Body/Lighting - Creaking Noise Near Center Mounted Brake Light
94 Noise from central rear end (presumed to be from center [additional] brake light)
94 12 72
2016737/6
March 20, 2012.
Supersedes Technical Service Bulletin Group 94 number 10 - 13 dated May 11, 2010 for reasons listed below.
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Affected Vehicles
Condition
^ Creaking noises from the rear of the vehicle, specifically from the center (additional) brake light area.
^ The center brake light lens may crack but the center brake light still functions properly.
Technical Background
^ Body flex in the area of the rear roof support frame rail and roof panel.
^ The clips of the center brake light rub on the lens.
The complaint is worse when driving on uneven roads. This condition does not affect center brake light operation.
Production Solution
^ Improved center brake light assembly and new body dimensions to install the light.
^ Additional bonding material added to the rear roof support frame rail to reinforce the roof panel.
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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.
Service
Tip: A repair authorization from the Technical Assistance Center is not necessary to complete this or any other R8 TSB.
Press on the center brake light to reproduce the noise. Be certain that the source of the noise is, in fact, the center brake light.
If the center brake light is the source of the noise, follow the instructions below to modify the support frame rail and roof panel before replacing the
center brake light.
Rear roof support frame rail and roof panel modification
Procedural overview: A two-part polyurethane adhesive (D 180KD2 A1), the
VAS 5155 hand cartridge gun, and a modified rubber hose (8K0 941 717) will be used to inject the adhesive, spaced 2 cm apart along the rear roof
support frame rail and roof panel. Access to the rail and panel will be through the roof panel center brake light opening.
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1. Insert the two-part polyurethane adhesive cartridge into the hand gun.
2. Cut a straight 12 cm section from rubber hose 8K0 941 717.
3. Slide modified rubber hose over the cartridge nozzle.
This will allow for precise injection of the adhesive.
4. Place a protective covering over the engine compartment lid to protect the glass and painted surfaces.
5. Remove center brake light assembly.
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6. Apply tape to the opening of the center brake light assembly to protect the painted surface.
7. Thoroughly clean the surfaces to be bonded using cleaning solution D 00940104 to ensure good adhesion.
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8. Apply the bonding adhesive every 2 cm (Figures 5 and 6). Use of a small mirror will aid in applying the adhesive in the areas to the left and right
of the center brake light opening.
Tip: Application of the adhesive must be completed within 30 minutes.
9. Immediately remove any bonding adhesive residue in unwanted areas. After curing, the bonding adhesive is extremely difficult to remove.
10. After two hours the bonding adhesive has sufficiently hardened and the new center brake light may be installed.
Center Brake Light Replacement
1. For vehicles from chassis number 42_9N001104, install new brake light 420 945 097 B without modification. The body of the vehicle has been
shaped to fit the new light.
2. For vehicles up to and including chassis number 42_9N001103, follow the instructions below to modify brake light 420 945 097 B prior to
installation.
3. Remove the two aluminum plates of the new light, as identified in Figure 7.
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4. In place of the aluminum plates, apply dampening material. Obtain dampening disc 8E0 260 329. Cut four rectangular strips from the disc 3 cm
long and 8 mm wide.
5. The strips must be installed as shown in Figure 9. A portion of the material must be placed under the seal of the center brake light.
The seal is compressed during installation. Correct installation of the strips will keep the body of the vehicle from contacting the housing of the
light.
Tip: If the material is not placed correctly, the customer concern for noise may recur.
6. The remaining strips must be installed on the corners of the center brake light. Push the strips under the seal as shown in Figure 10.
7. Brush all four strips with the wax for the brake light (part number D 308 SP5 A1) and install the light according to the repair manual.
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8. Ensure that the center brake light is correctly installed. The corners of the brake light must not touch the body.
