Bulkhead - Squeak/Rattles or Groan Noise
910-04DATE
7/98
V8 XJ Series
MODEL
1998 MY-ON
V8 XJ Series
VIN
812256-ON
Squeak or Groan From Bulkhead Area -
Check Mounting of False Bulkhead -
Repair Procedure
Issue:
Some 1998 MY V8 XJ-Series vehicles may experience concerns of squeaks, rattles or groaning noises that seem to be coming from the area of the fascia/bulkhead. Noises may be generated from sources within the engine compartment with a vehicle in motion, which appear to occupants of the vehicle to be radiated from the fascia or bulkhead. This bulletin describes procedures to follow before performing work in the area of the fascia inside the passenger compartment.
Action:
In case of a customer complaint of the above condition, check the following possible sources, then verify the repair with a road test.
This information is applicable to both sides of the vehicle.
FALSE BULKHEAD AND BRACE
Inadequately tightened paint-clearing bolts (Illustration 1) that retain the plastic false bulkhead molding to its brace (triangular in shape) will allow the plastic to "fret" against the metal brace plate, thus generating noise which is transmitted through the bulkhead and which is irritating to the occupants.
Inadequate tightening may be caused by either or both of the following:
^ Bolts cross-threaded.
^ Sound deadening panel trapped under the bolt head(s).
DIAGNOSIS
Loosen the three bolts by one turn, then road test the vehicle. If the noise has disappeared, the source of the concern has been pinpointed.
REPAIRS
It may be necessary to perform more than one of the actions below.
1. Carefully inspect whether the sound-deadening panel material is trapped under any of the bolt heads. If necessary, loosen the bolts to allow the material to be trimmed to clear the bolt heads, then retighten the bolts.
The use of a flashlight and a mirror attached to an extension handle may be useful when Inspecting and, if necessary, trimming the sound-deadening material.
2. Attempt to retighten the three bolts. If this is impossible due to cross-threading of the bolt(s) and weld-nut(s), remove the affected bolt(s), using a hammer and chisel, (Illustration 1). (A sham blow with a chisel will easily remove a weld-nut.) Install new bolts and nuts. Apply Loctite (Part No. JLM 1748) to the threads of the bolt before installing. Retrieve and discard any weld-nut which is removed, to avoid leaving in the vehicle the source of a rattle.
It is necessary that the bolts are tighten sufficiently to provide full clamping of the plastic molding to the triangular brace plate. Due to the restricted access a specific torque wrench setting is not appropriate.
3. Conduct a brief road test to verify the repair.
4. In case of a remaining squeak or groan apparently from the same area, hammer the flange of the plate which is spot-welded to the bulkhead and to which the triangular brace plate is attached. Use a hammer and drift to push the flange towards the bulkhead, particularly in the area of the recess towards the top of the plate.
Parts Information:
Warranty Information: