Campaign - Power Seat Binding
No: H384Ref: WSM
Replaces: 76/03/99/NAS
Issue: 1
Date: 09/28/99
Service Action
Power Seat Mechanism Binding
AFFECTED VEHICLE RANGE:
DISCOVERY Series II (LT) Up to YA243304
(Vehicles equipped with power seats)
SITUATION:
POWER SEAT BINDS
A customer may complain of binding or inoperative Discovery Series II power seats. This problem generally occurs when the seat is at its rear-most position. Mechanism lubrication and seat frame alignment issues are the cause of these symptoms.
RESOLUTION:
NOTE:
This Bulletin replaces and supersedes the procedures contained in TIB 76/03/99/NAS.
CLEAN, LUBRICATE AND ALIGN SEAT DRIVE MECHANISM
At the first available opportunity (next service or during warranty work) perform the following seat-related repairs.
^ Remove both front seats and disassemble the seat gear-drive mechanism.
^ Wire brush the coating from the threaded shaft, and apply a new specification grease.
^ Install the seats using the procedures and prescribed bolt torque. Install spacers as required.
PARTS INFORMATION:
LRN0002LABEL Campaign label Qty 1
LRNR600D EVO-LUBE R600-B Qty as required
FX11047LW Star washer Qty 4 required
WA110061L 2mm spacer Qty as required
Locally sourced:
^ Tie Wrap Qty 1
WARRANTY CLAIMS:
H384 Time 1.5 hrs.
Remove both left and right front seats and lubricate gear-drive mechanisms, secure pre-tensioner harness and install seat
Material Allowance is incorporated into the time allowance for repair
FAULT CODE: F
Normal warranty policy and procedures apply
Reimbursable during the term of the warranty only
REPAIR PROCEDURE
REMOVE FRONT SEATS AND DISASSEMBLE DRIVE MECHANISMS
1. Disconnect battery ground cable.
2. Refer to WSM. 78.10.43.99, and remove both front seats.
CAUTION:
Care must be exercised throughout this procedure to keep seating surface clean and protected. For access to mechanical seat components, seats should be placed upside down on a clean work-surface. This will prevent damage to seats and facilitate the required work on the underside of the removed seats.
3. Place seats upside down on a clean work surface.
4. Refer to WSM 78.70.25 and disassemble seat drive mechanism as follows:
^ Using an 8 mm Allen drive tool, remove both screw drive shaft-securing bolts. (Figure 1, Reference 1)
^ Slide seat runners fully forward to the front stops to gain access to gearbox securing pins. (Figure 1 Reference 2)
NOTE:
When tapping out gearbox securing pins, star lock washers and plastic spacers will fall loose. It is essential that original plastic "C" spacers be retained, as these are not available as separate parts.
^ Slide remote fusebox and relay electrical connectors off of seat frame and move aside to a protected location.
^ Using a mallet, tap out both gearbox-securing pins.
^ Discard used star washers and set aside four plastic "C" spacers (two from each side).
^ Remove both gearbox assemblies simultaneously complete with connecting driveshaft.
^ Disassemble connecting drive shaft from motor and slave gearbox.
CLEAN AND LUBRICATE EACH SCREW DRIVE SHAFT
CAUTION:
Dry lubricant material should be cleaned from the entire length of the screw drive, but it is particularly important that the first 60mm (2.5 inches) of the screw drive (measured from the gearbox end) be thoroughly and carefully cleaned.
1. Turn shaft nut to the screw drive front stop.
2. If a nylon washer is installed next to gearbox on the slave side screw drive, remove and discard.
3. Using a wire brush on a bench grinder, remove all traces of dry lube (black film appearance) from the screw drive, paying particular attention to the first 60 mm (2.5 inches) adjacent to gearbox. (Figure 2)
4. Apply a light bead of EVO-LUBE R600-B to the entire length of the cleaned shaft.
ASSEMBLE POWER SEAT DRIVE MECHANISMS
CAUTION:
Proper alignment of gearboxes and connecting driveshaft is critical to drive mechanism performance. Each gearbox/shaft nut assembly must be correctly positioned prior to installation.
NOTE:
When aligning the top face of the screw shaft nut with the gearbox, there will be some resistance. It may be necessary to rotate the screw shaft to achieve both proper orientation of the nut, and a snug fit between the nut and gearbox.
1. Turn screw shaft nut back down the screw drive shaft until it is snug against the gearbox.
2. Verify that the top face of the screw shaft nut is inline with the gearbox as shown in Figure 3.
3. If nut is not aligned, rotate screw shaft slightly to obtain correct alignment.
4. Verify shaft nut is snug (but not tight) against the gear housing.
5. Assemble motor and slave gearbox to connecting driveshaft and install onto seat frame.
6. Position and install gearbox-securing pins with two spacers on each side.
7. Install new star locking washers on each gearbox-securing pin. (Figure 4)
8. Slide seat runners back to the rear stop so that the shaft nut and bolt hole are properly aligned.
9. Apply Loctite 262 to screw shaft-securing bolts.
WARNING:
Proper torque on screw shaft-securing bolts is essential to seat mount integrity.
10. Install both screw shaft-securing bolts, and torque to 30 Nm (22 lbf. ft).
SEAT MOUNTING PROCEDURE AND FASTENER TORQUE
CAUTION:
Tie wraps must be installed in both locations "A" and "B" as depicted in Figure 5 for proper location and protections of the seatbelt pre-tensioner harness.
1. Secure the left side front seat pre-tensioner wiring harness to the seat frame with two tie wraps as shown in the illustration. (Figure 5)
2. Ensure all harnesses are clear of moving parts.
3. Connect all electrical harnesses to seat.
NOTE:
No more than 2 spacers for a total of 4 mm (0.160 in.) per mounting point (Position 2 or 3) may be used in the following steps.
4. Install the Position 1 bolt and tighten to 45 Nm (33 lbf.ft.). (Figure 6)
5. Measure the space between the seat frame and floor pan at Position 2.
6. Install a maximum of two 2 mm (0.080 in) spacer washers on the Position 2 fastener between the seat frame and floor pan to fill the measured gap.
7. Install the Position 2 bolt and tighten to 45 Nm (33 lbf.ft.).
8. Measure the space between the seat frame and floor pan at Position 3.
9. Install a maximum of two 2 mm (0.080 in) spacer washers on the Position 3 fastener between the seat frame and floor pan to fill the measured gap.
10. Install the Position 3 and tighten bolt to 45 Nm (33 lbf.ft.).
11. Install the Position 4 bolt and tighten to 45 Nm (33 lbf.ft.).
12. Connect battery ground cable.
13. Verify unhindered seat travel as follows:
^ With engine running, cycle the unoccupied seat from the fully forward position to the fully aft position.
^ Verify smooth seat movement during travel.
^ Verify no binding at the end of rearward seat travel.
INSTALL CAMPAIGN LABEL
NOTE:
Campaign labels may have multiple Campaign numbers written on them if multiple campaigns are performed at the same time.
1. When all specified repairs have been accomplished, prepare the campaign label (LRN0002LABEL) as follows:
a) Place the label on a hard surface.
b) Use a ballpoint pen to neatly write/scribe in the bare aluminum areas of the label the following information:
^ Service Action code "H384"
^ Your retailer code
^ The date of repair
2. Clean all grease and dirt from the radiator support member.
3. Peel the completed campaign label from the backing paper and position it on the cleaned area of the support member.
4. Roll the label with the special roller tool to ensure that the adhesive makes continuous contact with the support member surface.