Headlamp Welt - Cut/Torn
NUMBER: 08-02-00GROUP: Electrical
DATE: Feb.11,2000
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-05-99 DATED
MARCH 3, 1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN
ADDITIONAL MODEL YEAR, MODIFIED PROCEDURE, AND A NOTE ABOUT
SERVICE PARTS.
SUBJECT:
Headlamp Welt Service
OVERVIEW:
This bulletin involves replacing the headlamp welt(s) with revised parts.
MODELS:
1998 - **2000** (LH) Concorde/LHS/3OOM
SYMPTOM/CONDITION:
The headlamp-to-fender, hood, and fascia welt may become cut torn or otherwise damaged. To correct this condition it is no longer necessary to replace the headlamp assembly; the welt is now available as a serviceable part.
DIAGNOSIS:
Inspect headlamp welt for damage. Inspect mating fender/hood/fascia for cause of damage, repair as necessary. To replace welt perform the Repair Procedure.
PARTS REQUIRED:
AR(2) 05014909AA Welt, Headlamp
**NOTE:
THE HEADLAMP WELT INSTALLED AT THE ASSEMBLY PLANT CHANGED TO A MOLDED DESIGN IN JANUARY 2000 TO AID IN PRODUCTION INSTALLATION. THE WELT LISTED ABOVE SHOULD BE USED FOR ALL SERVICE REPLACEMENT NEEDS REGARDLESS OF THE STYLE WELT THE VEHICLE IS EQUIPPED WITH.**
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
1. Remove the headlamp housing assembly of the 2000 Concorde/Intrepid/LHS/300M .Ser.
2. Before removing the existing welt from the headlamp, mark the location of the welt on the lens with a grease pencil or masking tape. This is especially important in the fender and inboard fascia areas on the Concorde and LHS. Also note any areas where the welt material is "doubled-up." Depending on the fit to the vehicle being repaired, it may be necessary to duplicate this procedure.
**3. Concorde/LHS/3OOM built prior to January 2000 (Extruded Welt): Carefully remove the old welt material from the lamp by pulling it away from the lens. Do not use knives or blades to cut it, as you may damage the coating on the lens. On the Concorde and LHS it is best to start at the overlap joint on the bottom of the lamp, and on the 300M, start at the inboard edge. Note how the outboard end of the welt on the 300M is tucked under the lens clip. The lens clip can be removed with a small screwdriver. Save the clip for reinstallation (if necessary, a clip may be relocated from another location).
Concorde/LHS built starting January 2000 (Molded Welt): Remove the three screws securing the welt to the top of the lamp and unbuckle the welt from the circumference of the lens. Fill the three screw bosses/holes with silicone sealer, Mopar p/n 05010884AA, or equivalent**
4. Make sure the old welt adhesive residue is removed from the lamp. If necessary, a cloth LIGHTLY DAMPENED with isopropyl alcohol or Mopar Super Clean, p/n 04886330AA, may be used to remove the residue and prepare the surface for the new welt.
NOTE:
IT IS IMPORTANT THAT NO EXCESS SOLVENT RUNS ON THE LENS OR THE BOND JOINT OF THE HOUSING, AS THIS WILL CAUSE THE LENS TO STRESS CRACK. DO NOT APPLY SOLVENT DIRECTLY TO THE LENS.
5. Carefully peel away about 1 foot of the plastic strip that covers the adhesive on the new welt. Do not remove it all at once.
6. Begin to apply the welt material to the lamp by lightly pressing the adhesive strip to the lens in the same position as the old welt. On Concorde and LHS, the seam should be at the bottom of the lamp, while on the 300M it is best to start the welt application on the inboard upper corner of the lens. DO NOT STRETCH THE WELT MATERIAL WHEN APPLYING. Peel away the plastic strip on the adhesive as required while you work your way around the perimeter of the lamp. Follow the guide marks that you made in step 2. If the welt appears to be crooked, reposition it slightly before you press it down too firmly. When you get to the beginning of the welt on the Concorde and LHS, leave enough welt material to overlap the ends at least 1/2 inch, and trim it with a sharp knife or scissors. Tuck the end into the open section of the welt where you originally began the application. On the 300M, trim the end so that you have at least 1 inch. extending beyond the clip that you removed in step 3. Replace the clip so that it holds the welt in the correct position.
7. With the welt correctly positioned, press down firmly around the perimeter. Use a seam or molding application roller to obtain a good bond.
8. On the Concorde and LHS lamps, part of the leftover welt material may have to be used to "double up" the welt in the fender and/or the inboard fascia area in order to fill the gaps to the body completely. The old welt may have had this in place, as mentioned in step 2. If required, remove the plastic backing and apply as required. Minimizing the stretching referred to in step 6 will reduce the need for "doubling-up."
9. Install the headlamp housing assembly to the vehicle, being careful to adjust the lamp fastener in the outboard attachment hole so that the fit to the fender opening is correct.
10. Be sure to position the fascia so that the fit to the headlamp welt is correct. On LHS and Concorde, the forward edge of the welt along the bottom of the lamp should extend ABOVE the fascia, not below it.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-51-06-91/92 Welt Headlamp Replace 0.4 Hrs.
Right Or Left
FAILURE CODE: P8- New Part