Front/Rear Sunroofs - Rattle Noise
27/10/9576/38/95/US
SUBJECT:
Sunroof Rattle
MODEL:
Discovery
AFFECTED VEHICLES
LP
LH
LJ from 081991
LD
DETAIL
A rattle heard coming from either the front or rear sunroofs can be caused by gaps between the roof bows and the roof panel itself. This allows the roof panel to vibrate which in turn induces a rattle in the sunroof mechanism. This rattle is only evident when the sunroof is fully open.
ACTION REQUIRED
Upon custom complaint of a rattle in the sunroof area, road test the vehicle to confirm the rattle is coming from the roof area. If so, follow the procedure detailed below.
PARTS INFORMATION
Sikaflex 255FC - Sealer/Adhesive
PROCEDURE
1. Check that the sunroof glass screws are secure. If not, re-torque to 1.8 - 2.2 lb.ft (2.5 to 3.0 Nm).
2. If the sunroof is still rattling, remove the headliner.
3. Check to see if there is a gap between any of the roof bows and the roof (see illustration opposite), or if there is any evidence of flex between roof and roof bows.
4. Fill any gaps with an adhesive/sealer such as Sikaflex 255FC. Pay particular attention to the center of the roof/roof bow area. NOTE: it may be necessary to remove the sunroof assembly to gain access to apply the sealer.
5. Apply sufficient sealer to fill all the gaps.
6. Allow the sealer to cure (over night).
7. Replace the sunroof if removed.
8. Road test vehicle before refitting the headliner.
9. Refit the headliner.
WARRANTY
Normal warranty policy and procedure apply
COMP. CODE
9K2K
SRO
76.82.89/30 - Check and tighten screws - 0.60 hr
76.82.89/33 - Remove headliner and apply sealer - 3.05 hr
76.82.89/34 - Remove headliner, sunroof and apply sealer - 3.65 hr