Classification: Reference: Date

BT02-020b NTB02-090b January 24, 2005

ROOF RACK AIR DAM WIND NOISE OR POOR APPEARANCE

IMPORTANT: THIS BULLETIN HAS BEEN REVISED.
The Action, Parts Information, Claims Information, and Service Procedure sections were revised.
Please use this bulletin (NTB02-090b) ONLY.
Discard all previous copies of NTB02-090 and NTB02-090a.

APPLIED VEHICLE: 2002-2004 Pathfinder (R50) - SE model only

IF YOU CONFIRM:
• Wind noise, vibration, or "flutter" coming from the roof area with a roof rack installed.
• A gap between the Roof Rack Air Dam leading edge and the roofline.

ACTION:
Inspect the Roof Rack Air Dam.
a. If the Air Dam has a Rubber Seal along the front edge (see Figure A):

• First, only remove both front Roof Rack

covers and the Torx head Air Dam
screws shown in steps 1 & 2
(page 3).
• Do NOT replace the Air
Dam.
• Then, perform steps 20
through 28 (pages 9 and 10).

Rubber Seal
Front

TP040805a

Figure A
b. If the Roof Rack Air Dam does NOT have a Rubber Seal along the front edge (see
Figure A):
• Perform the entire procedure contained in this bulletin (starting with step 1).

1/10
PARTS INFORMATION

For Vehicles With Rubber Seal On Roof Rack Air Dam

DESCRIPTION PART NUMBER QTY
Air Dam Screw Adjustment Shim 999R1-XQ000S4 1

Permatex Medium Strength Threadlocker Blue 24200 (A) 999MP-AM005P (B)

For Vehicles Without Rubber Seal On Roof Rack Air Dam

DESCRIPTION PART # QTY
Air Dam Assy (Service Part Kit) 999R1-XP000S4 1

Front Pad (Service Part Kit) 999R1-XN000S8 1

Roof Guard Tape 999R1-XP000S5 1

Air Dam Screw Adjustment Shim 999R1-XQ000S4 1

Permatex Medium Strength Threadlocker Blue 24200 (A) 999MP-AM005P (B)

(A) Order through the Chemical Care Direct Ship Product Program which can be reached by:
Phone; 1 (800) 811-0502
Fax; 1 (770) 218-0148
Internet; www.nissanchemicals.com

(B) Do not claim the Theadlocker as this is considered a shop supply.

CLAIMS INFORMATION

For Vehicles With Rubber Seal On Roof Rack Air Dam

Submit a Primary Failed Part (PP) line claim using the following claim coding:
DESCRIPTION PFP OP CODE SYM DIA FRT
Adjust Roof Rack Air Dam 999R1-XQ000S4 YA74AA ZM 45 (1)
(1) Reference the current Nissan Warranty Flat Rate Manual and use the indicated FRT.

OR

For Vehicles Without Rubber Seal On Roof Rack Air Dam

Submit a Primary Failed Part (PP) line claim using the following claim coding:
DESCRIPTION PFP OP CODE SYM DIA FRT
Adjust Roof Rack per TSB 999R1-XP000S4 YY05AA ZM 45 0.7 hrs.

2/10
SERVICE PROCEDURE

1. Use a screwdriver to carefully pry all four of the plastic covers from the front and rear
supports of both side rails (see figure 1).
REMEMBER: Do NOT remove the Rear Covers if the Air Dam already has a Rubber Seal.

Remove both rear covers

Remove both
front covers

TP020256

Figure 1

2. Remove four Torx head screws from the air dam legs (see figure 2).

Torx head, 22.43mm long

screw
Air dam assembly

TP020257

Figure 2

3/10
3. Remove the air dam from the vehicle and discard it. (A new air dam will be installed.
See Parts Information).

4. Loosen the thumb-wheels on both the front and rear crossbars.

5. Slide both crossbars to the rear, out of the side rails (see figure 3).

Crossbar Assembly

r
rea
he
out t
sb ars
ros
ec
Slid

TP020258

Figure 3

4/10
6. Replace the rubber pads under the side rail front supports, both sides.
(see figure 4, and Parts Information.)
• At the side rail rear supports, remove the Torx head attaching screws from both
sides (two 16mm long, and two 35mm long).
• At the side rail front supports, remove the Torx head attaching screws from both
sides (two on each side, 35mm long).
• Install the new rubber pads under the side rail front supports.
• Re-position the side rails onto the roof and install the attaching screws.
NOTE: The holes furthest to the rear, on the side rail rear supports, will require the
shorter screws (Torx head, 16mm long). These shorter screws must be installed
first.

Side rail rear support

Short screw
Torx head
16mm long
Torque
35 - 39 in lb.
(3.9 - 4.5 Nm)

Side rail assembly

Torx head, 35mm long screw

Torque
35 - 39 in lb.
(3.9 - 4.5 Nm)

Replace rubber pads.

TP020259
Figure 4

5/10
7. Slide the crossbars back into the side rails from the rear.
NOTE: Make sure the tie-down loops of the front crossbar face forward and the tie-
down loops of the rear crossbar face rearward (see figure 5).

Tie-down loops forward Tie-down loops rearward

Tie-down
loops

Place the front crossbar

rearward of the sun roof

TP020260

Figure 5

8. Position the front crossbar rearward of the sunroof (see figure 5).

9. Tighten the thumb-wheels securely to prevent the crossbars from moving when the
vehicle is driven.
NOTE: After tightening the thumb-wheels ensure crossbars do not move forward or
backward.

6/10
 10. Clean the vehicle roof area between the side rail front supports to ensure good roof
guard tape “adhesion” (it sticks well). Use isopropyl alcohol and a clean, lint-free cloth.

11. Measure 4.6 inches (117 mm) back from the upper windshield molding.

12. Temporarily set the roof guard tape assembly behind the spot measured in step 11 and
between the side rail front supports (see figure 6).
• The part number should be facing up.
• The roof guard tape assembly, left and right edges, should be 4.6 in. (117mm)
rearward from the upper windshield molding edge.

Air dam assembly

Roof guard tape assembly

(Roof guard tape + premask)

4.6 in.
(117 mm)

Top View
Roof guard tape premask
Roof guard tape assembly

Roof guard tape TP020261

Figure 6

13. Temporarily place the new air dam assembly (see Parts Information) in its mounting
position between the side rail front supports.
• This is to make sure the air dam seal contacts approximately the centerline of the
roof guard tape.
• If the air dam seal does not contact the roof guard tap at approximately the
centerline, adjust the roof guard tape assembly as needed.

7/10
14. Remove the air dam assembly.
• Temporarily place masking tape on the vehicle roof to mark the location of the roof
guard tape assembly.
• This location was determined in step 13.
15. Remove the roof guard tape assembly from the vehicle roof. Carefully peel the
protective liner from the bottom of the roof guard tape assembly (see figure 7).
NOTE: The liner should separate from the roof guard tape and “premask.” The roof
guard tape and premask should remain attached to each other (see figure 7).

Roof guard tape

Roof guard tape "premask"

Protective liner (paper backing)

TP020380
Figure 7
16. With the part number facing up, carefully position the roof guard tape assembly
(premask with roof guard tape) back on the vehicle roof at the location you marked with
masking tape in step 14.
• It’s a good idea to have a second person help you position the tape assembly.
• Apply the tape very carefully to ensure there are no wrinkles in the tape.
17. Apply “uniform” (even) hand pressure across the premask and roof guard tape to
ensure good adhesion (it sticks well) to the vehicle roof.
18. Remove/peel the premask from the top of the roof guard tape (see figure 8). The roof
guard tape will remain attached to the vehicle roof. Discard the premask.

Roof guard tape remains

attached (stuck) to the roof

Remove (peel away) premask

from the top or the roof guard tape

ROOF GUARD - PATHFINDER 22162

TP020381
Figure 8
8/10
19. Place the air dam assembly into position on the side rail front supports (see figure 9).
NOTE: Make sure the air dam seal is at approximately the centerline of the roof guard
tape.

Roof guard tape

Front edge of air dam should be

on approximately the centerline
of the roof guard tape
Roof guard tape

TP020382
Figure 9

20. Apply a small amount of Permatex Medium Strength Threadlocker Blue 24200 (999MP-
AM005P) to the four Air Dam Attachment Screw threads.

21. Re-install the four Air Dam Screws leaving a small gap (about 2 mm) between the
Screw heads and the Air Dam.

22. Pull the Air Dam forward (towards the front of the vehicle) to get good contact of the Air
Dam Rubber Seal to the Roof Guard Tape.
NOTE: Perform steps 23, 24, and 25 (below) on one Air Dam Mounting Screw at a time.

23. Insert the Air Dam Screw Adjustment Shim between the Screw head and the Air Dam
(see Figure 10).

Air Dam

Air Dam

Air Dam
Rubber
Seal
Air Dam Adjustment
Mounting Screw Shim Front TP040805
Figure 10

9/10
24. While holding the Shim in place, tighten the Screw until the Shim cannot be removed
when lightly pulled by hand.

25. Slowly loosen the Screw until the Shim can be removed by hand with not much effort.
Repeat this step on the rest of the screws.
NOTE:
• You may feel that the Screws are not tight enough. However, you must not tighten
them any more after you finish step 25.
• The Threadlocker will hold the Screws in place.
• If you tighten the Screws any more, this may restrict the Air Dam Assembly from
expanding under hot conditions. This may cause Air Dam distortion and the incident
may return.

26. Push and pull the Air Dam Assembly side-to-side. It should slide on the screws. If not,
perform steps 23, 24, and 25 again.

27. Re-install all previously removed components in the reverse order they were removed.

28. Road test to confirm the incident is resolved.

10/10