Headlights - Moisture Inside
TSB 04-13-36/12/04
BODY - HEADLAMP - MOISTURE IN HEADLAMP
FORD:
2001-2003 Explorer Sport
2001-2004 Explorer Sport Trac
2002-2004 Explorer
ISSUE
Some 2001-2003 Explorer Sport, 2001-2004 Explorer Sport Trac, and 2002-2004 Explorer may exhibit condensation build up inside either headlamp assembly.
ACTION
To service, seal the headlamp assembly per the following Service Procedure.
SERVICE PROCEDURE
NOTE
DO NOT PERFORM THIS PROCEDURE IF THERE IS STANDING WATER INSIDE THE HEADLAMP ASSEMBLY AND/OR VISIBLE WATER SPOTS OR STAINS IN THE HEADLAMP LENS, BEZEL, REFLECTORS, OR TRACK THAT WILL NOT WIPE CLEAN. REPLACE THE HEADLAMP FOR THESE CONDITIONS.
NOTE
DO NOT PERFORM THIS PROCEDURE IF THE HEADLAMP ASSEMBLY IS DAMAGED DUE TO COLLISION/ACCIDENT.
1. Remove the headlamp assembly from the vehicle. Refer to Workshop Manual, Section 417-01.
2. Remove the bulbs from the headlamp assembly.
3. Using a fan, blow air into the headlamp housing through the bulb openings for ten (10) minutes to dry out any moisture that may be present.
NOTE
DO NOT USE SHOP AIR TO DRY OUT THE HEADLAMP. SHOP AIR CONTAINS MOISTURE AND OIL DROPLETS THAT MAY CONTAMINATE THE INSIDE SURFACE OF THE LENS.
4. Remove the four (4) metal retaining clips from the top and bottom of lamp. Note location and save clips for reinstallation after repair (Figure 1).
NOTE
HANDS MUST BE CLEAN AND FREE OF GREASE AND DIRT BEFORE CONTINUING WITH THIS REPAIR. HEADLAMP SURFACE CONTAMINATION WILL PREVENT GOOD TAPE ADHESION.
5. Wipe clean the headlamp assembly with a shop towel around the entire glue track area (seam between the clear lens and metallized lamp housing).
6. Inspect entire glue track for excess sealer expulsion, especially in corners. If there is any sealer expelled from the track, carefully trim excess sealer with a sharp knife, taking care to not damage the chrome surface of the housing (Figure 2).
7. Clean the glue track area with isopropyl alcohol.
NOTE
THE REMAINDER OF THE SERVICE PROCEDURE MUST BE PERFORMED AT A TEMPERATURE OF 60°F (15°C) MINIMUM.
8. Position lamp for repair on a workbench on a clean cloth or shop towel to prevent scratching the lens, bottom of lamp facing up, lens facing toward you, and housing facing away from you.
9. Precut pieces of Crest Crystal Clear Seam Tape to the appropriate length:
^ For Explorer cut a piece 115 cm (45").
^ For Explorer Sport and Sport Trac cut a piece 97 cm (38").
NOTE
USE 1" WIDE CREST CRYSTAL CLEAR SEAM TAPE, CREST PART NUMBER RT-C1. AVAILABLE AT NORMAL BODY SHOP SUPPLY SOURCES OR AT TOLL FREE NUMBER, U.S. AND CANADA, 1-800-822-4100.
NOTE
TAPE MUST BE APPLIED IN ONE (1) CONTINUOUS PIECE.
NOTE
ON TOP OF THE EXPLORER 4 DOOR HEADLAMP, THERE IS A TAB ON THE HOUSING AND A TAB ON THE LENS THAT MUST BE COMPLETELY COVERED BY TAPE TO OBTAIN A SATISFACTORY REPAIR. REFER TO (FIGURE 1). WHEN POSITIONING THE TAPE AT THE TABS, BIAS THE MIDDLE OF THE TAPE TOWARD THE TAB OVER APPROXIMATELY 25.5 MM (1") BEFORE REACHING THE TAB. COVER THE TAB, THEN TRANSITION BACK TO EVENLY APPLYING THE TAPE TO BOTH LENS AND HOUSING. INSPECT THE TABS TO MAKE SURE THE TAPE COMPLETELY SEALS THE LENS AND HOUSING.
10. While peeling backing paper off the tape, approximately 8-15 cm (3-6") at a time, apply the tape to the seam between the lens and housing, starting at bottom center of lamp (Figure 3). Position the middle of tape over glue track (seam), so tape is evenly applied to both lens and housing. Stretch tape slightly when applying, particularly around the corners. This is important to minimize tape bunching around the corners. It is recommended that tape be applied first to the chrome body, then wrapped over onto the lens to minimize trapping air bubbles. Continue applying tape around entire edge of lamp until reaching the starting point. Overlap tape about 25.5 mm (1"), and trim off excess tape.
11. Press down tape securely around entire edge to assure adhesion along entire repair area, particularly at the final overlap joint. A finger or small blunt tool should be used. A good tape seal is essential to a lasting repair.
12. Reinstall the four (4) lens retaining clips over the tape repair. If excess tape thickness prevents clip installation, carefully trim back edge of tape on housing side ONLY to permit clip installation (Figure 1).
13. Reinstall the light bulbs.
14. Reinstall headlamp assembly.
PARTS BLOCK
WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
041303A Reseal One 04.Hr.
Headlamp
Assembly
(Includes Time
To Remove
And Install
Headlamp)
041303B Reseal Both 0.7Hr.
Headlamp
Assemblies
(Includes Time
To Remove
And Install
Head lamps)
DEALER CODING
CONDITION
BASIC PART NO. CODE
13007 63
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