Liftgate - Creaking When Closing
NO.: 23-23-93GROUP: Body
DATE: Apr. 16, 1993
SUBJECT:
Repair Of Cracks At Attachment Points Of Liftgate Prop Rods
MODELS:
1989-1990 (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town & Country
1984-1988 (S) Caravan/Grand Caravan/Voyager/Grand Voyager
SYMPTOM/CONDITION:
The customer may complain of a creaking noise when closing the liftgate, or cracks may be visible in the "D"-post and/or liftgate at the prop rod attachment point(s).
DIAGNOSIS:
Visually inspect suspect area for cracks.
PARTS REQUIRED:
1 Reinforcement, Prop Rod Attachment Crack Repair Kit 4746529
Reinforcement Kit contains:
2 Reinforcement, Liftgate
4 Rivet, Structural
1 Reinforcement, Left "D"-post
1 Reinforcement, Right "D"-post
1 Instruction Sheet and Template
REPAIR PROCEDURE:
This bulletin involves installing reinforcements at the cracked areas of the "D"-posts and liftgate.
BODY HALF
1. Open and raise the liftgate, then support the liftgate with an appropriate stand.
2. Remove the prop rods.
3. Remove the interior trim from the "D"-posts.
4. Cut out two templates (attached to instructions in parts kit). Position the templates by aligning the long inboard edge of the templates with character line of the "D"- posts and the threaded hole the prop rods attach to. Mark the "D"-posts by tracing around the outside edges of the template.
5. Thread an 8M bolt (or the prop rod attachment bolt) into the prop rod attachment hole in the "D"-posts. This step is to provide a way to hold the part of the "D"- posts that are going to be cut out in step 6 and prevent them from dropping down into the "D"-posts and causing a rattle condition after the repair is completed.
6. Remove the liftgate weatherstrip from the pinch weld flange in the area next to the prop rod attach points and secure away from the work area.
7. Remove the quarter window latch mechanisms.
8. Feed any slack in the wiring and/or hose routed through the top of the "D"-posts so that it will not be pulled tight against the portion of the "D"-posts that will be cut in step 9. This will reduce the possibility of damage to the wiring and/or hose during the cutting process.
9. Using an oscillating saw, cut off wheel, tin snips, etc. cut the lines marked on the "D"-posts. Remove and discard the cut out pieces.
10. Inspect the wiring and/or hose in the "D"-posts for damage. Repair as necessary.
11. Secure the wiring and/or hose routed through the top of the "D"-posts so that they will not be damaged during the welding process.
12. Clamp the "D"-post reinforcements to the "D"-posts.
13. Protect the interior trim (headliner, carpet, seats, etc.) from welding sparks by using welding blankets or removal of the interior trim.
14. Fusion weld (CO2, TIG, MIG etc.) the reinforcements to the "D"-posts. Locate the welds at the 10 notches in the reinforcements. Make the welds approximately 3/4 of an inch long.
15. Grind off any weld high spots, especially along the weatherstrip pinch weld flange.
LIFTGATE HALF
16. Pry and/or hammer as necessary around the prop rod attachment points to eliminate any gap(s) in the sheetmetal.
17. Protect the interior trim from welding sparks by using welding blankets or removal of the interior trim.
18. Weld the cracks shut.
19. Grind off any high spots.
20. Position the liftgate reinforcements using the screw hole and the edge of the liftgate as a guide. Mark the small holes positions on the liftgate.
21. Center punch then drill 17/64 inch holes at the locations marked in step 20.
22. Attach the reinforcements to the liftgate with the structural rivets (P/N 6034573) included in the kit.
23. Weld the reinforcements to the liftgate in four places as illustrated.
REASSEMBLY
24. Refinish and paint the repaired areas.
25. Reinstall the liftgate prop rods.
26. Reinstall the liftgate weatherstrip.
27. Reinstall the quarter vent window latches.
28. Reinstall the interior trim.
POLICY: Information Only
TIME ALLOWANCE:
Labor Operation No.
23-85-42-90 4.1 Hrs.
(Install Reinforcements)
23-70-42-90 2.3 Hrs.
(Refinish)
Material Allowance $21.85
FAILURE CODE: 11 - Broken or Cracked