Lighting - Headlamp Sw. Is Loose Or Falls Into The Dash
94 Headlight switch is loose or falls into dashboard
70 10 21
2024896/1
December 6, 2010.
Affected Vehicles
Condition
The holder for the headlight switch is broken, so the headlight switch assembly is loose or falls into the dashboard.
Technical Background
When stepping into the vehicle, the driver can hit the headlight switch with his leg or knee. As a result, the rivets holding the headlight switch holder
in the dashboard break.
Production Solution
230
The sonic welding of the two parts was optimized for production for the 2008 MY and beyond.
Service
The service solution is to repair the dashboard for the headlight switch holder. The holder and headlight switch assembly do not need to be replaced
unless they are damaged.
This bulletin only covers the cost of the repair to the dashboard and not the replacement cost for the damaged components.
1. Remove the cover over the left side of the dashboard.
2. Remove the left panel vent according to the repair manual.
3. Disconnect the headlight switch assembly and remove it.
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The broken rivets are shown in Figures 2 and 3. The damaged areas are circled in yellow.
4. Apply the 2K plastic bonder D 180 KU1 A1 on the fastening points as shown in Figures 4 and 5. The bead should be approximately 5 mm in
diameter.
5. Reattach the holder to its original position in the dashboard.
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6. Once installed apply additional bonder over the four fastening points to build up a thicker set of bonder (Figure 6).
7. Apply additional bonder to the top of the holder from the panel vent access hole. This will provide additional strength to the repair. (See Figures 7
and 8.)
8. Allow bonder to set before reinstalling parts.
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Warranty
Required Parts and Tools
Additional Information
All parts and service references provided in this TSB are subject to change and/or removal. Always check with your Parts Department and service
manuals for the latest information.
