2000 Honda Passport · 2019. 2. 1. · 2000 Honda Passport S e rv i c e Bu l l e ti n 1 0 -0 7 9 Applies To:1 9 9 8 ... to r e vi se t h e i n fo r m at i o n m a r ke d b y th e

2/1/2019 10-079 • Safety Recall: Corrosion On Lower Trailing Link Front Brackets (Eligible For Warranty Coverage) (Revised 1/18/2012) • 2000 Hon…

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2000 Honda Passport

Service Bulletin 10-079January 18, 2012– Check the iN VIN status for eligibilityApplies To:1998–2002 Passport

Safety Recall: Corrosion On Lower Trailing Link Front Brackets(Eligible For Warranty Coverage)(Supersedes 10-079, Safety Recall: Corrosion On Lower Trailing Link Front Brackets, datedFebruary 17, 2011, to revise the information marked by the black bars)

CUSTOMER NOTIFICATIONNOTE: Effective January 4, 2012, there are twocampaigns for the lower trailing link front brackets. This All owners of affected vehicles that were originallybulletin addresses affected vehicles that are eligible for purchased or currently registered in a salt belt statewarranty coverage as shown on an iN VIN status were sent a notification of this campaign.inquiry.

Two different notifications were sent: one for vehiclesDo an iN VIN status inquiry, and if you are directed to less than 10 years old (as of September 22, 2010), andthis bulletin, submit a warranty claim for the repair another for vehicles more than 10 years old (as ofwork. September 22, 2010). Examples of both customer

notifications are at the end of this service bulletin.If you are directed to Service Bulletin 12-003, SafetyRecall: Corrosion On Lower Trailing Link Front Before beginning work on a vehicle, verify its eligibilityBrackets (Customer-Pay), do not submit a warranty by checking at least one of these items:claim as the repair is the customer’s responsibility. • The customer has a notification letter.

• The vehicle is shown as eligible on an iN VIN statusREVISION SUMMARY inquiry.A note was added to explain that some vehicles are no

In addition, check for a campaign completion label onlonger covered under warranty.the back edge of the driver’s door, just below the doorlatch. This label indicates that the campaign hasBACKGROUNDalready been completed. Complete the recall repair on

Over time, in areas that use road salt,* excessive an eligible vehicle even if the vehicle is now located incorrosion can develop on or near the brackets a non-salt belt state.attaching the lower trailing links to the frame. If the

Some vehicles affected by this campaign may be incorrosion reaches a heavy stage, a clunking noise mayyour used vehicle inventory. These vehicles must bebe heard during acceleration and braking. In rare casesrepaired before they are sold.of severe corrosion, a trailing link could separate from

the frame. If this happens, vehicle handling could be Should a dealership sell an unrepaired vehicle thataffected, increasing the risk of a crash. subsequently causes an injury or damage because of

the recalled item, the dealership will be solely* Road salt is commonly used in an area known as theresponsible to the damaged party, and will be required“salt belt.” As shown in the shaded area of the map,to defend and indemnify American Honda for anythe salt belt includes these states: Connecticut,resulting claims. To see if a vehicle in inventory isDelaware, Illinois, Indiana, Iowa, Kentucky, Maine,affected by this campaign, do an iN VIN status inquiryMaryland, Massachusetts, Michigan, Minnesota,before selling it.Missouri, New Hampshire, New Jersey, New York,

Ohio, Pennsylvania, Rhode Island, Vermont, WestVirginia, Wisconsin, and Washington D.C.

1 of 24© 2012 American Honda Motor Co., Inc. – All Rights Reserved ATB 45390-47474 (1201)

CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment,and training to correctly and safely maintain your vehicle. These procedures should not be attempted by “do-it-yourselfers,” and you should not assumethis bulletin applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact anauthorized Honda automobile dealer.

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REQUIRED MATERIALSCORRECTIVE ACTIONInspect the lower trailing link frame brackets for NOTE: Order Noxudol products directly from Noxudolcorrosion (see page 3) and, depending on the stage of at 818-308-8430. To receive the Honda dealer price,corrosion, do one of these repairs: be sure to mention that you are a Honda dealer, and

provide your dealer number. Because orders are• STAGE 1 REPAIR (about 50 percent of affectedshipped by Noxudol, expect 5–6 days betweenvehicles): Apply Noxudol 300 anti-corrosion waxordering the product and receiving it.(see page 5).Noxudol 300 Anti-Corrosion Wax: P/N 2-9005D-100-0• STAGE 2 REPAIR (about 40 percent of affected

STAGE 1 and STAGE 2 REPAIRS: One canvehicles): Apply Noxudol 300 and Noxudol 700repairs four vehicles.anti-corrosion wax (see page 6).STAGE 3 REPAIR: One can repairs two vehicles.• STAGE 3 REPAIR (about 9 percent of affectedSTAGE 4 REPAIR: One can repairs one vehicle.vehicles): Install Trailing Link Frame Bracket Kit A,

and apply Noxudol 300 and Noxudol 700 Noxudol 700 Anti-Corrosion Wax: P/N 2-9005D-000-0anti-corrosion wax (see page 9). STAGE 2 and STAGE 3 REPAIRS: One can

• STAGE 4 REPAIR (only about 1 percent of affected repairs one vehicle.vehicles): Install Trailing Link Frame Bracket Kit B, STAGE4 REPAIR: Two cans repair one vehicle.and apply Noxudol 300 and Noxudol 700anti-corrosion wax (see page 14).

TOOL INFORMATIONNOTE:PARTS INFORMATION• The pop nut installer, the 1/4 in. drill guide, and theFrame Rail Side Hole Plug (two required): 33/64 in. drill bit were auto-shipped to all dealers in

P/N 8-97175-885-0 the salt belt states as required special tools.(Needed only if the original plugs are damaged or • If you are a dealer located outside the salt beltmissing.) states, and have a vehicle that requires a STAGE 3

Trailing Link Frame Bracket Kit A: or STAGE 4 REPAIR, please call the Honda Tool1998–00 - P/N 8-98181-806-0 Loan Program at 1-800-824-9655 to obtain the

above tools on a loaner basis.2001–02 - P/N 8-98181-813-0NOTE: This kit is needed only for a STAGE 3 • 12–16 oz. hammer (commercially available)REPAIR.

• 3/16 in. x 9 in. flat punch (commercially available)Contains left and right type A reinforcement• 9 in. C-clamp* (two required, commercially available)brackets, flange bolt (2), flange nut (2), bracket bolt

(6), pop nut (9), front link bolt (2), front link nut (2), • Reciprocating saw and blades (14 TPI or more)*washer*, 3/4 in. round label (8), and pop nut test (commercially available)plate. • 3/8 in. drill motor* (commercially available)* Included in kit P/N 8-98181-806-0 only. • 1/2 in. drill motor* (commercially available)

Trailing Link Frame Bracket Kit B: • 1/4 in. drill bit* (commercially available)P/N 8-98181-814-0 • Ratcheting strap (2)* (commercially available)NOTE: This kit is needed only for a STAGE 4 • 4x4x7 in. wood block* (two required,REPAIR. commercially available)Contains left and right type B reinforcement • 4x4x10-1/4 in. wood block* (two required,brackets, flange bolt (2), flange nut (2), bracket bolt commercially available)(32), pop nut (35), rear link bolt (2), rear link nut (2),

• Pop Nut Installer*3/4 in. round label (32), pop nut test plate, M6 boltIncludes Pop Nut Installer, air regulator, and(4), M8 nut (4), wire harness clip (3), fuel hose clippneumatic fitting(6), fuel tank mounting bolt (5), fuel tank nut,

exhaust pipe gasket (2), EGR valve gasket (2), and • 1/4 in. Drill Bit Guide*brake line clip (7). • 33/64 in. Drill Bit*

* Needed only for STAGE 3 or STAGE 4 REPAIRS.

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INSPECTION PROCEDUREWARRANTY CLAIM INFORMATIONNOTE: Do this inspection on both sides of the vehicle.OP# Description FRT1. Raise the vehicle on a lift. To allow enough

4195A2 Inspect the trailing link front brackets, 0.3 clearance for the inspection, make sure the rearand do the STAGE 1 REPAIR. lifting points are at least 12 inches (300 mm) aheadof the rear trailing link front mounting brackets.4195A3 Inspect the trailing link front brackets, 0.4

and do the STAGE 2 REPAIR. 2. Visually inspect the lower trailing link front bracketA Add for removing and reinstalling side 1.0 area at the red circle in the photo below:

steps or running boards• If the vehicle’s bracket area is rusted to a similar

or lesser degree than that in the photo, go to4195A4 Inspect the trailing link front brackets, 1.4and do the STAGE 3 REPAIR. STAGE 1 REPAIR (see page 5).

A Add for removing and reinstalling side 1.0 • If the vehicle’s bracket area is rusted to a greatersteps or running boards degree than that in the photo, go to the next step.

10.04195A5 Inspect the trailing link front brackets • If the vehicle had a prior repair resulting in aand the entire underside of the vehicle, modification to the lower trailing link fronttake photos, open a case with Tech brackets, stop the inspection, call Tech Line toLine, and do the STAGE 4 REPAIR. open a case, then take photos of the area, andAdd for removing and reinstalling side send them to Tech Line.1.0Asteps or running boards.

Check for rust in this area.Failed Part: P/N 8-97366-503-0Defect Code: 5XZ00Symptom Code: R4800Skill Level: Repair Technician

3. If the vehicle has side steps or running boards,remove them.

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5. Using the 3/16 in. x 9 in. flat punch and the4. Use a 3/16 in. x 9 in. flat punch and a 12–16-oz.12–16-oz. hammer, strike the radius of the framehammer to strike the frame areas marked X in thecorners on each of the X-marked areas shownillustration below. Swing the hammer with a 10 tobelow. Again, swing the hammer with a 10 to 1212 inch stroke to be sure enough force is applied toinch stroke to be sure enough force is applied to thethe punch.flat punch.• If the flat punch doesn’t poke a hole in any of the• If the flat punch doesn’t poke a hole in any of theX-marked areas on the frame, go to STAGE 2

X-marked areas, go to STAGE 3 REPAIR (seeREPAIR (see page 6).page 9).• If the flat punch pokes a hole in any of the

• If the flat punch pokes a hole in any of theX-marked areas, or if there are pre-existing holesX-marked areas, go to STAGE 4 REPAIR (seein the frame above the lower trailing link frontpage 14).bracket, go to the next step.

Punch here.Punch here.

FRAME RAIL

FLATFRAMEPUNCH

BRACKET

FLATPUNCH

CROSS-SECTION

Strike the radiusof the frame corners.

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4. Fill out the information on a campaign completionSTAGE 1 REPAIRlabel. Stick this label to the back edge of theNOTE:driver’s door, just below the door latch.• Do this repair on both sides of the vehicle.NOTE: If you need more labels, order them from• Noxudol spray is highly flammable. Keep away from Helm using reorder number Y0895.ignition sources (no smoking). Keep at a

temperature not exceeding 120°F (50°C).• Wear hand and eye protection to avoid direct contact

with the Noxudol spray. Spraying should be done inan area with adequate ventilation. DOOR

LATCH1. Using a wire brush and a scraper, remove any

loose frame coating and rust from the outside framerail and the lower trailing link frame bracket in the20-inch (500 mm) section shown below.

Wire brush andscrape this area.

Rear LowerTrailing LinkRecall Campaign500 mmCompletionDate ______________

Dealer No. __________

CROSS-SECTIONOF FRAMEAND BRACKET

NOXUDOL 300

2. Use a dry rag to remove any remaining dust ordebris. If the area is wet, dry it with an air nozzle.

3. Spray a coat of Noxudol 300 onto the lower trailinglink frame brackets, and on the outside of the framerails in the area you just cleaned. The total sprayarea is about 20 inches (500 mm). Be careful not tooverspray onto the exhaust system or body paintedareas.

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6. Attach the long nozzle to the Noxudol 700 can, thenSTAGE 2 REPAIRuse a pen or tape to mark the nozzle at 12 inchesNOTE:(300 mm) and at 7 inches (200 mm) from the• Do this repair on both sides of the vehicle. nozzle end. These marks indicate how far you will

• Noxudol spray is highly flammable. Keep away from insert the nozzle into the frame rails for some of theignition sources (no smoking). Keep at a following steps.temperature not exceeding 120°F (50°C).

• Wear hand and eye protection to avoid direct contact .with the Noxudol spray. Spraying should be done inan area with adequate ventilation.

1. Remove the frame rail side hole plug from thedriver’s and passenger’s side frame rails.

FRAME RAIL SIDE HOLE PLUG

7. Place a drain pan below the frame’s drain hole nextto the trailing link bracket. This will catch the excessNoxudol 700 that runs out of the frame’s drain hole,which is expected and normal.

2. Using a hammer, knock on the outside of the framerail around the lower trailing link bracket area toloosen any rust on the inside of the frame.

3. Using an air nozzle, blow into the frame rail hole, upand down inside the frame, to move any debrisaway from the trailing link bracket area.

4. Using a wire brush and a scraper, remove anyloose frame coating and rust from the outside framerail and the lower trailing link frame bracket in the20-inch (500 mm) section shown below.

LONGBRACKETWire brush and NOZZLE

scrape this area. FRAMEDRAIN HOLE

500 mm

5. Use a dry rag to remove any remaining dust ordebris. If the area is wet, dry it with an air nozzle.

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10. Insert the Noxudol 700 spray nozzle about 7 inches8. Insert the Noxudol 700 spray nozzle about(200 mm) into the frame rail side hole, toward the12 inches (300 mm) into the frame drain holerear of the vehicle. Then spray the Noxudol whilelocated on the bottom of the frame rail, toward thepulling out the nozzle. Spray four times.rear of the vehicle. Then spray the Noxudol while

drawing out the nozzle. Spray two times.FRAME RAIL SIDE HOLE

FRAME DRAIN HOLE

FWDFWD

11. Insert the Noxudol 700 spray nozzle into the framerail side hole, pointing up, until it touches the top of9. Insert the Noxudol 700 spray nozzle aboutthe frame. Spray the Noxudol upward while pulling12 inches (300 mm) into the frame rail side hole,out the nozzle. Spray two times.toward the front of the vehicle. Then spray the

Noxudol while drawing out the nozzle. Spray four FRAME RAIL SIDE HOLEtimes.

FRAME RAIL SIDE HOLE

FWD

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15. Reinstall both frame rail side hole plugs. If either12. Insert the Noxudol 700 spray nozzle into the frameplug was damaged or missing, install a new one.rail side hole, pointing down, until it touches the

bottom of the frame. Spray the Noxudol downward 16. If the side steps or the running boards werewhile pulling out the nozzle. Spray two times. removed, reinstall them.FRAME RAIL SIDE HOLE 17. Fill out the information on a campaign completion

label. Stick this label to the back edge of thedriver’s door, just below the door latch.NOTE: If you need more labels, order them fromHelm using reorder number Y0895.

DOORLATCH

13. Remove the long spray nozzle from the Noxudol700 can, and attach the regular spray valve. Spraya coat of Noxudol 700 on the outside of both lowertrailing link frame brackets and frame rails in the20-inch (500 mm) section shown below. Be carefulnot to overspray onto the exhaust system or body

Rear Lowerpainted areas.Trailing Link

Wire brush and Recall Campaignscrape this area.CompletionDate ______________

Dealer No. __________

500 mm

CROSS-SECTIONOF FRAMEAND BRACKET NOXUDOL

700 and 300

14. Spray a coat of Noxudol 300 on the same areasyou sprayed in step 13. Be careful not to oversprayonto the exhaust system or painted areas on thebody.

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4. Using two ratcheting straps, lash up both sides ofSTAGE 3 REPAIRthe rear axle to remove the tension on the trailingNOTE: Do this repair on both sides of the vehicle.links:

1. Remove the frame rail side hole plug from both • Attach one end of the straps to the lower trailingframe rails. link rear mounting bracket on the rear axle.

• Route the strap around the rear axle, makingFRAME RAIL SIDE HOLE PLUGsure not to route it over any brake lines.

• Attach the other end of the straps to thetransmission mount crossmember.

• Ratchet the straps to apply enough forwardtension on the rear axle to allow the lower trailinglink front mounting bolts to be moved by hand.

REAR AXLE

RATCHETINGSTRAP

2. Remove the lower trailing link front mounting nutsfrom both trailing links. The mounting bolts will beremoved later.

BODY MOUNT #4(Remove the lower half.)

TRANSMISSIONMOUNTCROSSMEMBER

5. Using a hammer, knock on the outside of the frameLOWER TRAILING LINKFRONT MOUNTING NUT rail around the lower trailing link bracket area to(Remove.) loosen any rust on the inside of the frame.

3. Remove the lower half of body mount #4 from bothsides of the vehicle.

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6. Using a wire brush and a scraper, remove any TYPE A REINFORCEMENT BRACKETloose frame coating, weld spatter, and rust from theoutside frame rail and the lower trailing link framebracket in the 20-inch (500 mm) section shownbelow.

Wire brush andscrape this area.

500 mm

7. Use a dry rag to remove any remaining dust ordebris. If the area is wet, dry it with an air nozzle. Passenger’s Side: All Models

8. Temporarily install both type A reinforcement TYPE A REINFORCEMENT BRACKETbrackets using the original lower trailing link frontmounting nuts, C-clamps, and new body mountstuds and nuts.NOTE:• When securing the C-clamp on the passenger’s

side, be sure not to contact the brake lines on theinside of the frame rail.

• On some 2000 models and all 2001–02 models,you need to remove the fuel tank protectormounting bolt from the driver’s side. Save thebolt; it’s required for the temporary and the finalinstallation of the driver’s side type Areinforcement bracket.

Driver’s Side: Some 2000 models, and all 2001-02models (Weld nut allows temporaryinstallation of front nut.)

TYPE A REINFORCEMENT BRACKET

Driver’s Side: All 1998-99 models,and some 2000 models

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12. Test fit a pop nut into each hole to be sure drilling is9. Using a 3/8 in. drill motor, a 1/4 in. drill guide, and acomplete.1/4 in. bit, drill three pilot holes per side into the

bottom of the frame rail, through each hole in the NOTE: If a pop nut doesn’t fit, don’t try to enlargetype A reinforcement bracket. the hole by pivoting the drill bit. Doing this creates

an uneven seating surface for the pop nut. To helpNOTE: On some 2000 models and all 2001–02drill an even seating surface, make sure you keepmodels, the driver’s side requires only two holesyour drill bit sharp.due to the welded nut inside the frame, at the front

bracket hole. Do not drill a hole in this location. 13. Insert an air gun into the frame rail hole, and blowup and down the inside of the frame rails to move

REINFORCEMENT any rust or metal debris away from the area.BRACKET14. Attach the pop nut installer to shop air, and adjust

the tool’s air pressure regulator to between 72 and87 psi.NOTE:• The tool’s air pressure is critical: if it’s too low,

the pop nuts cannot be correctly installed; if it’stoo high, the tool will be damaged.

• If this is your first time using the pop nut installer,or if you haven’t used it in a while, practiceinstalling one or two pop nuts onto the pop nut1/4 IN. DRILL GUIDE AND BIT

DRILLING THROUGH TYPE A test plate:BRACKET AND INTO FRAME- Place a pop nut at the tip of installer’s threaded

mandrel. Make sure to keep your fingers awayfrom the gap between the pop nut and thebase of the mandrel. Squeeze the installer’strigger; the pop nut threads onto the mandrel.

DRILLED PILOT HOLES

POPNUT

POPPOPNUTSNUTS

POP NUT INSTALLER WITHAIR PRESSURE REGULATOR

- Insert the pop nut into a hole on the pop nut-* POP NUT ON ALL 1998 99 AND test plate. Make sure the pop nut is seatedSOME 2000 MODELS;against the plate.WELD NUT ON SOME 2000 AND

-ALL 2001 02 MODELS.

10. Remove both type A reinforcement brackets. Savethe body mount studs and nuts for the final POP NUTSPOP NUTinstallation, and discard the original trailing link TEST PLATEfront mount mounting nuts.

11. Using a 1/2 in. drill motor and a 33/64 in. bit, drillfinal holes where you made the pilot holes.

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16. Cover all six holes with the 3/4 in. round labels from- Squeeze and hold the installer’s trigger untilthe kit. This will prevent the Noxudol anti-corrosionthe mandrel reverses and unthreads the popwax from contaminating the pop nut threads andnut.the weld nut threads (if applicable). Also, use- Measure the diameter of the expanded (crush)masking tape to cover the other areas shownsection of the installed pop nut; it should be atbelow. This will prevent the Noxudol fromleast 15 mm. If you need more practice, installcontaminating the bracket mounting surfaces.another pop nut on the test plate.MASKING TAPE

15.0 mm

15. Install pop nuts in the holes you drilled on the frame(six holes for all 1998–99 models and some 2000models, five holes for some 2000 models and all2001–02 models). Make sure each pop nut isseated against the frame before you pull the trigger.Continue holding the trigger until the mandrelreverses direction. Once reversed, pull backslightly, and the mandrel unthreads out of thepop-nut. ROUND

LABELS

17. Apply Noxudol 700 and Noxudol 300 anti-corrosionwaxes (see steps 5 thru 13 of STAGE 2 REPAIR).

18. Remove the round labels and the masking tape.19. Remove the passenger’s side lower trailing link

front mounting bolt.NOTE: On 2000–02 Passports, interference fromthe exhaust silencer (muffler) prevents removal ofthe front mounting bolt. On these vehicles, use areciprocating saw to cut off the bolt head, then slidethe rest of the bolt through the other side of themount.

LOWER TRAILINGLINK FRONTMOUNTING BOLT

RECIPROCATINGSAW

PASSENGER-SIDE POP NUTS INSTALLED

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22. Install the driver’s side type A reinforcement20. Install the passenger’s side type A reinforcementbracket using the hardware in the kit. The requiredbracket using the hardware in the kit:parts vary, depending on the vehicle model yearInstall the trailing link front mounting nut and boltand frame design. To correctly install the driver’shand-tight, then torque the remaining bolts andside type A reinforcement bracket, use thenuts, in the order shown on the illustration below:illustrations below for reference..• Torque the bracket bolts to 35 N m (25 lb-ft).All 1998–99 models and some 2000 models require

• Torque the body mount stud and nut to three bolts and one body mount stud and nut; some.30 N m (22 lb-ft). 2000 models require three bolts, one body mountstud and nut, plus one washer; all 2001–02 modelsBODY MOUNT STUD AND NUT require three bolts, one body mount stud and nut,.30 N m (22 lb-ft)plus one fuel tank protector bolt.

4

32 1

LOWER TRAILINGLINK FRONTMOUNTING BOLT BRACKET BOLTS(Hand tighten.) .35 N m (25 lb-ft)

21. Remove the driver’s side lower trailing link frontmounting bolt:• Push the bolt out toward the fuel tank as far as

possible.• Cut off the bolt head with a reciprocating saw.• Push the bolt out through the opposite side of the

bracket.

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26. Fill out the information on a campaign completionInstall the lower trailing link front mounting nut andlabel. Stick this label to the back edge of thebolt hand-tight, then torque the remaining bolts anddriver’s door, just below the door latch.nuts, in the order shown on the illustration below:

.• Torque the bracket bolts to 35 N m (25 lb-ft). NOTE: If you need more labels, order them fromHelm using reorder number Y0895.• Torque the body mount studs and nut to

.30 N m (22 lb-ft).LOWER HALF OFBODY MOUNT #4

. DOOR50 N m (37 lb-ft)LATCHBODY MOUNT

STUD AND NUT.30 N m (22 lb-ft)

4

31 2

Rear LowerTrailing LinkRecall CampaignCompletionLOWER TRAILING

LINK FRONTBRACKET BOLTS Date ______________.35 N m (25 lb-ft) MOUNTING BOLT

Dealer No. __________(Hand tighten.)

• Reinstall the lower half of body mount #4 on both.msides of the vehicle. Torque the nuts to 50 N

(37 lb-ft). STAGE 4 REPAIR23. Remove the ratcheting straps. NOTE:

• If the vehicle requires a STAGE 4 repair or had a24. Lower the vehicle to the ground, then torque theprior repair resulting in a modification to the lowerlower trailing link front mounting bolts totrailing link front bracket area, an additional.165–180 N m (122–133 lb-ft).inspection of the entire underside of the vehicle must

25. If the side steps or the running boards were be completed and any damage and/or modificationsremoved, reinstall them. to the frame must be noted to determine if the

campaign service remedy can or should becompleted.

• Contact Tech Line to open a case:- Inform them of any relevant information that may

affect the completion of the repair.- Provide photos of the lower trailing link bracket

area to the following e-mail address:[email protected]. (Include the VIN andthe Tech Line reference number in the subject titleof the e-mail.)

- Based on your information, Tech Line willdetermine the vehicle’s eligibility for completing aSTAGE 4 repair or, if the a vehicle had amodification to the lower trailing link bracket area,determine the repair level needed. If any issuespreventing completion of the repair, or any newevidence is learned during the repair that willprevent completion, contact Tech Line to reportyour findings.

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5. Remove the fuel tank assembly:• Type B reinforcement brackets used in a STAGE 4REPAIR require holes to be drilled in specific areas • Disconnect the fuel line at the fuel filter and theof the frame (inboard and outboard sides). Prior to fuel return hoses.receiving the brackets for a repair, match the

• Disconnect the fuel tank at locations 2, 3, and 4.locations of these holes to the frame in theshown below.illustrations below; this will help you to determine if

the brackets can be installed. Photos of the inboardand outboard frame areas will show the feasibility of

‘01/’02 MYthe installation and must be provided to Tech Line.INBOARD SIDE OF DRIVER’S FRAME RAIL

‘98/’00 MY

DRIVER’S SIDE TYPE BREINFORCEMENT

1 - FUEL TANKBRACKET2 - FUEL LINE CLIP3 - FUEL LINE CLIP4 - FUEL LINE CLIPOUTBOARD SIDE OF DRIVER’S FRAME RAIL

5 - FUEL PIPE MOUNTING BOLTS6 - FUEL TANK MOUNTING BOLTS

6. Loosen the parking brake cable mounting bracketson both sides of the frame (four places).

DRIVER’S SIDE

• This repair includes removing and reinstalling thefuel tank assembly, fuel lines, and vent lines. Takenormal precautions during removal, storage, andreinstallation of these parts. Make sure to do thisrepair in a well vented area, away from any ignitionsources.

• This repair involves raising the body off the frameand cutting the original rear trailing link frontmounting brackets off the frame rails. To avoidpermanent frame damage that would make thevehicle unrepairable, carefully follow all of the steps.If you are unfamiliar with this type of repair, sublet itto a qualified body/frame repair shop.

• If needed, refer to the appropriate Passport ServiceManual for any steps not fully detailed. PASSENGER’S SIDE

• Do this repair on both sides of the vehicle. 4

1. Remove the radiator grille. 3

2. Remove the linear EGR valve.3. Remove the rear bumper assembly.4. Remove the exhaust silencer (muffler).

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Documents

2000 Honda Passport · 2019. 2. 1. · 2000 Honda Passport S e rv i c e Bu l l e ti n 1 0 -0 7 9 Applies To:1 9 9 8 ... to r e vi se t h e i n fo r m at i o n m a r ke d b y th e