Stop Lamp, Rear Windshield, Replacing

Stop lamp, rear windshield, replacing

Special tools:
951 2636 Terminal removal tool 951 2636 Terminal Removal Tool

Removing the stop lamp

Use clean gloves

To avoid customer complaints:
- gloves which leave no prints must be used
- visible surfaces, where the stop lamp can cover the rear windshield, must be kept unmarked and fault-free
- visible surfaces on the stop lamp must be kept unmarked and fault-free.

Preparatory work





Remove:
- three rear clips (1) in the headlining by twisting a quarter of a turn and pulling it out
- the rear interior lighting (2). The mounting mechanism consists of metal springs
- foam rubber (3) from the top of the headlining. Be careful. It must be reused.

Note! Note the position of the foam rubber.

- connector (4) from the stop lamp
- stop lamp wiring. Pull it out through the hole for the rear interior lighting.

Removing the stop lamp





Warning! The stop lamp must be removed from the headlining. Do this carefully as the headlining is made of corrugated cardboard.

Use a weatherstrip tool to cut as close to the stop lamp tape as possible. This is to avoid damaging the headlining.
Start with the two pieces of tape on the section that points forwards. Then cut the two pieces of tape closest to the rear windshield.
Do one corner at a time.

Identification

Identifying the stop lamp




Version 1stop lamp can be identified as follows:
- The P/N (1), stamped onto the left-hand side of the stop lamp, is 9154503
- the connector (1) on the stop lamp has a smooth surface facing downwards and an enclosing collar.
Version 2stop lamp can be identified as follows:
- The P/N (2), stamped onto the left-hand side of the stop lamp, is 9483132
- the connector (2) on the stop lamp has a smooth surface facing upwards.

Removing loose paper
Remove loose paper from the inside of the headlining where the stop lamp was located.

Note! Do not damage the headlining.

Replacing the stop lamp to the same model
If the stop lamp is being replaced with one of the same model, no modifications need to be made. Continue with: Installing components.

Replacing the stop lamp, version 1 to version 2
If a version 1 stop (brake) lamp is replaced with a version 2 stop (brake) lamp (see Identifying the stop lamp) the cables should exchange positions (change polarity). See Reversing polarity of cables.

Reversing polarity of cables

Opening the secondary catch




Use a thin screwdriver with a 3-4mm wide blade.
Carefully undo the hooks on the secondary catch.

Removing cable





Note! Transfer one cable at a time.

Press the cable terminal through the cavity.
Insert the terminal removal tool 951 2636 Terminal removal tool 951 2636 Terminal Removal Tool from the contact side into the upper cavity bank, by the cable terminal. The beveled side of the tool should face sideways.
Extract the cable terminal.
Repeat for each cable.

Checking the cable terminal




Inspect the locking tabs on the terminal for damage. Check that the tabs are not pressed inward.

Installing the cable




Use a new connector, P/N 978305.
Install the yellow-red cable in terminal 1.
Install the brown cable in terminal 5.
When the cable terminal is inserted in the cavity a click is often heard when the primary catch engages.
Pull the cable gently to check that the cable terminal is properly seated in the cavity.

Closing the secondary catch




When the secondary catch is closed a click is often heard.
If it cannot be closed this might be because the cable terminal is not completely inserted in the cavity.

Installing components

Testing the stop lamp




Connect a new stop lamp.
Check its function.
Disconnect it.

Removing the backing




Remove the backing (1) from the double-sided adhesive tape on the stop lamp.

Installing the stop lamp




Position the stop lamp on the headlining with the bevel (1)againstthe headlining.Do notallow the double-sided adhesive tape touch the headlining.

Note! To avoid squeaking it is important that the stop lamp is correctly positioned on the headlining.

Press the stop lamp into place on the headlining.

Finishing work




Connect the connector (1) to the stop lamp.
Tape (2) stop lamp wiring to the headlining so that they cannot make a noise.
Install foam rubber (3), just behind the hole for the rear interior lighting. Use contact adhesive, P/N 1161434, if there is too little adhesive left on the foam rubber for it to stick to the headlining.
Install clip (4) in the headlining by pressing straight up and twisting a quarter turn.
Install the interior lighting (5) by pressing straight up.

Function test

Checking the stop lamp
Check the function of the stop lamp with the low beam on and the turn signal lamp activated.
Check the function of the interior lighting.