Sunroof Drain Hose Rattle (Install Mastic Patch)

This bulletin is being revised due to part number packaging changes. Please discard Corporate Bulletin Number 04-08-67-007 (Section 08 -- Body).

Under certain driving conditions, some customers may comment on a rattle-type noise in the rear sunroof area.

The rattle-type noise in the rear area of the sunroof may be caused by intermittent contact between the rear sunroof drain hose and the upper rail of the space frame.

Install mastic patch on the upper rail of the space frame directly above sunroof drain tube connector.

1. Verify customer concern by driving on a bumpy road. The rattle may be heard at the rear of the sunroof area and may be heard either on the driver or passenger side of the vehicle.
2. Once the concern is verified, remove headliner to gain access to the rear sunroof drain hose(s). (Refer to the Headliner Replacement (w/sunroof) procedure (SI Document ID #879108) in the appropriate Saturn ION Body and Accessories Service Manual.)
3. Locate sunroof drain hose to sunroof drain attachment point.
4. Ensure that both sunroof drain hoses are installed all the way on both sunroof drain tubes.

Important: Prior to placing mastic patch, clean surface with Isopropyl rubbing alcohol to remove any residue that may reduce the adhesive characteristics of the mastic patch.

Important: Install one mastic patch on each side of vehicle on the upper rail of the space frame.




5. Using a mastic patch, position the patch directly above the drain hose to drain tube attachment.
6. Press mastic patch firmly to secure it to the upper rail of the space frame.
7. Prior to re-installing headliner, test drive vehicle to ensure the concern is resolved.
8. If customer's concern is resolved, re-install headliner. (Refer to the Headliner Replacement (w/sunroof) procedure (SI Document ID #879108) in the appropriate Saturn ION Body and Accessories Service Manual.)
9. If customer's concern is not resolved, continue diagnosing with headliner removed until rattle is located and repaired.

*The mastic patch, P/N 25655346, includes 1 piece; therefore, two packages are required for each repair.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for B2853 (Sunroof Drain Hose - Rear, R & R or Replace).