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TSB 19/04 - BA Decklid Paint Damage
Models: All BA Falcon Sedan
Subject/Concern: PAINT DAMAGE ON DECKLID AT APPLIQUE
Cause: The sharp edge on the applique may damage decklid paint surface.
Action: Raise the applique clear of the decklid panel.
Warranty Status: Reimbursable within the provisions of the Warranty and Policy Manual.
Concern Description:
Sharp edges on the outer edge of the decklid applique may cause paint damage to sheetmetal. Vehicles with chrome appliques are more likely to incur damage, the issue can also occur on vehicles with body coloured appliques.
Service Action:
Fairmont Ghia Applique Only:
1. Refer to the workshop manual (WM 501-8-4) to remove the applique from the decklid - Note there are tw plastic clips at the bottom of the applique as well as the 6 mounting studs.
2. Clean the deck lid area previously covered by the applique and repair any paint damage. Marks can be polished out and any paint damage should be treated and brush touched.
3. Clean the back of the applique to ensure it is free from dust and moisture.
4. Remove and retain the foam washers from the two outermost studs on the applique.
5. Place one transparent 3M Bumpon on the LHS and RHS of the decklid side of the applique.
6. Reconnect wiring loom
7. Fit the applique to the deck lid - checking the 2 plastic clips at the bottom of the applique engage with the deck lid.
8. Install and tighten the two bottom nuts and the two inner top nuts. Do not install the outer nuts.
9. Fit the two foam washers removed in step 4 on the inside of the decklid over the outer studs.
10. Install two 5mm washers over the foam washers and place one drop of Loctite onto the threads of each of the outer studs.
11. Install the two outer nuts. Using a feeler gauge, tighten the two outer nuts until there is a 0.3mm ga between the applique and deck lid measured along the required edge as shown in Figure 3.
12. Adjust the outer nut tension so the minimum gap is 0.3mm.
XT, XR, Futura & Fairmont Appliques Only:
1. Remove applique from deck lid of vehicle.
2. Clean the deck lid area previously covered by the applique and repair any paint damage. Marks can be polished out and any paint damage should be treated and brush touched.
3. Clean the back of the applique and check it is free from dust and moisture
4. Remove and retain the foam washers from the two outermost studs on the applique.
5. Cut 2 x 10mm strips of the Black 3M Bumpon Tape
6. Once the deck lid paint is repaired and dry, place one piece of the tape under the outer-most RHS mounting hole on the deck lid as indicated in the picture.
7. Place the other piece of tape under the outer-most LHS mounting hole of the deck lid.
8. Reconnect wiring loom and ensure applique onto deck lid. Use feeler gauge to confirm 0.3mm gap between applique and deck lid sheetmetal. Gap length 25mm as indicated.
9. Install and tighten the two inner top nuts. Do not install the outer nuts.
10. Place the 2 foam washers removed in step 4 on the inside of the decklid over the outer studs.
11. Install two 5mm washers over the foam washers and place a single drop of Loctite onto the threads of each of the outer studs.
12. Install the two outer nuts and, using a feeler gauge, tighten the two outer nuts until there is a 0.3mm gap between the applique and luggage compartment measured along the required edge as shown.
13. Adjust the outer nut tension so the minimum gap is 0.3mm.
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