Tailgate Lock - Rattle
DATE: Feb. -95SECTION: 8
GROUP: 83
NO: 810
Rattle from tailgate lock
855
REFERENCE: TP 8201201, SECTION 8 (82-6, 88), INTERIOR, EXTERIOR, 850 1993 This service bulletin replaces Tech-DCS Gram 83-02 dated 4/14/94.
Rattle from tailgate lock
There are 3 reasons the tailgate locking mechanism on 855 cars can rattle:
1. The lock rivets are loose
2. The striker plate has been deformed and/or requires adjustment
3. The lock requires greasing
From chassis number 88348 on 855 cars have been revised to address the conditions listed above.
On 855 cars with chassis numbers from 33594, a new injection molded plastic lock with reinforced rivets has been introduced. If the lock rattles on cars with a higher chassis number than 33594 the lock should not be changed, instead follow the operations in method 2 in this service bulletin.
Often the application of grease will help cure the problem, but the steel frame should always be adjusted as in method 2 when greasing, to ensure the rattle does not reoccur.
Note:
If the lock or striker plate need to be replaced on cars wan lower chassis numbers than 88348 both lock and striker must be changed. This is because the striker eye is party coated with black plastic.
The complete lock has the P/N 9152637-6
The lock striker has P/N 9152638-4.
METHOD 1 (VIN LOWER THAN 33595)
Check if the rivets have loosened by trying to turn the outer lock plate against the inner. If there is any movement then the riveted joint is loose. Replace using P/N 91526374 and lock striker P/N 9152638A. If the car chassis number is lower than 50370, also replace the carrier using P/N 91523886 (B in the illustration).
NOTE!
On cars with chassis number 25000 or lower the existing link 3512703-4 must be replaced with a new link P/N 6846659-8 when replacing the lock (A in the illustration).
METHOD 2 (VIN HIGHER THAN 33594)
Over a period of time the plate guides can bend slightly outward and fail to engage fully.
When the steel frame needs to be adjusted, the following repair is suggested as an alternative to replacing the bracket:
Remove:
- rocker panel (door sill) molding
- lock striker
- rubber stop.
CHECK WIDTH MEASUREMENTS
- Adjust as required to the measurements given in accompanying drawing.
WELD LOCK STRIKER PLATE AS SHOWN
- Cover the area around the bracket wire fire resistant material to protect the car.
- Use a MAG welding unit
- Begin weld approx. 10 mm (318") in on the bracket Weld 10 mm (3/8") on the outer sides and round the corners (A).
- Grind weld down, but not so that it weakens the strength of the weld.
USE PRIMER ON THE BRACKET
- First apply anti-corrosion paint, then graphite grey topcoat
REINSTALL STRIKER WITH RUBBER STOP
- Adjust lock striker as far as possible inward but not so far that excessive force is required to close the tailgate.
ADJUST TAILGATE
- Adjust tailgate as per SB 8-84-811
NOTE!
The tailgate can be located max. 4 mm (5/32") inside the lower edge of the rear light clusters and never outside the edge. (Normally the tailgate should be in line with the lamp clusters.)
Install rocker panel (door sill) molding
Apply grease P/N 1161246-2 (50 g. tube) on:
- Rubber bumps
- Striker plate side catches and the striker locking catch
- On the lock catch rim.
WARRANTY STATEMENT: Claims may be submitted under the New Car Limited Warranty when a manufacturing defect is present using claim type: 01
OPERATION NO. LABOR DESC. TIME
83434-2 Tailgate lock replace 0.3 hr
83435-2 Rubber bump on tailgate, replace 0.1 hr
83912-2 Tailgate striker plate, welding reinforcement 0.7 hr