Body - Sunroof Judder/VibrationNo.: TSB-03-42A-005DATE: December, 2003MODEL: 2000-04 EclipseSUBJECT:SUNROOF JUDDER

This bulletin supercedes TSB-01-42A-005, issued June 2001, to include 2002-04 models and provide new sunroof cable assembly part numbers, which have improved nylon drive rail sliders. Revised information is indicated by arrow and triangle symbol.

PURPOSE

On some affected vehicles, the sunroof may judder or vibrate during opening/closing operation. In some cases, it may be necessary to replace the drive cable assemblies. This bulletin describes how to install the new, improved drive cable assemblies (listed in the PARTS INFORMATION section of this bulletin). Refer to MMSA Service Video # 82, CD-R 2000-42A-002 for these procedures, except be sure to clean the sunroof rails and apply sunroof grease before installing the drive cables.

AFFECTED VEHICLES

--> 2000-2004 Eclipse models equipped with sunroof

PARTS INFORMATION

Use the new, improved Genuine Mitsubishi Parts listed.

WARRANTY INFORMATION

Procedure1. If the sunroof cannot be closed completely, reset the timing as follows:

a. With the sunroof open, press and hold the switch closed. If the sunroof stops, press the switch again and continue to hold it.

b. When the sunroof reaches the closed position, continue to hold the switch closed for 15 to 30 seconds. This will reset the timing of the sunroof motor controller and drive cables.

c. Confirm proper sunroof operation by opening and closing the sunroof.2. If the sunroof judders or vibrates during opening or closing, remove the headliner from

the vehicle. Refer to Group 52A in the Eclipse service manual.CAUTION THE SUNROOF MUST BE COMPLETELY CLOSED AT THIS TIME.3. Open the sunroof sunshade. With the sunroof in the completely closed position, remove

the four Phillips or Torx screws securing the glass to the sunroof assembly. Remove the sunroof glass.

4. Remove the sunroof assembly from the vehicle. Refer to Group 42 in the Eclipse service manual. Place the sunroof assembly upside down on a large workbench. Be sure to protect the sunroof from scratches.

5. Remove the sunroof motor. Refer to Group 42 in the Eclipse service manual.6. Remove the roof drip channel (2 screws).7. Remove the rear guide rail stoppers.8. Remove the sunshade stopper screws and stoppers from each side.

a. Inspect the screw holes in the rail vanes. If the holes are rough use a file to smooth the edges. The sunshades could be damaged by rough edges during removal.

9. Remove the front and rear sunshades as a set.

PERFORM STEPS 10 THROUGH 21 ON BOTH SIDES OF THE SUNROOF ASSEMBLY.

10. Push the drive cable assembly lift mechanism rearward with a flat-blade screwdriver.

Gently rotate it over the top of the "tab" in the guide rail. Continue pushing rearward, and remove it from the guide rail.

11. Remove the drive cable assembly from the rail. Disconnect and remove the old drive cable.

INSTALLING THE NEW DRIVE CABLE ASSEMBLY

Note the original location and position of all parts associated with the drive cable assembly.

The sunroof will not operate properly if the drive cable assembly is not correctly installed.

12. Thoroughly clean the sunroof rails of all grease, dirt, and foreign material.

13. Apply Sunroof Grease (listed in the PARTS INFORMATION section of this bulletin) to the top and underside of the housing rail on both sides in the areas shown.

--> Apply 1 oz. (approx. 1/2 tube) of Sunroof Grease per vehicle.CAUTION Use only the Sunroof Grease listed in this bulletin, or judder could result.a. Also apply a uniform coating of Sunroof Grease to the length of the new drive cable.14. Install the new drive cable. Leave the drive cable extended approximately 6 inches

from the rail.

15. Place the new lift mechanism in the tilt-up position. The lift link guide roller must be positioned at the top front of ramp of the lift link shoe.

16. Place the lift link pin into the groove of the link shoe. Be sure that the collar remains on the link pin and is in the groove in the link shoe slot.

17. Mount the link shoe on the lower (outside) pin of the link bracket, with the flange side facing inward.

18. Mount the check block to the front (inside) shoe. Place the check block pin into the hole of the front shoe, with the check block fin facing up.

19. Place the inside pin of the lift guide (located at the front edge of the middle shoe) into the end of the check block groove in the guide rail.

20. Install the drive cable assembly into the guide rail as follows:

a. Insert the inside front shoe into the rail. Then push the lift mechanism about one inch into the rail.

b. Insert the inside check block onto the pin on the lift link shoe, so that the groove in the check block fits over the sliding pin on the shoe. Then guide the check block and lift mechanism into the rail about 1.5 inches. Be sure that the guide pin on the lift mechanism remains above the rail.

c. Mount the outer link shoe on the lower outside pin of the lift mechanism. Guide the shoe and lift mechanism into the rail.

Gently push the drive cable assembly into the guide rail a little at a time.

d. Attach the drive cable as shown.

e. Gently rotate the drive cable assembly over the top of the "tab" in the guide rail.

f. Use the rod under the lift mechanism to pull it up into the full tilt-up position.

21. Lower the drive cable assembly lift mechanism by using a flat-blade screwdriver to push it forward.

IMPORTANT Push the lift guide to its maximum forward position. Confirm that the plastic tabs on the sides of the drive cable assembly are positioned inside the guide rail.

SUNROOF TIMING

22. To time the sunroof use a flat-blade screwdriver to push the lift mechanism until the mark on the lift mechanism is aligned between the two marks on the guide rail. (Marks are shown here as white for clarity.)

23. Reinstall the front and rear sunshades.24. Reinstall the sunshade stoppers and screws25. Reinstall the rear guide rail stoppers.26. Reinstall the root drip channel.

27. Reinstall the sunroof motor. Be sure the gear teeth are properly mated. Tighten the bolts alternately. Final torque is 5.4 1.5 Nm (48 13 in/lb).

28. Reinstall the sunroof assembly into the vehicle, leaving the attaching hardware loose to allow for adjustment. Refer to Group 42 in the Eclipse service manual.

29. Verify that the side-b-side alignment does not vary more than 2 mm:

On the left and right sides of the vehicle, measure from the edge of the body (sunroof opening) to the inner edge of the silver sunroof housing, at the front and back as shown. The front left and front right measurements should be as nearly equal as possible (maximum 2 mm variation). The rear left and rear right measurements should also be as nearly equal as possible (maximum 2 mm variation).

30. Install the sunroof glass. Adjust the glass height to be flush with the vehicle roof. Be

sure the glass front-to-back and left-to-right clearances are nearly equal. If they are not, adjust the glass to achieve proper clearance. If the clearances cannot be adjusted to be nearly equal, loosen the six nuts securing the sunroof to the body, and move the sunroof assembly slightly to achieve proper clearance. Retighten the nuts after adjustment.

31. Check sunroof operation. If the sunroof does not operate properly, perform Step 1 this bulletin. Recheck sunroof operation. If still not operating properly, remove the sunroof from the vehicle, remove the motor, and readjust the timing as described in Step 22. Then repeat Steps 27 through 30.

32. Reinstall the headliner. Refer to Group 52 in the Eclipse service manual.