Campaign - Midnight Blue Pearl Paint Warranty Extension
08-031April 3, 2010
Applies To:
2003-07 Odyssey w/Midnight Blue Pearl Paint - ALL VINs Beginning with 5FN
Warranty Extension: Paint Peeling on Dark Blue 2003-07 Odysseys
(Supersedes 08-031, dated January 8, 2010, to revise the information marked by the black bars and asterisks)
*REVISION SUMMARY
^ Under PARTS INFORMATION, the windshield side trim retainer part number was changed.
^ Under REQUIRED MATERIALS, the adhesive materials were changed.
^ Under REPAIR PROCEDURE, steps 12 thru 18 were added to the 2005-07 Odyssey Paint Repair procedure.*
BACKGROUND
American Honda is extending the warranty for Alabama-produced 2003-07 Odysseys with dark blue (midnight blue pearl, B-518P) paint. On potentially affected vehicles, the exterior paint may peel off the horizontal (flat) surfaces and in recessed areas around the glass or the sliding doors. Because of this possible problem, the following areas of exterior paint are now covered for 7 years, with no mileage limit:
^ Roof (including under the top edge of the tailgate, under the top edge of the sliding glass doors, and the top panel of the sliding doors)
^ Hood
^ Top half of the quarter panels
^ Top half of the fenders
NOTE:
All other painted areas are covered by the normal warranty of 3 years or 36,000 miles, whichever occurs first.
CUSTOMER NOTIFICATION
Notifications will begin mailing to owners of 2006-07 Odysseys the week of January 18, 2010. An example of the customer notification is at the end of this service bulletin.
Before beginning work on a vehicle, verify its eligibility by doing a VIN status inquiry and by making sure the customer has a notification letter.
CORRECTIVE ACTION
If you find paint peeling or flaking in any of the areas listed under BACKGROUND, repaint all of the listed areas.
PARTS INFORMATION
REQUIRED MATERIALS
NOTE:
The required materials are only needed on 2005-07 Odysseys.
WARRANTY CLAIM INFORMATION
NOTE:
^ Prior DSPM approval is needed before repainting areas other than those listed under BACKGROUND.
^ The labor cost for most repairs will be in the $1,800-2,000 range. If your body shop gives you an estimate of more than $2,000, prior DPSM approval is needed.
Operation Number: 9109A1
Flat Rate Time: 24.7 hours
Failed Part: P/N 62100-SHJ-A20ZZ
Defect Code: 5PT00
Symptom Code: Q7700
Skill Level: Repair Technician
INSPECTION PROCEDURE
Inspect the following areas for paint problems (peeling, flaking or, in some cases on the hood and the roof, coming off in sheets):
^ Roof (including under the top edge of the tailgate, under the top edge of the sliding doors, and the top panel of the sliding doors)
^ Hood
^ Top half of the quarter panels
^ Top half of the fenders
If you find paint peeling or flaking in any of the above areas, go to REPAIR PROCEDURE.
REPAIR PROCEDURE
NOTE:
This procedure contains repair information for you and your body shop. When you send the vehicle to the body shop, give them a copy of this service bulletin.
The repair is to repaint the roof (including under the top edge of the sliding door and the tailgate), the hood, the top half of the quarter panels, and the top half of the fenders.
This warranty extension does not include repairing of these areas:
^ Bumpers
^ Front doors
^ Sliding doors (except for top panels)
^ Bottom half of quarter panels
^ Bottom half of fenders (except for blending)
^ Tailgate
Any additional areas needing repainting require prior DPSM approval.
Primer and Paint Information
The electro-deposition primer (ED primer) is the base primer before reaching bare metal. When the paint is peeled down to the ED primer, you will see a yellow color. The ED primer turns more chalky white as it is exposed to UV light.
Wherever ED primer is exposed, you must sand down to base metal to get proper paint adhesion.
If paint color is still present in an area that needs repainting, use 400 or 500 grit sandpaper to remove all of the color coat down to the ED primer.
2003-04 Odyssey Paint Repair
1. Remove the windshield:
^ Refer to steps 1 thru 9 on pages 20-39 and 20-40 of the 1999-2004 Odyssey Service Manual, or
^ Online, enter keyword WINDSHIELD, select Windshield Replacement from the list, and do steps 1 thru 9.
2. Remove the left and right roof rails:
^ Refer to page 20-145 of the service manual, or
^ Online, enter keyword ROOF, and select Roof Rail Replacement from the list.
3. Remove the left and right roof moldings:
^ Refer to page 20-146 of the service manual, or
^ Online, enter keyword ROOF, and select Roof Molding Replacement from the list.
4. Remove the left and right quarter glass:
^ Refer to page 20-55 of the service manual, or
^ Online, enter keyword QUARTER, and select Quarter Glass and Regulator Replacement from the list.
5. Remove the tailgate:
^ Refer to page 20-136 of the service manual, or
^ Online, enter keyword TAILGATE, and select Tailgate Replacement from the list.
6. Remove the windshield washer nozzles from the hood.
7. Backtape or remove the top molding on each sliding door to expose the area to paint underneath.
8. Mask off the interior and any unaffected exterior areas as needed.
9. Using 400 or 500 grit sandpaper, sand all the areas to be repainted. Where body color is present, sand down to the ED primer. If the ED primer is exposed, sand down to bare metal.
10. Repaint the sanded areas using best shop practices. Make sure all repainted areas are properly blended into the unaffected areas.
11. After the paint has cured, reinstall all removed parts. Replace any damaged retainers.
2005-07 Odyssey Paint Repair
1. Remove the windshield:
^ Refer to steps 1 thru 9 on pages 20-66 and 20-67 of the 2005-2006 Odyssey Service Manual, or steps 1 thru 9 on pages 20-72 and 20-73 of the 2007-2010 Odyssey Service Manual, or
^ Online, enter keyword WINDSHIELD, select Windshield Replacement from the list, and do steps 1 thru 9.
2. Remove the left and right roof rails:
^ Refer to page 20-227 of the 2005-2006 Odyssey Service Manual, or page 20-265 of the 2007-2010 Odyssey Service Manual, or
^ Online, enter keyword ROOF, and select Roof Rail Replacement from the list.
3. Remove the left and right roof moldings:
^ Refer to page 20-228 of the 2005-2006 Odyssey Service Manual, or page 20-266 of the 2007-2010 Odyssey Service Manual, or
^ Online, enter keyword ROOF, and select Roof Molding Replacement from the list.
4. Remove the left and right quarter glass:
^ Refer to page 20-75 of the 2005-2006 Odyssey Service Manual, or page 20-81 of the 2007-2010 Odyssey Service Manual, or
^ Online, enter keyword QUARTER, and select Quarter Glass Replacement from the list.
5. Remove the tailgate:
^ Refer to page 1-9 of the 2005 Odyssey Model Series Body Repair Manual, or Online, do this:
- Select SEARCH BY PUBLICATION;
- Select Body Repair Manuals
- Select Odyssey;
- Select Odyssey 2005-2010 Body Repair Manual
- Select General Information;
- Select page 1-9.
6. Remove the windshield washer nozzles from the hood.
7. Backtape or remove the top molding on each sliding door to expose the area to paint underneath.
8. Mask off the interior and any unaffected exterior areas as needed.
9. Using 400 or 500 grit sandpaper, sand all the areas to be repainted. Where body color is present, sand down to the ED primer. If the ED primer is exposed, sand down to bare metal.
10. Repaint the sanded areas using best shop practices. Make sure all repainted areas are properly blended into the unaffected areas.
*11. After the paint has cured, reinstall all removed parts. Replace any damaged trim clips. If any of the windshield side trim retainers are damaged or missing, do steps 12 thru 18.
12. Remove the damaged retainers or adhesive from the body:
NOTE:
Before you install the windshield side trim on the A-pillars, any broken trim retainers (there are four retainers on each side) must be replaced. Do the following steps to replace the trim retainers. Do not use the retainer replacement steps in the service manual.
^ Using a heat gun, heat the retainer or leftover adhesive to between 212°F-248°F (100°C-120°C).
^ Use a plastic scraper to loosen the retainer from the body, and scrape off any adhesive on the vehicle.
^ Use pliers to gently pull the retainer from the body.
^ Avoid damaging the paint by applying heat gradually to the retainer.
^ Be careful not to scratch the body.
^ Avoid damaging plastic parts by removing them or covering them with aluminum foil.
13. Clean the bonding surface on the body with a shop towel dampened with 3M General Purpose Adhesive Cleaner or isopropyl alcohol. After cleaning, keep oil, grease, and water from getting on the bonding surface.
14. Test-fit the retainer in its proper mounting position. There are dimples in the body near the glass that indicate each retainer location. The paint color should be different where the retainer was removed.
15. Prepare the 3M Adhesive:
NOTE:
3M Scotch-Weld DP-100 NS Adhesive is supplied in a dual syringe plastic Duo-Pak cartridge as part of the 3M Scotch-Weld EPX Applicator system. To use:
^ Insert the Duo-Pak cartridge into the Duramix applicator gun.
^ Using light pressure on the trigger, start the plunger into the cylinders.
^ Remove the Duo-Pak cartridge cap; expel a small amount of adhesive, making sure both sides of the Duo pak cartridges are flowing evenly and freely.
^ Attach the EPX mixing nozzle to the Duo-Pak cartridge.
^ Begin dispensing the adhesive.
16. Clean the retainer bonding surface with isopropyl alcohol and let it dry, then apply an even coat of adhesive to the bonding surface.
17. Position the retainer on the A-pillar in the same location as the original retainer. The retainer should be in the corner of the A-pillar and evenly spaced against the body.
18. Press the retainer onto the body, and let the adhesive harden for 30 minutes before installing the windshield side trim. The adhesive reaches maximum hardness after 24 hours.*