DECKLID Will Not Stay Open In Full Open Position (96-T-02A)

Publication date: 1998-11-01
Reference number: 96-T-02A

DECKLID WILL NOT STAY OPEN IN FULL OPEN POSITION

TECHNICAL SERVICE BULLETIN

Reference Number(s): 96-T-02A, Date of Issue: November, 1998
Superceded Bulletin(s): 96-T-02

DECKLID DOES NOT STAY OPEN IN FULL OPEN POSITION AND/OR TOO HARD TO OPEN. (REPOSITION OR REPLACE REAR COMPARTMENT LID HINGE TORQUE RODS.)

APPLICATION

Model(s): 1996-99 Saturn Models

Group/Seq. No.: Body - 01

Corporation No.: 681504R

Bulletin No.: 96-T-02A

Date: November, 1998

NOTE: Due to revisions under Models Affected, this bulletin supercedes Bulletin 96-T-02, which should be discarded.

VEHICLES AFFECTED

1996-1999 Saturn Sedans.

CONDITION

When in full open position, decklid may not stay open or may fall down, or has greater than normal opening force.

CAUSE

Decklid torque rods may have been improperly installed during production. Also, if a rear decklid spoiler is installed at the retailer, the new torque rods may not have been installed to accommodate the weight of the decklid spoiler.

CORRECTION

Refer to the Procedure in this bulletin to relocate torque rods to correct location in rear compartment.

For SL, SL1, and SL2 models without rear decklid spoiler option (D80), the correct torque rods are P/N 21098704 and P/N21098705. These torque rods are colored black and have no identifying paint marks on them.

For SL and SL1 models, the torque rods must be installed in the rear position (position 1) of the rear decklid hinges. See Fig 1 .
For SL2 models, the torque rods must be installed in the front position (position 2), of the rear decklid hinges. This is due to the increased weight of the center reflex panel installed on the SL2. See Fig 1 .

For SL2 models equipped with the rear decklid spoiler option (D80), the correct torque rods are P/N 21098706 and P/N 21098707. These torque rods are black in color with a gray paint marking on the "U" bend area of the torque rods. See Fig 2 . The torque rods must be installed in the front position (position 2), of the rear decklid hinges.

If a rear decklid spoiler is added to a Saturn Sedan, the rear decklid specific torque rods (P/N 21098706 and P/N 21098707) must be used in the front slots (position 2), of the rear decklid hinges. Failure to use these torque rods with the rear decklid spoiler will result in poor hold open quality of the rear decklid.

If an SL2 rear center reflex panel is installed on an SL or SLl, the torque rods must be moved from the rear slots (position 1), to the front slots (position 2), on the rear decklid hinges. Use tool SA9192B and the following procedure to move torque rods.

NOTE: The addition of extra weight to the rear deck lid by aftermarket products may affect the performance of the torque rods.

NOTE: No warranty should be submitted for adjustments or installation of new torque rods due to retailer installed spoilers or reflexes.

Fig 1: Torque Rod Installation Locations

Fig 2: Torque Rod Paint Marking Locations

PROCEDURES

REMOVAL

CAUTION: REAR COMPARTMENT LID WILL FALL WHEN TORQUE RODS ARE REMOVED IF SUPPORT IS NOT PROVIDED.

Place a prop under rear compartment lid that will safely support rear compartment lid.
Attach tool SA9192B to lower torque rod and twist torque rod, then remove torque rod from bracket. See Fig 3 .
Relax lower torque rod, remove tool and remove lower torque rod. Note position of lower torque rod for installation.
Attach tool SA9192B to upper torque rod and twist upper torque rod, then remove upper torque rod from bracket.
Relax upper torque rod, remove tool and remove upper torque rod. Note position of upper torque rod for installation.

Fig 3: Torque Rod Twist Tool

INSTALLATION

Install upper torque rod into left hinge arm.
Install tool SA9192B to upper torque rod and twist upper torque rod, then install upper torque rod into bracket of right hinge at proper position. (Refer to TORQUE ROD POSITION TABLE for proper position of torque rod.)
Relax upper torque rod and remove tool.
Install lower torque rod into right hinge arm.
Install tool SA9192B to lower torque rod and twist lower torque rod, then install lower torque rod into bracket of left hinge at proper position. (Refer to the above table for proper position of torque rod.)
Relax lower torque rod and remove tool.

TORQUE ROD POSITION

Position	Application
1	SL, SL1 without rear decklid spoiler
2	SL2 without rear decklid spoiler SL, SLl, SL2 with rear decklid spoiler

WARRANTY INFORMATION

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System using the appropriate Electronic Labor Time Guide and Labor Operation Code B5460 Right Side and/or B5461-Left Side.