SUBJECT: Sunroof Sun Shade Rattles In Full Open Position
NO: 23-46-98
GROUP: Body
DATE: Oct. 9, 1998
MODELS: 1997 - 1998 (PL) Neon
SYMPTOM/CONDITION:The sunroof sun shade rattles in the full open position due to the roof deadner pad not fully bonding to the roof and/or the track foam/sponge bumpers are coming loose from the track.
DIAGNOSIS: Open the sun shade to the full open position. Drive the vehicle and listen for a rattle coming from the sun shade/roof area. If the rattle is heard perform the Repair Procedure.
PARTS REQUIRED:
AR (1) 04546820 Deadner Pad, Roof Panel
AR (1) 05027248AA Bumper, Sunroof Rear Track Pad - Right
AR (1) 05027249AA Bumper, Sunroof Rear Track Pad - Left
NOTE: THE SUNROOF REAR TRACK BUMPERS MUST BE REPLACED AS A SET.
REPAIR PROCEDURE:

This bulletin involves reapplying or replacing the existing deadner pad and/or replacing the rear track pad bumpers as needed.
1 . Remove the headlining following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) beginning on page 23-19.

2. With the headlining removed the deadner pad will be visible (Figure 1). Inspect the large deadner pad and the two C-pillar pads. If the deadner pad is completely disengaged, from the roof it must be replaced, proceed to Step 3. If the deadner  pad is loose or partially detached it can be reattached following the procedure beginning with Step 4 (Figure 1).

3. Position the new deadner pad as shown in (Figure 1).
4. Use a six inch roller to pressurize and apply the deadner pad. A constant uniform force should be used to apply the pressure across the complete surface of the deadnerpad.

5. Use the six inch roller to firmly seat the C-pillar pads.
6. Inspect the rear track bumpers, if they are loose or missing they must be replaced.
7. Remove the loose bumper or locate the bumper that has fallen off and discard.
8. Clean the surface with isopropyl alcohol and let dry.
9. Remove the backing paper from the new bumper and apply to the same location that the old bumper was removed from (Figure 1). Repeat the procedure for the other side.

10. Install the headlining following the procedure in the 1998 Neon Service Manual (Publication No. 81-270-8025) on page 23-20. Insure that the door weatherstrips are properly seated around the headlining.

11. Verify proper operation of the sunroof and confirm that rattle has been eliminated.

TIME ALLOWANCE:
Labor Operation No- 23-10-30-93 1.0 Hrs. Sunshade, Sunroof - Repair - 2 Door Vehicles  
23-10-30-94 1.1 Hrs. Sunshade, Sunroof - Repair - 4 Door Vehicles
POLICY: Reimbursable within the provisions of the warranty.