TECHNICAL SERVICE BULLETIN Bulletin Number 13R/03

Passenger and Light/Medium Commercial Issue Date: 12 March, 2003

Circulate to Service Manager Parts Manager Foreman Receptionist Technicians

PLEASE DESTROY ALL PREVIOUS COPIES OF TSB 13/03

Subject/Concern: BA FRONT WINDOW REGULATOR ‘CLUNK’
Models: All BA Falcon – built before January 2003

Summary
Cause: The window regulator cable may catch on a weld nut during normal operation, when the
side window glass is in the fully up or fully down position. This may cause a "clunking"
sound as the cable "jumps" off the weld nut under tension.
Action: Do not replace regulator, repair using the following procedure.
Warranty Status: Reimbursable within the provisions of the Warranty and Policy Manual.

Parts Required
Description Part Number Quantity
SCREW & WSHR - M8 x 26.5 HEX FLNG W- 705244-S421 1

Service Procedure

Concern Description:

A number of BA front door window regulators have been returned through WARPEC and found to be ‘No Fault
Found’. In vehicle analysis has shown the root cause to be that the window regulator cable may catch on a weld nut
during normal operation, when the side window glass is in the fully up or fully down position. This may cause a
"clunking" sound as the cable "jumps" off the weld nut under tension. The weld nut was used as a door handle
anchor point during AU, but is not required for BA. It has now been deleted.

To address this issue on pre January 2003 built vehicles a M8 corflex bolt, as per AU production, should be driven
through the weld nut. The protruding length of the bolt will prevent the cable from passing the weld nut.

Window
Regulator
Weld Nut Cable

Normal Condition Stressed Condition

Figure 1. Inside surface of the door panel

../Cont’d.
Service Action:

When the customer presents this concern, ensure the window is at a stop position 25mm from the top of its stroke.
Remove the door trim as per the repair manual section 18-7-1. Peel back the weather shield to expose weld nut
forward and above the inner door handle release. Drive a M8 x 26.5 mm bolt (W- 705244-S421) into weld nut as
shown in Figure 2. Torque to 11.4 – 15.6 Nm.

Figure 2. M8 x 26.5 mm Bolt and Weld Nut Location.

Replace weather shield.

Replace Door Trim.
Confirm window operates without ‘clunk’.

Operation Number/Standard Repair Time

Operation Description Operation Number Time
R & R Door Trim Panel 23942A 0.4
Place M8 Bolt 12999X 0.1

Repair/Claim Coding
Warranty Claim Causal Part Condition
Enter 03013 in box "X" of warranty claim to reference this TSB. W-705244-S421 57

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