2038999

Technical Bulletin
Model(s)
Year
Eng. Code
Trans. Code
VIN Range From
VIN Range To
Passat
1998-2001
All
All
All
All
Passat Wagon
1998-2001
All
All
All
All
Condition
55 14 10 December 16, 2014 2038999
Corrosion Around Handle On Rear Lid
Corrosion where handle contacts rear lid (Figure 1).
Figure 1 (rear lid handle)
Corrosion on the contact area of the left and right sides of the rear lid / handle (Figure 2).
Figure 2 (corrosion on right side of the rear lid / handle)
Page 1 of 7 plus attachments
© 2014 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Note:
To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
Procedures Manual.
Documentation required per Warranty Policies and Procedures Manual.
For vehicles outside of the Limited Warranty Against Corrosion Perforation this Technical Bulletin is for
information only.
Technical Background
Paint abrasion from sharp edge on the contact area on the handle.
Production Solution
Deviations discovered after end of production.
Page 2 of 7 plus attachments
© 2014 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Service
Procedure:
1. Replace the rear lid.
Or
2. Repair the rear lid. Only perform this operation if the total repair cost is 80% or less of the total replacement
cost.
1. Replace the rear lid:
If the handle contact area in the rear lid exhibits through-corrosion (perforation), DO NOT repair, install a
new lift gate.
• Remove all necessary parts / trim pieces of the original lift gate. See Repair Group 70 and Repair Group 55 in
Elsa.
• Remove the rear window from the original rear lid. See Repair Group 64 in Elsa (Wagon Only).
• Paint the new rear lid according to Volkswagen guidelines.
• Remove the original rear lid. See Repair Group 55 in Elsa.
• Install the new rear lid. See Repair Group 55 in Elsa.
• Install the rear window in the new rear lid. See Repair Group 64 in Elsa (Wagon Only).
• Trim protective foil (part number: AKL 448 030 05), or similar clear vinyl tape (locally sourced), to fit in the left
and right handle contact surface areas (Figure 1). Attach to rear lid before installing the handle.
• Install all remaining parts / trim pieces previously removed. See Repair Group 70 and Repair Group 55 in Elsa.
• Adjust the rear lid fit according to the repair manual. See Repair Group 55 in Elsa.
2. Repair the rear lid:
Before the repair, check the handle contact area in the rear lid. If the handle contact area exhibits throughcorrosion (perforation), DO NOT repair, install a new rear lid.
• Remove all necessary parts / trim pieces from the rear lid. See Repair Group 70 and Repair Group 55 in Elsa.
• Remove the rear lid. See Repair Group 55 in Elsa.
• Remove the corrosion with a pneumatic brush grinder. Make sure that the rear lid does not get damaged.
Note:
If through-corrosion (perforation) is not present, rear lid replacement will only be accepted if it qualifies
per the Reimbursement Policy section of the Warranty Policies and Procedure Manual. This section
provides important guidelines when considering component repair vs. replacement options (the “80%
rule”).
Page 3 of 7 plus attachments
© 2014 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
• Apply a VOC compliant epoxy primer as an anti-corrosion treatment and primer (locally sourced).
• Re-paint the rear lid according to Volkswagen guidelines.
• Install the rear lid. See Repair Group 55 in Elsa.
• Trim protective foil (part number: AKL 448 030 05), or similar clear vinyl tape (locally sourced), to fit in the left
and right handle contact surface areas (Figure 1). Attach to rear lid before installing the handle.
• Install all remaining parts / trim pieces previously removed. See Repair Group 70 and Repair Group 55 in Elsa.
• Adjust the rear lid fit according to the repair manual. See Repair Group 55 in Elsa.
Warranty
Note:
• Dealers may complete the repair as described without prior authorization (through a WISE Warranty Repair
Acceptance request).
• Documentation required: Clear pictures, completed estimate and body shop invoice must be saved and kept on
file at the Dealership for audit purposes.
• Labor time units (TU), Material units (MU), and Material unit rate are correct at the time of publication. The time
units and/or material units may differ if the repair catalogue is updated. The information in the repair catalogue
applies, except for the open time items (labor operations ending in 99) which are calculated at actual time
multiplied by the body shop labor rate. The material allowance (Paint material price per unit) is subject to
change. Refer to WISE > Resource Center > Forms > Paint/Corrosion for the most current forms.
• This section is applicable for vehicles within the terms of Volkswagen’s Limited Warranty Against Corrosion
Perforation. For vehicles outside the terms of the Limited Warranty Against Corrosion Perforation this section is
for information only.
• This bulletin may be provided to outside shops to ensure the proper repair is completed.
Note:
Claim Processing Options
Option 1: Utilize the attached form examples and interactive forms on WISE to assist with calculating the
reimbursement amounts. This will expedite the claim review process and reduce the time to pay the claim.
Note that miscalculations are subject to claim adjustment.
For the complete set of pre-populated Paint/Corrosion Claim Form templates associated with this Technical
Bulletin, refer to WISE > Resource Center > Forms > Paint/Corrosion.
Option 2: Email repair estimates to [email protected]. The Paint and Corrosion Team will calculate the
warranty allowance and complete the required form(s) on behalf of the dealer.
Page 4 of 7 plus attachments
© 2014 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
1)
Procedures Manual
Model(s)
Year(s)
Eng. Code(s)
Trans. Code(s)
VIN Range From
VIN Range To
Passat
1998-2001
All
All
All
All
Passat Wagon
1998-2001
All
All
All
All
SAGA Coding
1)
Claim Type:
160
HST
Damage Location
(Depends on Service
No.)
--
030
Damage
Service Number:
Code
5559
0003
Passat (3B2)
030
2)
Passat Wagon (3B5)
030
2)
Parts Manufacturer
Repair
Please use the following part number in “Outside Materials”
4)
LACKMATF: Paint and Materials
MU @ $12 per unit
Epoxy Primer (Locally Sourced)
Claim Dollar Amount (MAX: $40)
Please use the following Labor Operation in “Outside Labor”
4)
Select the appropriate Labor Operation below:
- L0010000: External Painting-straight color
Claim Dollar Amount
- L0020000: External Painting-metallic/2-layer
- L0030000: External Painting-pearl color
Use this for all body repair in this bulletin:
Claim Dollar Amount
- A0041000: Body Shop repair no paint
Replace
Please use the following part number in “Outside Materials”
4)
Page 5 of 7 plus attachments
© 2014 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
LACKMATF: Paint and Materials
MU @ $12 per unit
Please use the following Labor Operation in “Outside Labor”
4)
Select the appropriate Labor Operation below:
- L0010000: External Painting-straight color
Claim Dollar Amount
- L0020000: External Painting-metallic/2-layer
- L0030000: External Painting-pearl color
Use this for all body repair in this bulletin:
Claim Dollar Amount
- A0041000: Body Shop repair no paint
Causal Part:
L00#0000
Diagnostic Time
4)
GFF Time expenditure
01500000 = 00 TU max.
NO
Road Test
01210002 = 00 TU
NO
01210004 = 00 TU
Technical Diagnosis
01320000 = 00 TU
NO
Claim Comment: Input “As per Technical Bulletin 2038999” in comment section of Warranty Claim.
1)
For Vehicles outside the Limited Warranty Against Corrosion Perforation this bulletin is information only
2)
Corrosion claim vendor code will be the damage location.
3)
Labor Time Units (TUs) are subject to change with ELSA updates.
4)
Documentation required per Warranty Policies and Procedures Manual.
5)
See attachment “srt_reference_table.pdf” for labor time reference.
Page 6 of 7 plus attachments
© 2014 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Required Parts and Tools
Replacement (Sedan)
Part No:
Part Description
Quantity
3B5 827 025 D
Rear Trunk Lid
1
AKL 448 030 05
Protective Foil
0.1
Replacement (Wagon)
Part No:
Part Description
Quantity
3B9 827 025 L
Rear Lift Gate
1
AKL 448 030 05
Protective Foil
0.1
Repair
Part No:
Part Description
Quantity
AKL 448 030 05
Protective Foil
0.1
For Special Tools see Repair Manual.
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.
Page 7 of 7 plus attachments
© 2014 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Paint/Corrosion Claim Form
Dealer No.
400000
Repair
Order No.
910000
VIN (17-Digits)
WVWMA23B0YE000000
Color No. (4-digit ElsaPro Paint No.)
LB3Y
100.00
Dealer Labor Rate
If repeat repair, provide explanation in box below:
Paint material price per unit
Service No.
Damage
Code
Dmg
Loc
Part manufacturer
(Vendor Code)
5559
0003
030
030
12.00
Dealer-owned paint shop?
Yes
Original paint material?
Yes
Description of Repair
Paint Labor Operation(s)
No
No
Time
Units
Mat'l
Units
Paint new rear lid
55906150
110
9
Paint body part (handle)
51016150
30
3
51017153
160
Verify ALL Labor Operation Time Units
and Material Units
Note: Authorization and claim reimbursement are contingent on the usage of original
parts for the repair
Body Painting Prep Time
The vehicle history must be checked for any previous damage. Digital photographs must be included with the repair order per VWoA instructions. If there is a
sublet invoice for painting, the invoice amount must be split between outside (sublet) labor and outside (sublet) material.
Part Number
Part Description
Part Qty
Part Price
per Unit
Total Part
Price
Description of Repair
Paint Subtotal
Repair/Replace Labor
Operation(s)
300
12
Time
Units
Remove and install rear lid
55901900
70
Replace rear lid
55905550
90
Trim and install protective foil
55572399
20
Wax body
51017500
30
Full pre-populated forms can be found in the
following location:
WISE > Resource Center > Forms > Paint/
Corrosion > TB# Form specific to the vehicle
and the repair.
Outside Material
LACKMATF
Part Amount Subtotal
$
-
Total Paint Material Amount
$
144.00
Total Parts Amount
$
144.00
VW Representative
Authorization No.
Body Labor Subtotal
Total TU/MU
Authorization Date
TB 2038999
Authorization
valid until:
Warranty
VW Representative Name (printed)
VW Representative Signature
210
510
12
L00#0000 $
300.00
A0041000 $
210.00
Parts and Materials: $
144.00
Total: $
654.00
Paint/Corrosion Claim Form
400000
Dealer No.
Repair
Order No.
910000
VIN (17-Digits)
WVWNA23B0YE000000
Color No. (4-digit ElsaPro Paint No.)
LB7Z
Dealer Labor Rate
If repeat repair, provide explanation in box below:
100.00
Paint material price per unit
Service No.
Damage
Code
Dmg
Loc
Part manufacturer
(Vendor Code)
5559
0003
030
030
12.00
Dealer-owned paint shop?
Yes
Original paint material?
Yes
Description of Repair
Paint Labor Operation(s)
No
No
Time
Units
Mat'l
Units
Paint lift gate
55597963
160
9
Paint body part (handle)
51016150
30
3
51017173
160
Verify ALL Labor Operation Time Units
and Material Units
Note: Authorization and claim reimbursement are contingent on the usage of original
parts for the repair
Body Painting Prep Time
The vehicle history must be checked for any previous damage. Digital photographs must be included with the repair order per VWoA instructions. If there is a
sublet invoice for painting, the invoice amount must be split between outside (sublet) labor and outside (sublet) material.
Part Number
Part Description
EPOXY
Part Qty
Epoxy Primer
Part Price
per Unit
1 $
Total Part
Price
40.00
Example Part Qty and Part Price per Unit only
Description of Repair
Paint Subtotal
Repair/Replace Labor
Operation(s)
350
12
Time
Units
Remove and install lift gate
55591910
90
Remove and install lift gate trim
55572399
30
Remove and install handle
66511900
20
Remove and install logo
66501900
20
Remove corrosion on lift gate
55596300
60
All other parts should be claimed separately in
the SAGA claim
Example Time Units
Full pre-populated forms can be found in the
following location:
WISE > Resource Center > Forms > Paint/
Corrosion > TB# Form specific to the vehicle
and the repair.
Outside Material
LACKMATF
Part Amount Subtotal
$
40.00
Body Labor Subtotal
220
Total Paint Material Amount
$
144.00
Total TU/MU
570
Total Parts Amount
$
184.00
VW Representative
Authorization No.
Authorization Date
TB 2038999
Authorization
valid until:
Warranty
VW Representative Name (printed)
VW Representative Signature
12
L00#0000 $
350.00
A0041000 $
220.00
Parts and Materials: $
184.00
Total: $
754.00
SRT Reference Table for TPI# 2038999
Repair (1998-2001 B5 Passat) – Models(3B2)
Body Labor
Labor Operation: Remove and
install rear lid
55 90 19 00 = 70 TU
Labor Operation: Remove and
install rear lid trim
70 87 19 00 = 30 TU
Labor Operation: Remove and
install handle
55 57 23 99 = 30 TU
Labor Operation: Remove and
install logo
66 51 19 00 = 20 TU
Labor Operation: Remove and
install rear lettering
66 50 19 00 = 20 TU
Labor Operation: Remove corrosion
on rear lid
55 90 63 00 = * TU
Includes: trim and install protective
foil
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
A0041000
Refinish Labor
Labor Operation: Prepare painting
51 01 71 73 = 160 TU
Labor Operation: Paint rear lid
55 90 79 53 = 160 TU
Labor Operation: Paint body part
(handle)
51 01 61 50 = 30 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
L00#0000*
*Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint rear lid
Labor Operation: Paint body part
(handle)
8 MU
3 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
* Rear lid replacement should be considered if the total repair cost will exceed 80% of the total replacement cost.
Refer to the Reimbursement Policy section of the Warranty Policies and Procedure Manual. This section provides
important guidelines when considering component repair vs. replacement options (the “ 80% rule” ).
Replace (1998-2001 B5 Passat) – Models(3B2)
Body Labor
Labor Operation: Remove and
install rear lid
55 90 19 00 = 70 TU
Labor Operation: Replace rear lid
55 90 55 50 = 90 TU
Labor Operation: Trim and install
protective foil
55 57 23 99 = 20 TU
Labor Operation: Wax body
51 01 75 00 = 30 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
A0041000
Refinish Labor
Labor Operation: Prepare painting
51 01 71 53 = 160 TU
Labor Operation: Paint new rear lid
55 90 61 50 = 110 TU
Labor Operation: Paint body part
(handle)
51 01 61 50 = 30 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
L00#0000*
*Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint new rear lid
Labor Operation: Paint body part
(handle)
9 MU
3 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
Repair (1998-2001 B5 Passat Wagon) – Models(3B5)
Body Labor
Labor Operation: Remove and
install lift gate
55 59 19 10 = 90 TU
Labor Operation: Remove and
install handle
55 57 23 99 = 30 TU
Includes: trim and install protective
foil
Labor Operation: Remove and
install logo
66 51 19 00 = 20 TU
Labor Operation: Remove and
install rear lettering
66 50 19 00 = 20 TU
Labor Operation: Remove corrosion
on lift gate
55 59 63 00 = * TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
A0041000
Refinish Labor
Labor Operation: Prepare painting
Labor Operation: Paint lift gate
Labor Operation: Paint body part
(handle)
51 01 71 73 = 160 TU
55 59 79 63 = 160 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
51 01 61 50 = 30 TU
L00#0000*
*Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint lift gate
Labor Operation: Paint body part
(handle)
9 MU
3 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
* Lift gate replacement should be considered if the total repair cost will exceed 80% of the total replacement cost.
Refer to the Reimbursement Policy section of the Warranty Policies and Procedure Manual. This section provides
important guidelines when considering component repair vs. replacement options (the “ 80% rule” ).
Replace (1998-2001 B5 Passat Wagon) – Models(3B5)
Body Labor
Labor Operation: Remove and
install lift gate
55 59 19 10 = 90 TU
Labor Operation: Replace lift gate
55 59 55 60 = 250 TU
Labor Operation: Trim and install
protective foil
55 57 23 99 = 20 TU
Labor Operation: Wax body
51 01 75 00 = 30 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
A0041000
Refinish Labor
Labor Operation: Prepare painting
Labor Operation: Paint new lift gate
Labor Operation: Paint body part
(handle)
51 01 71 53 = 160 TU
55 59 61 60 = 130 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
51 01 61 50 = 30 TU
L00#0000*
*Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint new lift gate
Labor Operation: Paint body part
(handle)
10 MU
3 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF