding forward and between edges of the latch plates while slipping upper lip to outside of header edge. Install and tighten header garnish screw.
IMPORTANT:
The sunshade should be mounted so that the larger pivot hole is nearest to the front of the vehicle when the sunshade is attached. Check the fit for the sunshade. The screws should fit in evenly with no difficulty.
8. Install sunshade aligning mounting holes, installing screws and tightening.
LABOR OPERATION:
T1871
TIME ALLOWANCE:
0.6 HR.
NOISE RELATED (III)
Application:
1992
CONDITION:
Number three bow snaps past number four bow when top is lowered and stowed.
CORRECTION:
Relocate number four bow. Refer to Figure 5.
1. Unlatch top at front header.
2. Unlatch and raise number five bow to vertical position and push forward.
3. Pull number four bow rearward of the number five bow. Number four bow springs will cause a toggle affect, holding it in this position.
4. To keep the number four bow rearward of the number five bow, place a wood block or equivalent between the number four and five bow at one side of the vehicle where the number four bow attaches to the number five bow.
5. Push the number four bow forward until the toggle action of the springs causes the bow to move forward and trap the wood block.
6. Both number four and five bows should now be forward of the number three bow.
7. This positioning will allow enough flexibility in the top cover to access the stay pads.
8. Mark the side stay pad staple locations with a grease pencil. Refer to Figure 5. Mark number four bow on the inboard side of pad. This will aid positioning of the pad at the new location.
9. Detach side stay pad staples from number four bow.
10. Mark staple locations on the rear stay pads with a grease pencil. Mark number four bow on outboard side of pad. This will aid positioning of the pad at the new location.
11. Detach rear stay pad staples from number four bow.
12. Measure and mark new staple locations 6.5 mm (1/4") rearward of old locations on both pads with a grease pencil.
13. Staple the rear and side stay pads (in that order) to the number four bow at the new staple locations, 6.5 mm (1/4") rearward, marked previously with a grease pencil. Note alignment marks on number four bow.
14. Remove wood block and toggle number four bow forward of number five bow.
15. Unlatch and raise tonneau to vertical position.
16. Lower top to ensure that snap is eliminated.
17. Raise and relatch top.
LABOR OPERATION:
T1873
TIME ALLOWANCE:
0.6 HR.