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 paintcamp@vw.com. 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.)