Tail Lamp Water Ingress
AFFECTED VEHICLE RANGE:
DEFENDER (LD) SA948271 to VA999484
SITUATION:
In vehicles within the above VIN range, condensation may appear on the inside of the tail lamp assemblies. The condensation is caused by inadequate sealing of the lamp. A service procedure to repair the lamps and prevent further water ingress has been developed. The procedure involves installing a rubber boot over the bulb socket and sealing the lamp housing.
RESOLUTION:
If any one of the tail lamps on a vehicle shows signs of condensation, reseal all of the tail lamps as described below.
PARTS INFORMATION:
LRN-00-0004 Tail Lamp Boot Qty 5
LRN-00-0007 Snap Grip Clamp Qty 5
LRN40840 Loctite 408 As Required *
LRNA25223 RTV Sealer As Required *
XBP100190 3 Pin Bulb Holder As Required
XBP100180 2 Pin Bulb Holder As Required
LRN-00-0005 2 Pin Connector Repair Kit As Required
LRN-00-0006 3 Pin Connector Repair Kit As Required
* A three (3) dollar material allowance per vehicle may be claimed as compensation for sealant and Loctite 408
WARRANTY CLAIMS:
86.40.89128 Time 1.40 hrs.
Install boots to all 5 rear lamps
86.40.89129 Time 0.10 hrs.
Install one connector repair kit (may be claimed up to 5 times per vehicle)
FAULT CODE:.N
Normal warranty policy and procedures apply
REPAIR PROCEDURE:
PREPARATION
1. Remove tail lamp assembly from vehicle.
2. Remove bulb holder from tail lamp.
3. Wipe lamp housing clean.
4. Wipe tail lamp wiring clean.
SEAL LAMP HOUSING
NOTE: Only a very small amount of Loctite 408 is needed to seal the lamp. The adhesive will instantly fill any voids in the seam through capillary action.
1. Around the entire circumference of the lamp apply a very small amount of Loctite 408 to the seam between the lamp lens and reflector. (Figure 1)
2. Using a shop towel, immediately wipe the adhesive off of the lamp.
3. Install the lamp housing onto the vehicle.
INSPECT LAMP CONNECTOR
1. Inspect bulb holder contacts for signs of corrosion and replace if necessary.
2. Inspect tail lamp connector terminals.
^ If the connector shows signs of corrosion, perform "Installation of Connector Repair Kit" section.
^ If connector condition is satisfactory, go to "Original Wiring Insertion Through Boot" section.
INSTALLATION OF CONNECTOR REPAIR KIT
NOTE: Connect replacement connector to vehicle harness as indicated in the table.
1. Cut wires as close to connector as possible and discard old connector.
2. Feed harness wires through boot.
3. Strip 6 mm of insulation off of wires.
4. Ensure that connections are made as specified in the NOTE table.
5. Position wires within solder splice as shown in Figure 2.
6. Use a heat gun to fully melt solder band onto wires.
NOTE: Refer to TIB 86/25/97/NAS for additional guidelines in using solder splices.
ORIGINAL WIRING INSERT IGNOREION THROUGH BOOT
1. Remove terminals from connector as follows:
^ Remove yellow anti-backout piece from connector.
^ Remove terminals from connector by releasing the locking tab as shown in Figure 3.
2. Feed wires through boot.
3. Refer to connector pinout if necessary and insert terminals into the original connector cavities.
4. Install removed yellow anti-backout piece.
BOOT INSTALLATION ONTO LAMP
1. Connect tail lamp wiring.
2. Slip rubber boot completely over tail lamp housing.
3. Position snap-grip clamp in channel on large end of boot.
4. Squeeze clamp closed as far as possible by hand.
5. Squeeze clamp closed an additional two teeth using pliers.
7. Insert applicator tip of RTV dispenser in the open end of the boot wiring tube.
8. Pinch closed the other end of the wiring tube just before "accordion" folds to prevent sealer from entering the boot.
CAUTION: To ensure a correct repair it is important that the wiring tube be completely filled with RTV.
9. Inject sealer into the wiring tube until it is filled completely.
NOTE: Avoid disturbing the boot and wiring until the RTV sealer cures. (Approximately 30 minutes)
10. Permit sealer to cure without disturbing the boot.
AFFECTED VEHICLE RANGE:
DEFENDER (LD) SA948271 to VA999484
SITUATION:
In vehicles within the above VIN range, condensation may appear on the inside of the tail lamp assemblies. The condensation is caused by inadequate sealing of the lamp. A service procedure to repair the lamps and prevent further water ingress has been developed. The procedure involves installing a rubber boot over the bulb socket and sealing the lamp housing.
RESOLUTION:
If any one of the tail lamps on a vehicle shows signs of condensation, reseal all of the tail lamps as described below.
PARTS INFORMATION:
LRN-00-0004 Tail Lamp Boot Qty 5
LRN-00-0007 Snap Grip Clamp Qty 5
LRN40840 Loctite 408 As Required *
LRNA25223 RTV Sealer As Required *
XBP100190 3 Pin Bulb Holder As Required
XBP100180 2 Pin Bulb Holder As Required
LRN-00-0005 2 Pin Connector Repair Kit As Required
LRN-00-0006 3 Pin Connector Repair Kit As Required
* A three (3) dollar material allowance per vehicle may be claimed as compensation for sealant and Loctite 408
WARRANTY CLAIMS:
86.40.89128 Time 1.40 hrs.
Install boots to all 5 rear lamps
86.40.89129 Time 0.10 hrs.
Install one connector repair kit (may be claimed up to 5 times per vehicle)
FAULT CODE:.N
Normal warranty policy and procedures apply
REPAIR PROCEDURE:
PREPARATION
1. Remove tail lamp assembly from vehicle.
2. Remove bulb holder from tail lamp.
3. Wipe lamp housing clean.
4. Wipe tail lamp wiring clean.
SEAL LAMP HOUSING
NOTE: Only a very small amount of Loctite 408 is needed to seal the lamp. The adhesive will instantly fill any voids in the seam through capillary action.
1. Around the entire circumference of the lamp apply a very small amount of Loctite 408 to the seam between the lamp lens and reflector. (Figure 1)
2. Using a shop towel, immediately wipe the adhesive off of the lamp.
3. Install the lamp housing onto the vehicle.
INSPECT LAMP CONNECTOR
1. Inspect bulb holder contacts for signs of corrosion and replace if necessary.
2. Inspect tail lamp connector terminals.
^ If the connector shows signs of corrosion, perform "Installation of Connector Repair Kit" section.
^ If connector condition is satisfactory, go to "Original Wiring Insertion Through Boot" section.
INSTALLATION OF CONNECTOR REPAIR KIT
NOTE: Connect replacement connector to vehicle harness as indicated in the table.
1. Cut wires as close to connector as possible and discard old connector.
2. Feed harness wires through boot.
3. Strip 6 mm of insulation off of wires.
4. Ensure that connections are made as specified in the NOTE table.
5. Position wires within solder splice as shown in Figure 2.
6. Use a heat gun to fully melt solder band onto wires.
NOTE: Refer to TIB 86/25/97/NAS for additional guidelines in using solder splices.
ORIGINAL WIRING INSERT IGNOREION THROUGH BOOT
1. Remove terminals from connector as follows:
^ Remove yellow anti-backout piece from connector.
^ Remove terminals from connector by releasing the locking tab as shown in Figure 3.
2. Feed wires through boot.
3. Refer to connector pinout if necessary and insert terminals into the original connector cavities.
4. Install removed yellow anti-backout piece.
BOOT INSTALLATION ONTO LAMP
1. Connect tail lamp wiring.
2. Slip rubber boot completely over tail lamp housing.
3. Position snap-grip clamp in channel on large end of boot.
4. Squeeze clamp closed as far as possible by hand.
5. Squeeze clamp closed an additional two teeth using pliers.
7. Insert applicator tip of RTV dispenser in the open end of the boot wiring tube.
8. Pinch closed the other end of the wiring tube just before "accordion" folds to prevent sealer from entering the boot.
CAUTION: To ensure a correct repair it is important that the wiring tube be completely filled with RTV.
9. Inject sealer into the wiring tube until it is filled completely.
NOTE: Avoid disturbing the boot and wiring until the RTV sealer cures. (Approximately 30 minutes)
10. Permit sealer to cure without disturbing the boot.
