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sunroofrattletsb051402.jpg | Hits: 4304 | Posted on: 12/17/05 | View original size (9.16 KB)

TSB 05-14-02 Sunroof Rattle 04-05 F150
ISSUE: Some 2004-2005 F-150 (excluding Heritage) and 2006 Lincoln Mark LT vehicles equipped with a roof opening panel and built before 6/1/2005, my exhibit a headliner buffeting or rattle type noise when going over bumps or closing any door with excessive force.

ACTION: Install foam shims between the headliner foam blocks and the roof panel.

SERVICE PROCEDURE

NOTE: DO NOT REMOVE OR REPLACE THE HEADLINER WHILE PERFORMING THIS TSB. ALL REPAIRS ARE TO BE MADE WITH THE HEADLINER IN PLACE.

NOTE: THIS REPAIR WILL NOT ELIMINATE THE NORMAL WIND BUFFETING NOISE ASSOCIATED WITH AN OPEN sunroof, REAR WINDOW, OR BACK GLASS WHILE DRIVING AT HIGHWAY SPEEDS.

1. Gently pull forward on the rear most section of the roof-opening panel trim.
NOTE: REMOVE ONLY ENOUGH OF THE ROOF-OPENING PANEL TRIM TO GAIN ACCESS BETWEEN THE HEADLINER AND THE ROOF PANEL.

2. Cut the foam shim into two (2) equal size pieces.
3. Carefully slide hand and forearm between the headliner and the roof panel. Locate the existing foam blocks on either side of the dome lamp, they are attached to the headliner assembly.
4. Install one (1) foam shim between each of the existing foam blocks and the roof panel. Place the adhesive side of the foam shim towards the roof panel (Figure 1).
5. Firmly press the roof-opening trim back into its original position.

For other TSBs, check here.