TAIL LAMP CONDENSATION OR WATERLEAKS

SUBJECT: TAIL LAMP CONDENSATION OR WATERLEAKS (REPLACE THE TAIL LAMP)

MODELS: 1994-96 PONTIAC GRAND PRIX (COUPES)

CONDITION:

SOME OF THE ABOVE LISTED VEHICLES MAY HAVE CONDENSATION IN THE TAIL LAMPS OR A WATERLEAK IN THE TAIL LAMPS THAT APPEARS AS CONDENSATION OR WATER DROPLETS.

THE TWO CONDITIONS CAN BE IDENTIFIED AS FOLLOWS:

1. CONDENSATION APPEARS AS A FINE MIST OR WHITE FOG, LOCATED PRIMARILY IN THE CORNERS OF THE LAMPS, AFTER A PERIOD OF HIGH HUMIDITY AND TYPICALLY COVERS NO MORE THAN HALF OF THE LENS INNER SURFACE. THESE CONDITIONS USUALLY CLEAR FROM THE LAMP IN 2 HOURS WITH THE LIGHTS ON OR WITHIN 24 HOURS WHEN PARKED IN A STABLE, DRY ATMOSPHERE.

2. WATERLEAKS IN THE LAMPS APPEAR AS A WHITE MIST OR FOG THAT TYPICALLY COVERS MORE THAN HALF OF THE INNER LENS, OR LARGE DROPS OF WATER THAT COLLECT AND RUN DOWN THE INNER LENS SURFACE.

CAUSE:

MAY HAVE MULTIPLE CAUSES INCLUDING ASSEMBLY INTERFERENCE WITH THE BODY, UNEVEN TAIL LAMP MOUNTING SURFACES, INSUFFICIENT SEALING OF THE TAIL LAMP LENS AND HOUSING, ETC.

CORRECTION:

REPLACE THE TAIL LAMP. TRIM LENS AND APPLY ADDITIONAL SEALANT PRIOR TO INSTALLATION AND PROPER FITTING OF THE LAMP TO THE VEHICLE.

IMPORTANT: IN THE NEAR FUTURE, A NEW "SERVICE ONLY" REPLACEMENT TAIL LAMP ASSEMBLY WILL BE AVAILABLE THAT ALREADY HAS THE MODIFICATION MADE TO THE LENS AS DESCRIBED IN STEP #8 OF THE FOLLOWING PROCEDURE. THIS NEW SERVICE ONLY REPLACEMENT TAIL LAMP ASSEMBLY WILL HAVE A NEW SERVICE PART NUMBER AND CAN BE VISUALLY IDENTIFIED BY THE MODIFICATION MADE TO THE LENS AS SHOWN IN FIGURE 6.

UNTIL THE NEW SERVICE ONLY REPLACEMENT TAIL LAMPS ARE AVAILABLE, USE THE FOLLOWING COMPLETE PROCEDURE WHEN INSTALLING THE NEW "PRODUCTION" TAIL LAMP ASSEMBLY PART NUMBERS LISTED BELOW. WHEN THE NEW "SERVICE ONLY" REPLACEMENT TAIL LAMP ASSEMBLY BECOMES AVAILABLE, THIS SAME PROCEDURE, WITH THE EXCEPTION OF STEP #8, SHOULD BE FOLLOWED.

PARTS REQUIRED:

- CLEAR AUTO BODY SEALANT, 3M ULTRAPRO #08302 (OR EQUIVALENT) (THE 3M ULTRAPRO #08302 CLEAR AUTO BODY SEALANT IS A 5 OZ. TUBE, WHICH WHEN USED AS INSTRUCTED, CAN SEAL AT LEAST TWO TAIL LAMP ASSEMBLIES).

- PRODUCTION REPLACEMENT TAIL LAMP ASSEMBLY: P/N 5977913 (LEFT) P/N 5977914 (RIGHT)

- FOUR TO SIX FLAT WASHERS, (1/4 I.D. BY 3/4 O.D.) FOR SHIMMING THE TAIL LAMP ASSEMBLY TO THE BODY.

PROCEDURE:

1. OBTAIN A NEW TAIL LAMP ASSEMBLY.

2. USING A SHARP UTILITY KNIFE, REMOVE THE "SEVEN" LAMP GASKET TABS AS SHOWN IN FIGURES 1-3.

3. RAISE DECK LID TO THE FULL OPEN POSITION, REMOVE THE REAR COMPARTMENT END PANEL TRIM, TAIL LAMP BULB SOCKETS, RETAINING NUTS AND REMOVE THE AFFECTED TAIL LAMP ASSEMBLY.

4. REMOVE EXCESS BODY SEALER FROM THE BOTTOM OF THE 1/4 PANEL EXTENSION AS SHOWN IN FIGURE 4.

5. REMOVE EXCESS BODY SEALER FROM THE OUTBOARD CORNER OF THE REAR END PANEL AS SHOWN IN FIGURE 5.

6. APPLY A THIN LAYER OF BODY SEALER OVER ANY METAL THAT WAS EXPOSED DURING STEPS #4 AND #5.

7. BEND DOWN THE METAL TAB LOCATED ON THE REAR END PANEL TO A HORIZONTAL POSITION. SEE FIGURE 5.

8. POSITION AND APPLY SEVERAL LAYERS OF MASKING TAPE ON THE NEW PRODUCTION TAIL LAMP ASSEMBLY USING THE DIMENSIONS SHOWN IN FIGURE 6.

IMPORTANT: DO NOT PERFORM THIS STEP IF INSTALLING A NEW SERVICE ONLY REPLACEMENT TAIL LAMP ASSEMBLY.

A. USING A SHARP UTILITY KNIFE OR FILE, REMOVE THE REMAINING 2MM X 75MM EXPOSED "WEDGE-SHAPED" AREA OF THE LAMP AS SHOWN IN FIGURE 6. DO NOT REMOVE ANY ADDITIONAL MATERIAL BEYOND THE DIMENSIONS SHOWN.

B. REMOVE THE MASKING TAPE FROM THE LAMP.

9. FIT THE NEW TAIL LAMP ASSEMBLY TO THE BODY AND NOTE IF ANY MOUNTING STUDS ARE CONTACTING THE SIDES OF THE MOUNTING HOLES IN THE REAR END MOUNTING PANEL AS SHOWN IN FIGURE 4.

A. IF CONTACT OR INTERFERENCE IS NOTED, INCREASE THE CLEARANCE BY FILING OUT OR ELONGATING THE MOUNTING HOLE AT THE POINT OF INTERFERENCE.

IMPORTANT: WHEN FILING OR ELONGATING THE MOUNTING HOLES TO IMPROVE CLEARANCE, ONLY REMOVE AS MUCH MATERIAL AS NECESSARY AT THE POINT OF INTERFERENCE. DO NOT ENLARGE THE ENTIRE HOLE.

10. INSPECT AND VERIFY THAT THE METAL "HEM TABS" LOCATED ON THE UNDERSIDE OF THE 1/4 PANEL EXTENSION ARE NOT CAUSING INTERFERENCE WITH THE TAIL LAMP DURING INSTALLATION. SEE FIGURE 5. IF IT APPEARS THAT THEY ARE HANGING DOWN TOO FAR AND CAUSING INTERFERENCE, CAREFULLY TAP THEM UP USING A BALL PEEN HAMMER.

11. ONCE THE FITTING OF THE NEW TAIL LAMP ASSEMBLY IS COMPLETED, REMOVE THE NEW LAMP ASSEMBLY FROM THE VEHICLE.

12. APPLY TOUCH-UP PAINT WHEREVER BODY SEALER WAS REMOVED FROM THE BODY OR WHERE MOUNTING HOLES WERE MODIFIED.

13. USING 3M ULTRA PRO #08302 CLEAR AUTO BODY SEALANT, OR EQUIVALENT, APPLY ADDITIONAL SEALING MATERIAL BETWEEN THE LENS AND GASKET ON THE NEW TAIL LAMP HOUSING IN THE AREAS SHOWN IN FIGURES 7-9.

IMPORTANT: THE SEALANT APPLIED TO THE TAIL LAMP SHOULD BE ALLOWED TO AIR DRY AT ROOM TEMPERATURE FOR AT LEAST THREE HOURS PRIOR TO WATER LEAK TESTING. DO NOT ATTEMPT TO REDUCE THE DRYING TIME BY APPLYING HEAT TO THE SEALANT.

14. INSTALL FLAT WASHERS AS NECESSARY TO MAKE A .060 IN. SPACER (SHIM) ON TAIL LAMP MOUNTING STUD #1 AND ALSO ON MOUNTING STUD #2. SEE FIGURE 5 FOR MOUNTING STUD LOCATION IDENTIFICATION AND WASHER PLACEMENT.

15. INSTALL THE TAIL LAMP ASSEMBLY TO THE BODY WITH THE WASHERS PROPERLY POSITIONED AND TIGHTEN THE NUTS TO 5 N.M (44 LB IN) USING THE TIGHTENING SEQUENCE SHOWN IN FIGURE 4.

16. VERIFY THAT THE OUTBOARD CORNER OF THE TAIL LAMP ASSEMBLY FITS PROPERLY TO THE 1/4 PANEL AS SHOWN IN FIGURE 10.

IMPORTANT: IF THE TAIL LAMP ASSEMBLY DOES NOT FIT PROPERLY TO THE BODY AT THE LOCATION SHOWN IN FIGURE 10, REMOVE THE TAIL LAMP ASSEMBLY AND PERFORM THE FOLLOWING:

A. REMOVE ONE WASHER AT A TIME FROM MOUNTING STUD #1 TO REDUCE THE GAP BETWEEN THE LOWER HALF OF THE TAIL LAMP ASSEMBLY AND THE 1/4 PANEL.

B. REMOVE ONE WASHER AT A TIME FROM MOUNTING STUD #2 TO REDUCE THE GAP BETWEEN THE UPPER HALF OF THE TAIL LAMP ASSEMBLY AND THE 1/4 PANEL.

C. REINSTALL THE TAIL LAMP TO THE BODY AND VERIFY THAT THE TAIL LAMP FITS PROPERLY TO THE 1/4 PANEL. IF NECESSARY, CONTINUE REMOVING ONE WASHER AT A TIME FROM THE APPROPRIATE MOUNTING STUD UNTIL THE TAIL LAMP FITS PROPERLY TO THE BODY.

17. INSTALL THE TAIL LAMP BULB SOCKETS TO THE TAIL LAMP.

IMPORTANT: PRIOR TO WATER LEAK TESTING, ALLOW THE SEALANT APPLIED TO THE TAIL LAMP TO AIR DRY AT ROOM TEMPERATURE FOR AT LEAST THREE HOURS. DO NOT ATTEMPT TO REDUCE THE DRYING TIME BY APPLYING HEAT TO THE SEALANT.

18. WATER LEAK TEST THE TAIL LAMP AND BODY TO ENSURE A SATISFACTORY REPAIR.

19. INSTALL THE REAR COMPARTMENT END PANEL TRIM.

PARTS INFORMATION:

P/N DESCRIPTION === ===========

5977913 PRODUCTION REPLACEMENT TAIL LAMP ASSEMBLY - (LEFT)

5977914 PRODUCTION REPLACEMENT TAIL LAMP ASSEMBLY - (RIGHT)

PARTS ARE CURRENTLY AVAILABLE FROM GMSPO.

WARRANTY INFORMATION:

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

LABOR OPERATION LABOR MATERIAL NUMBER DESCRIPTION TIME ALLOWANCE =============== =========== ===== =========

N1590 RIGHT TAIL LAMP 0.3 HR $2.50

ADD: FOR TAIL LAMP AND BODY .8 HR MODIFICATIONS. INCL.: WATER TEST.

N1591 LEFT TAIL LAMP 0.3 HR $2.50

ADD: FOR TAIL LAMP AND BODY .8 HR MODIFICATIONS. INCL.: WATER TEST.

FIGURES: 10 ATTACHMENTS: 00

FIGURE 1: 1. TABS TO BE REMOVED.

FIGURE 2: 1. TABS TO BE REMOVED.

FIGURE 3: 1. TABS TO BE REMOVED.

FIGURE 4: 1. EXCESS BODY SEALER.

FIGURE 5: 1. METAL TAB. 2. MOUNTING STUD #2 LOCATION. 3. MOUNTING STUD #1 LOCATION. 4. EXCESS BODY SEALER. 5. HEM TABS. 6. TAIL LAMP BOSS. 7. WASHERS. 8. NUT. 9. BODY METAL.

FIGURE 6: 1. BLACK RUBBER SEAL. 2. AREA TO BE REMOVED. 3. 75MM. 4. LENS SECTION 5. MASKING TAPE. 6. 2MM.

FIGURE 7: 1. TAIL LAMP LENS. 2. RUBBER SEAL. 3. SEALANT MATERIAL IN GAP BETWEEN REAR OF LENS AND RUBBER SEAL. 4. AREA WHERE SEALANT MATERIAL IS TO BE APPLIED.

FIGURE 8: 1. SEALANT MATERIAL OVER REMOVED TAB. 2. RUBBER SEAL. 3. SEALANT MATERIAL. 4. PLASTIC LAMP HOUSING. 5. SEALANT MATERIAL OVER REMOVED TAB.

FIGURE 9: 1. SEALANT MATERIAL OVER REMOVED TABS.

FIGURE 10: 1. ZERO GAP AT THIS LOCATION. 2. SMALL GAP AT THIS CORNER IS NORMAL.

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.

COPYRIGHT 1996 GENERAL MOTORS CORPORATION. ALL RIGHTS RESERVED.