Service Procedure
SERVICE PROCEDUREThis recall will involve the inspection of rear gate stay stud bolts for proper tightening torque. The number of affected vehicles produced with insufficiently tightened rear gate stay stud bolts is expected to be very low. In some of these cases, replacement of one or both welded nuts along with both rear gate stays and stud bolts may be necessary. Replacement of the rear gate stays will only be necessary when indicated by the inspection results described in the Inspection Procedure.
Note:
Do not replace the rear gate stays unless specifically instructed to do so while following the inspection procedure.
Inspection Procedure
1) Tools required:
^ 12 MM Combination Wrench
2) Inspection procedure shown above.
The proper torque for the Stud Bolt is: 4.5 + 0.5 ft.lb. (19.6 +/- 6 Nm or 2.0 +/- 0.6 kgf-m).
Rear Gate Stay Kit Replacement Procedure
Note:
The procedure will only need to be followed if indicated by the inspection procedure.
Note:
Even if only one Rear Gate Stay welded nut requires replacement, the reat gate stay, stud bolts and 33 mm flat washer on both sides must be replaced to ensure consistent appearance.
Tools and parts kit required:
^ Electrical drill
^ Hole saw tap or drill bit (22 mm in diameter)
^ Drill bit (3.3 mm)
^ File
^ Rivet gun
^ Water paint marker
^ Nox Rust or equivalent anti-rust protection
^ Touch-up paint
^ Bolt to temporarily hold the Nut Plate (8 mm in diameter and 25 mm or longer) [The spare tire holder can be used as a substitute for a bolt.]
^ Stay RG (Rear Gate) Kit (P/No.: 63269FE210)
^ Vacuum cleaner
Replacement procedure:
Note:
Only replace one rear gate stay and related hardware at a time. Do not attempt to separate the stud bolts from the gate stay. The Stay will be permanently damaged if an attempt is made to disconnect it from the Stud Bolt.
(a) Support the tailgate in the full upright position by using a suitable devise such as an adjustable jack stand.
(b) Using a 12 mm open end wrench, remove the rear gate stay by unfastening both the upper and lower stay stud bolts.
Note:
On some models it will be necessary to remove the lower trim panel found around the lower stud bolt.
(c) Using a water paint marker, draw a 22 mm diameter circle around the existing welded nut and a 3.3 mm diameter circle on the rear gate as illustrated above. The 3.3 mm rivet hole must be drilled adjacent to the spot weld as illustrated [DO NOT drill out the spot weld!].
Caution:
The wire harness for the rear window defroster is located within the area of the tailgate to be drilled. To avoid damaging the harness, be careful not to drill deeper than necessary.
(d) Using a 22 mm hole saw or drill bit, drill a 22 mm (0.87 in) hole by centering the hole saw tap bit or drill bit within the existing welded nut. If the welded nut is found to be missing, a hole saw should not be used. Only use a 22 mm (0.87 in) drill bit to enlarge the hole.
(e) Drill a 3.3 mm (0.13 in) hole through the tailgate panel for the blind rivet at the marked position.
Caution:
The drilled areas will have sharp metal surfaces. Use appropriate care when touching these areas.
(f) Carefully remove any chips and burrs from around the holes. Use touch-up paint and anti-rust protection to preserve the unpainted metal surface. Use a vacuum cleaner to remove any metal chips from the vehicle.
Note:
Never use compressed air to remove metal chips.
(g) Temporarily insert an 8mm bolt into the Nut Plate from the Stay RG Kit.
Note:
The vehicle's spare tire holder can be used as a substitute for an 8 mm bolt.
(h) With the bolt attached, insert the Nut Plate (nut facing inward) inside the 22 mm hole.
(i) Align the rivet hole in the Nut Plate with the 3.3 mm hole in the tailgate. Insert the blind rivet through the tailgate and into the plate. Align and center the hole in the Nut Plate within the 22 mm hole. Be sure the Nut Plate is flush against the inner wall of the tailgate. Using a rivet gun, permanently fasten the rivet.
(j) Remove the holding bolt from the Nut Plate
(k) Take 2 Washers (16 mm and 33 mm in diameter) from the kit and combine them with a new Stud Bolt. The 2 washers should be installed in proper order, as indicated in the illustration above. Tighten the stud bolt to the plate. (Torque spec 4.5+0.5 ft.lb. (19.6 +/- 6 Nm or 2.0 +/- 0.6 kgf-m))
(l) Install and tighten the lower stud bolt to the body. Reinstall the lower stud bolt trim panel.
(m) If the welded nut on the opposite side is found to be normal, replace the rear gate stay with a new one from the kit using the remaining new stud bolts. Add the 33 mm washer from the kit during installation to unify the appearance. The 16 mm washer included in the Stay RG Kit should not be used. It will only be necessary when a 22 mm hole was drilled, and the Nut Plate installed. Otherwise, repeat the replacement procedure previously described to correct the opposite side.
SERVICE PROGRAM IDENTIFICATION LABEL
Type or print the necessary information on a recall identification label. The completed label should be attached to the vehicle's upper radiator support.
Additional labels are available through the Customer Dealer Services Department.
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES