Sunroof - Ratcheting Noise When Opening Or Closing

NUMBER: 23-49-99

GROUP: Body

DATE: Nov. 12, 1999

SUBJECT:
Sunroof Makes A Ratcheting Type Noise When Opening Or Closing

OVERVIEW:
This bulletin involves replacing the motor bracket drive tube locator.

MODELS:
1996 - 1999 (PL) Neon

SYMPTOM/CONDITION:
The sunroof makes a ratcheting type noise while opening or closing. The noise is most noticeable at the full open or full closed position. The noise is caused by an oversized drive tube locator allowing the motor gear to override the drive tubes.

DIAGNOSIS:
While opening and closing the sunroof listen for the ratcheting noise, if the noise is heard perform the Repair Procedure.

PARTS REQUIRED:
1 05016539AA Locator, Motor Bracket Drive Tube
4 04856501 Tie Strap

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 sunroof module following the procedure in the 1999 Neon Service Manual (Publication No. 81-270-9125) page 23-14.

2. Ensure that the sunroof module is in the full closed position and remove the sunroof motor from the sunroof module assembly.





3. With a 3 mm (.012 in.) drill bit remove the rivet holding the locator to the motor bracket (Figure 1).





4. Place the new locator over the drive tubes and secure with the rivet provided with the new locator. Make sure that the spring insert is in place under the bracket (Figure 2).

5. Install the motor. Ensure that the motor is positioned in the same place it was removed from.

NOTE:
WHEN INSTALLING THE SUNROOF MODULE INSURE THAT THE DRAIN TUBE CLAMPS ARE INSTALLED IN THE POSITION THEY WERE REMOVED FROM DURING DISASSEMBLY. USE A TIE STRAP OR EQUIVALENT TO SECURE THE DRIVE TUBES IN THE SAME LOCATIONS THE CLAMPS WERE REMOVED FROM DURING DISASSEMBLY.

6. Install the sunroof module following the procedure in the 1999 Neon Service Manual (Publication No. 81-270-9125) page 23-14.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: 23-30-64-92 1.7 Hrs.

FAILURE CODE: P8 - New Part