REAR DOOR WATER LEAKS (INSTALL DEFLECTORS, INSULATORS, SEALER

Subject: REAR DOOR WATER LEAKS (INSTALL DEFLECTORS, INSULATORS, AND SEALER)

Model and Year: 1991-92 FOUR-DOOR S/T UTILITY

Some owners of 1991-1992 4-door S/T model trucks may comment about rear door water leaks.

This condition may occur when water paths in the door develop allowing water to drain into the inside of the vehicle.

To correct this condition, it is necessary to install a water deflector to the door, add a foam patch between the top forward corner of the fixed glass, the run channel and the divider bar assembly and install sealer in the cut out area along the top of the door at the divider bar attachment.

SERVICE PROCEDURE:

1. Remove two fastening screws and remove armrest.

2. Remove the door pillar molding.

3. Remove the manual window handle, if equipped.

4. Remove the door trim panel (held in place with six plastic retainers) using Trim Panel Removal Tool J-38778, or equivalent.

5. Carefully remove the door inner panel water deflector part way down to allow installation of the deflector assembly.

6. Clean the affected sheet metal panel area using either a 50-50 mixture (by volume) of water and isopropyl alcohol; or flash naphtha, or equivalent (procure locally). Allow to dry thoroughly.

7. Install a water deflector (P/N 15603079) on the door inner panel (one per side) as shown in Figure 1. The bottom portion of the deflector should be positioned in the door panel access opening.

8. Remove the fixed glass assembly. Refer to applicable S/T Model Service Manual, Section 10A1-Doors, Rear Door Window Replacement.

9. Install insulator (P/N 15675045) between the top forward corner of the fixed glass run channel and divider bar assembly (Figure 2).

10. Reinstall the fixed glass assembly.

11. Clean the cut out area located on the top of the door above the divider bar attachment (approx. 3 in. long) with either a 50-50 mixture (by volume) of water and isopropyl alcohol; or flash naphtha, or equivalent. Allow to dry thoroughly.

12. Use a sufficient quantity of 3M Ultra Pro Auto Body Sealant (clear), vendor Part Number 051135-08302 or equivalent and fill the cut out area located on the top of the door above the divider bar.

13. Smooth sealer.

14. Reinstall the door panel water deflector.

15. Reinstall the door trim panel.

16. Reinstall the door pillar molding.

17. Reinstall the armrest.

PARTS INFORMATION: PART NO. DESCRIPTION VEHICLE QTY -------- ----------- ----------- 15603079 Deflector Asm.-Rear S/D Water 1/side 15675045 Insulator Patch-Window 1/side

*051135-08302 3M Ultra Pro Auto Body Sealant 5 Oz.Tube (clear)

* Procure from your local 3M automotive distributor.

Parts are currently available from GMSPO.

WARRANTY INFORMATION: For vehicles repaired under warranty use:

LABOR OP. DESCRIPTION LABOR TIME --------- ----------- ---------- T-7641 Right 0.3 hrs. T-7642 Left 0.3 hrs.

NOTE: Labor Operation is coded to base vehicle coverage in the warranty system.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.