Lighting - Moisture Inside Tail Lamp

Group: TRIM

Number: 05-80-002

Date: MAY, 2005

Model: 2002-2005 SONATA

Subject
WATER LEAK AT TAILLIGHT GASKET

This bulletin supersedes TSB # 03-80-002 to include instructions for removing moisture from the taillamp.

DESCRIPTION:

If a Sonata vehicle develops a water leak between the taillight lenses and the body, it may result in moisture in the taillights, a wet trunk mat or water in the spare tire well. If this occurs, the gasket may be out of place or not properly sealing.

This TSB describes how to identify and seal a leaking taillight gasket. Additional leak detection techniques can be found in TSB 98-60-001.





The complete taillight assemblies, part numbers 92401-3D050 and 92402-3D050, should not be replaced for this condition.

VEHICLES AFFECTED:

^ Model: 2002-05 SONATA vehicles

PROCEDURE:





1. Verify that the point of the leak is in the taillight gasket area. Remove the trim covers from behind the taillights. Apply leak detection powder to the area around the inside of the taillight gasket.

Use Kent Automotive Leak Trace Powder or equivalent





2. Run water over the outside of the vehicle.





3. Look inside the trunk to see if there are wet marks on the leak detection powder. If not, refer to TSB 98-60-001 for additional tips on locating water leaks. If wet marks are found, continue with step 4.





4. Remove the taillight assembly.

5. Remove and inspect the taillight gasket. If it is damaged, replace it (P/N 92452-3D000).

6. Inspect the taillight. If moisture is inside the light, remove the bulbs and blow clean dry shop air at a low pressure through the taillight assembly until the moisture is removed.





7. Clean the gasket sealing surfaces. Apply a thin bead of weatherstrip sealant to the taillight side, and position the gasket onto the taillight.

3-M Clear Auto Sealer, Kent Automotive Reseal, or equivalent weatherstrip sealant are recommended.





8. Apply a very thin bead (1/8") of weatherstrip sealant to the body side of the gasket, and reinstall the taillight. Do not overtighten the mounting nuts.

9. Reconnect the wire harness connector. Reinstall the taillight cover trim.

WARRANTY INFORMATION:

Normal warranty coverage applies.

MATERIAL SOURCES:

Kent Automotive: 1-800-654-6333 www.kent-automotive.com

3-M: Available locally