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Discussion Starter · #1 ·
NUMBER: 23-038-06
GROUP: Body
DATE: September 8, 2006

SUBJECT: Front Of Roof Rack Lifting From Roof

OVERVIEW:

This bulletin involves replacing the adhesive tape at the front of the roof rack side rail(s).

MODELS:

2007 (KA) Nitro

NOTE: This bulletin applies to vehicles built on or prior to October 9, 2006 (MDH
0904XX).

SYMPTOM/CONDITION:

The front inboard corner of roof rack is lifting from the roof.

DIAGNOSIS:

Inspect the front of the roof rack side rails, if the adhesive tape on the underside of the
front of the roof rack is no longer bonded to the roof rack side rail(s) / and or the roof panel,
perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description
AR NPN 3M Attachment Tape 06397 (12mm (1/2 in.) wide X 50mm
(2 in.) long or equivalent
1 NPN 3M Adhesion Promoter 06396 or equivalent

REPAIR PROCEDURE:

1. Open front roof rack side rail cap.
2. Remove 5 roof rack side rail fasteners.
3. Carefully remove roof rack side rail from vehicle.
4. Remove the adhesive tape from the roof panel and the underside of the roof rack side
rail.
5. Wipe clean the roof panel surface and roof rack side rail tape mounting surface, (Fig.
1), with a clean lint free cloth moistened with isopropyl alcohol. Wipe the bonding
surface immediately with a dry lint free cloth.
6. Wipe the roof panel surface and roof rack side rail tape mounting surface with 3M
Adhesion Promoter 06396.

23-038-06 -2-


7. Visually inspect the mounting surfaces prior to the bonding process to ensure that all
of the adhesion promoter has evaporated. The maximum time between surface
preparation and application is 20 minutes.
8. Apply the adhesive tape to the underside of the roof rack side rail in the area provided,
(Fig. 1), and apply strong hand pressure for a minimum of 5 seconds.
Fig. 1 TAPE APPLICATION

1 -APPLY TAPE HERE

9. Remove the backing liner from the adhesive tape and place the roof rack side rail back
onto the vehicle.
10. With the roof rack side rail in place install the 5 fasteners torque to 6.2 Nm (55 in. lbs.).
11. Close the front roof rack side rail cap.
12. Apply strong hand pressure to the front of the roof rack side rail (above the adhesive
tape) for a minimum of 5 seconds.
13. Repeat Step #1 through Step #12 for the opposite side, if necessary.
POLICY:

Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount
23-06-10-95 Replace Roof Rack Tape -One Side (C) 0.2 Hrs.
23-06-10-96 Replace Roof Rack Tape -Both Sides (C) 0.4 Hrs.

FAILURE CODE:


ZZ Service Action
 

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Roof Rack Lifting Up

I purchased mine on 9/25/2006 and discovered the rack coming up immediately upon getting it home that evening. Informed the dealership the next day and they said that a new plastive rail needed to be ordered. Still haven't seen it yet.
 

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Discussion Starter · #3 ·
Wonder why the dealership did perform this TSB. Would have saved you the long wait. Unless the rail is warped. Keep us informed to the outcome. Thanks.
 

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07Lifted,4X4,6sp-man,3.7L
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30,657 Posts
Also see this thread about the "New designed" roof rails and part #'s in post 345.
 
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