Disclaimer2010 Land Rover Range Rover Sport (LS) V8-5.0L Technical Service Bulletin # TECLS501013 Date: 060328

Disclaimer2010 Land Rover Range Rover Sport (LS) V8-5.0L Technical Service Bulletin # TECLS501013 Date: 060328

Body - Rattle From Upper Tailgate Area

2010 Land Rover Range Rover Sport (LS) V8-5.0L Page 138

No.: LS-501-013

Issue: 1

Date: March 28, 2006

SECTION: 501-03

Tailgate Support Mounting

AFFECTED VEHICLE RANGE:

Range Rover Sport (LS) VIN: 6A900129 onwards

CONDITION SUMMARY:

TAILGATE SUPPORT RATTLE

A customer may report a rattle from the upper tailgate area.

Cause:

Torque relaxation of the upper support ball fitting, which could develop into damage to the mounting, may be the cause.

Action:

Should a customer express concern regarding the above, refer to the Repair Procedure detailed in this bulletin.

PARTS

WARRANTY

REPAIR PROCEDURE

INSPECT TAILGATE SUPPORT MOUNTING

WARNING:

The tailgate must be supported with a brace before removing the tailgate support.

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1. Remove the upper tailgate support from the D-pillar ball fitting. (Figure 1)

2. Check for the presence of four spot welds indicating the installation of a reinforcement plate. (Figure 1)

3. If the spot welds are present and secure remove the ball fitting.

4. If no damage is evident to either the ball fitting or the securing nut thread, perform the following:

^ Apply liquid thread lock (STC50552) to the ball fitting thread.

^ Install the ball fitting and tighten to 23 Nm (17 lbf-ft).

^ Install the upper tailgate support to the ball fitting.

^ Verify proper operation of tailgate and no rattle is present while driving.

5. If the spot welds are not present, inspect for the following damage conditions:

^ Buckling of the drain channel in the ball fitting area

^ The securing nut thread is damaged

^ The securing nut has been displaced into the D-pillar

6. If any of these damage conditions is present, perform the Repair Tailgate Support Mounting section of this bulletin.

REPAIR TAILGATE SUPPORT MOUNTING

NOTE:

GTR lookup sequence is as follows:

GTR Home> NAS > Service Information/LS Range Rover Sport/2006 > Workshop Manuals> Range Rover Sport/2005 Workshop Manual

> Bookmark "Body & Paint/501 - 08 Exterior Trim and Ornamentation"> Link "Rear Quarter Window Moulding (76.43.32)"

1. Refer to GTR section 76.43.32 and remove the exterior rear quarter window molding for access.

2. Refer to GTR Body & Paint section Bookmark "501-05 Interior Trim & Ornamentation"> Link "D-Pillar Trim Panel (76.13.30)" and remove

the interior D-pillar trim.

2010 Land Rover Range Rover Sport (LS) V8-5.0L Page 140

3. Release the retaining clips securing the sunroof drain tube to the D-pillar and move the drain tube aside. (Figure 2)

NOTE:

GTR lookup sequence is as follows:

GTR Home> NAS > Service Information/LS Range Rover Sport/2006 > Workshop Manuals> Range Rover Sport 2005 Workshop Manual

> Bookmark "Body & Paint/501-20B Supplemental Restraint System/Removal and Installation"> Link "Side Air Curtain Module

(76.74.40)"

WARNING:

Safety precautions related to Supplementary Restraint Systems (SRS) as detailed in GTR section (76.74.40) must be followed.

4. Refer to GTR section 76.74.40 and release the side curtain air bag module and carefully move the module aside to a safe distance from the

D-pillar to prevent damage during welding.

2010 Land Rover Range Rover Sport (LS) V8-5.0L Page 141

5. Apply suitable protection to all other vehicle components to prevent damage during welding and cutting operations. (Figures 3 & 4)

NOTE:

GTR Bookmark "Body & Paint/501-25A Body Repairs-General Information/Description and Operation"> Link "Body Repairs"

CAUTION:

Cutting measurements provided must be used to prevent unintentional cutting of internal panels. (Figure 5)

6. Using a suitable cutting tool, cut a section from the exterior surface of the D-pillar, leaving a section at the top rear corner of the cutout

attached. (Figure 5)

7. Fold the section out to gain access to the rear of the ball fitting mounting.

8. Remove any missing, loose or dislodged parts or pieces from the D-pillar cavity to prevent future rattles.

NOTE:

GTR lookup sequence is as follows:

GTR Home> NAS > Service Information/LS Range Rover Sport/2006 > Workshop Manuals> Range Rover Sport 2005 Workshop Manual

> Bookmark "General Information/Service Information/100-00 General Information/Description and Operation" Link "Important Safety

Instructions".

CAUTION:

Welding repair operation precautions must be followed to prevent damage to battery, Electronic Control Module (ECM), Restraints

2010 Land Rover Range Rover Sport (LS) V8-5.0L Page 142

Control Module (RCM) or any other electrically controlled module. Refer to GTR section 100-00 General Information, Important Safety

Instructions link for precautions and safety measures.

9. If a reinforcement plate was not previously installed, perform the following:

^ Remove all remnants of the ball fitting retaining nut.

^ Drill six (6) 8 mm diameter holes in the replacement reinforcement plate. (Figure 6 - Left side plate shown)

CAUTION:

Care must be taken not to drill through the drain channel when removing an installed reinforcement plate.

NOTE:

When released the, the plate will be guided by the wire and may be removed from the D-pillar cavity.

10. If a reinforcement plate was previously installed, and the ball fitting retaining nut is no longer attached to the reinforcement plate, remove the

reinforcement plate as follows:

^ Pass a length of MIG welding wire through the cut section of the D-pillar outer panel through the ball fitting hole and temporarily secure at

both ends.

^ Drill out the eight (8) spot welds on the inner panel that secure the reinforcement plate using an 8 mm (5/32 in) spot weld removal drill bit.

(Figure 7)

NOTE:

The new reinforcement plate must be installed between the mating surfaces of the quarter panel and the drain channel seam.

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11. Using a suitable lever, create a gap between the mating surfaces of the quarter panel and drain channel seam. (Figure 8)

NOTE:

The ball fitting hole and the reinforcing plate nut fitting must align. The plate must also be flat against the D-pillar.

12. Insert the new reinforcement plate into the gap, between the two body panels, aligning the ball fitting hole with the plate flat against the

D-pillar. (Figure 9)

13. Temporarily install the old ball fitting with an additional over-sized washer.

14. Tighten the old ball fitting to 23 Nm (171 bf-ft) to secure the reinforcement plate during welding and correct any local distortion of the panel

around the ball fitting hole. (Figure 10)

CAUTION:

Heat-affected areas must be minimized and necessary actions taken to prevent damage to any plastic or rubber trim items.

2010 Land Rover Range Rover Sport (LS) V8-5.0L Page 144

15. From the inside of the D-pillar through the newly cut section, puddle weld all six holes in the new reinforcement plate to the D-pillar structure.

(Figure 11)

16. If a previous reinforcement plate was not installed, use an 8 mm (5/32 in) spot weld removal drill bit to drill two holes into the drain channel

to align with the new reinforcement plate. (Figure 12)

17. Puddle weld the reinforcement plate to the drain channel through the two holes. (Figure 12)

18. Weld a 20 mm (3/4 in) length of the plate to the inner D-pillar to prevent creaks. (Figure 13)

19. Fold the cut section of the exterior D-pillar (from Step 6) back to its original position.

20. Prepare the area of the cut section for welding.

2010 Land Rover Range Rover Sport (LS) V8-5.0L Page 145

21. Weld the cut section back into place.

22. Flatten down any deformation in the drain channel in the area of the two puddle welds. (Figure 15)

23. Repair paint in the welded areas.

24. Apply a suitable seam sealant to cut edge of the repair window in the exterior of the D-pillar to prevent water leaks.

25. Remove the old ball fitting and oversized washer.

26. Apply an aerosol spray through the ball fitting hole to protect the interior surface of the welded section from corrosion.

27. Remove the paintwork protection added to the vehicle.

28. Secure the retaining clips holding the wiring harness and the sunroof drain tube (if sunroof installed) to the D-pillar.

29. Refer to GTR section 76.74.40 and install the side air curtain module.

30. Refer to GTR section 76.13.30 and install the interior D-pillar trim.

31. Refer to GTR section 76.43.32 and install the exterior rear quarter window molding.

32. Assess the degree of damage to the ball fitting hole in D-pillar and verify that the repaired mounting surface is flat.

NOTE:

If the ball fitting hole is greater than 10 mm (3/8 in) diameter, an additional flat washer will be required behind the new ball fitting

assembly.

33. Apply liquid thread lock to the new ball fitting.

34. Install the ball fitting with additional flat washer, if required, and tighten to 23 Nm (17 lbf-ft).

35. If an additional washer is required, install a similar washer behind the opposite side ball fitting to match appearance.

CAUTION:

Visually check the upper tailgate support strut for damage before securing to the ball fitting.

36. Secure the upper tailgate support strut to the ball fitting.

37. Verify proper operation of tailgate and no rattle or creak is present while driving.

2010 Land Rover Range Rover Sport (LS) V8-5.0L Page 146