SUBJECT: Roof Rack Wind Noise
NO: 23­05­95
GROUP: Body & Sheet Metal
DATE: Feb. 24, 1995
MODELS: 1995 (PL) Neon
NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A ROOF RACK AND BUILT PRIOR TO AUG. 8, 1994 (MDH 08­08­XX).
SYMPTOM/CONDITION: Wind "rush" noise coming from the roof area while driving above 40 mph.
DIAGNOSIS:
Drive the vehicle, preferably with the customer, at road speeds above 40 mph. If the noise is as described in the symptom/condition section, remove the front roof rack cross rail using a Torx T­30 tool, as outlined in the 1995 Neon Service Manual (Publication No. 81­270­5025), Page 23­29. Drive the vehicle again to verify that the noise has been eliminated.
PARTS REQUIRED:
AR 5303152 Front Cross Rail, Right Side Stanchion
AR 5303153 Front Cross Rail, Left Side Stanchion
AR 5303154 Rear Cross Rail, Right Side Stanchion
AR 5303155 Rear Cross Rail, Left Side Stanchion
1 4546820 Roof Sound Deadener Patch
REPAIR PROCEDURE:

This bulletin involves removing the headliner and installing a roof sound deadener patch and on certain vehicles replacing all four cross rail stanchions on the roof rack with a redesigned part. NOTE: VEHICLES BUILT ON OR AFTER TO JUN. 2, 1994 (MDH 06­02­XX) DO NOT REQUIRE INSTALLATION OF THE CROSS RAIL STANCHIONS. PROCEED TO STEP 4.
1. Remove the front and rear roof rack cross rails as outlined in the Service Manual Page 23­29.
2. Install the new stanchions, as called out in the Parts Required section, on each end of the cross rails, making sure that each stanchion is oriented with the arrow facing forward. Figure 1. NOTE: THE NEW STANCHIONS HAVE BEEN MODIFIED TO PROVIDE A DIFFERENT PITCH TO THE CROSS RAIL AND MUST BE INSTALLED IN THE CORRECT ORIENTATION AND ON THE APPROPRIATE CROSS RAIL IN ORDER FOR THE REPAIR TO BE EFFECTIVE.
3. Install the cross rails into the roof rack side rails.
4. On the inside of the vehicle, remove the headlining, as outlined in the Service manual Page 23­25.
5. Remove the cover paper from the Roof Sound Deadener Patch, P/N 4546820 and position the patch in the middle of the roof panel just in front of the second set of riv­nuts that secure the roof rack to the roof. Figure 2.
6. Using a paint roller, secure the patch to the roof surface. Avoid allowing air to be trapped between the patch and the roof.
7. Install the headlining in the vehicle. 

POLICY: Reimbursable within the provisions of the warranty.