V551601 2038993

Technical Bulletin
Model(s)
Year
Eng. Code
Trans. Code
VIN Range From
VIN Range To
Passat Wagon
1998 – 2010
All
All
All
All
Condition
55 16 01 January 19, 2016 2038993 Supersedes Technical Bulletin V551407 dated December 19, 2014 to
update model year applicability.
Corrosion on Rear Lid at Rear Window Area
Figure 1
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
When the rear window heater is switched ON, power is transmitted to the outer sealing lip of the rear window.
In some places the window sealer makes contact with the bus bar of the rear window heater.
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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
Production Solution
Not applicable.
Service
1a. Repair rear lid and replace rear window Only perform this operation if the total repair cost is 80% or less of
the total replacement cost.
Or
1b. replace rear lid and replace rear window
Note:
If the rear lid is rusted through, do not repair, replace with a new part.
Install a new rear glass in every case, since the complete removal of the sealer from the bus bar cannot be
guaranteed. Use sealer part number DH 009 100 03 or DA 004 600 A2 - for sealing the window.
To avoid repeat cases make sure that no sealer gets on the bus bar of the rear window. Cover the bus bar with
masking tape during installation and remove the tape after sealing.
1a. Repair the rear lid, replace rear window:
 Remove the rear window according to the repair manual. See repair group 64 in Elsa
 Remove the corrosion on the outer rear lid with the pneumatic brush grinder.
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”).
 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 new rear window glass according to the repair manual. See repair group 64 in Elsa.
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© 2016 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
1b. Rear lid and rear window replacement:
 Remove all necessary parts / trim pieces of the original rear lid. See Repair Group 70 and Repair Group 55 in
Elsa.
 Paint the new rear lid according to the 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 new rear window glass according to the repair manual. See repair group 64 in Elsa.
 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.
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© 2016 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
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.
To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
Procedures Manual 1)
Model(s)
Year(s)
Eng. Code(s)
Trans. Code(s)
VIN Range From
VIN Range To
Passat Wagon
1998 – 2010
All
All
All
All
SAGA Coding
Claim Type:
1601)
Damage
Service Number:
Code
5559
0003
Parts Manufacturer
HST
Damage Location
(Depends on Service No.)
--
030
Passat Wagon (3B5,3B6,3C5)
0302)
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
- L0020000: External Painting-metallic/2-layer
Claim Dollar Amount
- L0030000: External Painting-pearl color
Use this for all body repair in this bulletin:
- A0041000: Body Shop repair no paint
Claim Dollar Amount
- A0061000: Glass Replacement
Replace
Please use the following part number in “Outside Materials” 4)
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© 2016 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
- L0020000: External Painting-metallic/2-layer
Claim Dollar Amount
- L0030000: External Painting-pearl color
Use this for all body repair in this bulletin:
- A0041000: Body Shop repair no paint
Claim Dollar Amount
- A0061000: Glass Replacement
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 2038993” 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.
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© 2016 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
Part number
Designation
3B9 827 025 AR
Lift Gate (rear trunk lid) (B5)
3C9 827 025 D/M/K
Lift Gate (rear trunk lid) (B6)
Repair and Replacement
D 004 660 M2
1K window sealer
Always check ETKA for latest information on part applicability.
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.
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© 2016 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
400000
Dealer No.
Repair
Order No.
910000
VIN (17-Digits)
If repeat repair, provide explanation in box below:
WVWPD63BX4E000000
Color No. (4-digit ElsaPro Paint No.)
LA7W
Dealer Labor Rate
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 lift gate
Paint Labor Operation(s)
No
No
Time
Units
Mat'l
Units
55597963
160
51017173
160
9
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
All other parts should be claimed separately in
the SAGA claim
Description of Repair
Outside Material
64865510
190
Remove and install lift gate
55591910
90
Remove and install rear lock mechanism
55571960
10
Remove and install rear logo
66511900
20
Remove and install rear letterings
66501900
20
Remove corrosion on rear lid
55596300
60
Wax body
51017500
30
Example Time Units
Part Amount Subtotal
$
40.00
Body Labor Subtotal
420
$
108.00
Total TU/MU
740
Total Parts Amount
$
148.00
Authorization Date
TB 2038993
L00#0000 $
A0041000 & A006100
Authorization
valid until:
Warranty
VW Representative Name (printed)
9
Time
Units
Total Paint Material Amount
VW Representative
Authorization No.
Repair/Replace Labor
Operation(s)
320
Replace the rear window
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.
LACKMATF
Paint Subtotal
VW Representative Signature
9
320.00
$
420.00
Parts and Materials: $
148.00
Total: $
888.00
Paint/Corrosion Claim Form
Dealer No.
400000
Repair
Order No.
910000
VIN (17-Digits)
WVWPD63BX4E000000
Color No. (4-digit ElsaPro Paint No.)
LA7W
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 lift gate
Paint Labor Operation(s)
No
No
Time
Units
Mat'l
Units
55596160
130
51017153
160
10
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)
290
10
Time
Units
Remove and install lift gate
55591910
90
Replace lift gate
55595560
250
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
$
120.00
Total Parts Amount
$
120.00
VW Representative
Authorization No.
Body Labor Subtotal
Total TU/MU
Authorization Date
TB 2038993
Authorization
valid until:
Warranty
VW Representative Name (printed)
VW Representative Signature
370
660
10
L00#0000 $
290.00
A0041000 & A006100 $
370.00
Parts and Materials: $
120.00
Total: $
780.00
SRT Reference Table for TPI# 2038993
Repair (B5 Passat Wagen) – Model(3B5) 1998-2001
Body Labor
Labor Operation : Replace the rear
window
64 86 55 10 = 190 TU
Labor Operation : Remove and
install lift gate
55 59 19 10= 90 TU
Labor Operation : Remove and
install rear lock mechanism
55 57 19 60 = 10 TU
Labor Operation : Remove and
install rear 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
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:
A0061000
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 lift gate
55 59 79 63 = 160 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 boot lid
9 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 (B5 Passat Wagen) – Model(3B5) 1998-2001
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 : Wax body
51 01 75 00 = 30 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
A0041000
Glass replacement:
Subtract total glass replacement
cost from total above. Enter in
SAGA under Outside Labor
Operation:
A0061000
Refinish Labor
Labor Operation: Prepare painting
51 01 71 53 = 160 TU
Labor Operation: Paint lift gate
55 59 61 60 = 130 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 lift gate
10 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
Repair (B6 Passat Wagen) – Model(3C5) 2006-2010
Body Labor
Labor Operation : Replace the rear
window
64 86 55 10 = 190 TU
Labor Operation : Remove and
install lift gate
55 59 19 00= 130 TU
Labor Operation : Remove and
install rear lock mechanism
55 57 19 60 = 10 TU
Labor Operation : Remove and
install rear 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
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:
A0061000
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 lift gate
55 59 79 53 = 130 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 boot lid
9 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 (B6 Passat Wagen) – Model(3C5) 2006-2010
Body Labor
Labor Operation : Remove and install
lift gate
55 59 19 00 = 130 TU
Labor Operation : Replace lift gate
55 59 55 50 = 220 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
Glass replacement:
Subtract total glass replacement
cost from total above. Enter in
SAGA under Outside Labor
Operation:
A0061000
Refinish Labor
Labor Operation: Prepare painting
51 01 71 53 = 160 TU
Labor Operation: Paint lift gate
55 59 61 50 = 130 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 lift gate
13 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
SRT Reference Table for TPI# 2038993
Repair (Passat Wagon) – Model (3B6) 2001-2006
Body Labor
Labor Operation : Replace the rear
window
64 86 55 10 = 190 TU
Labor Operation : Remove and
install lift gate
55 59 19 10= 90 TU
Labor Operation : Remove and
install rear lock mechanism
55 57 19 60 = 10 TU
Labor Operation : Remove and
install rear logo
66511900 = 20 TU
Labor Operation : Remove and
install rear lettering
66 50 19 00 = 20 TU
Labor Operation : Remove
corrosion on lift gate
55596300= * 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:
A0061000
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 lift gate
55 59 79 63 = 160 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 boot lid
9 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 (Passat Wagon) – Model(3B6) 2001-2006
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 : Wax body
51 01 75 00 = 30 TU
Refinish Labor
Labor Operation: Prepare painting
51 01 71 53 = 160 TU
Labor Operation: Paint lift gate
55596160 = 130 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
A0041000
Glass replacement:
Subtract total glass replacement
cost from total above. Enter in
SAGA under Outside Labor
Operation:
A0061000
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 lift gate
10 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF