GROUP

NUMBER

CAMPAIGN
DATE

Technical Service Bulletin

24-01-033H
MODEL(S)
KONA (OS)
KONA ELECTRIC
(OS EV)

MAY 2024

OUTER TAILGATE HANDLE SWITCH REPLACEMENT
(SERVICE CAMPAIGN TBQ)

SUBJECT:

 IMPORTANT
Dealers must perform this service campaign on all affected vehicles prior to customer retail delivery
and whenever an affected vehicle is in the shop for any maintenance or repair.
Access the “Vehicle Information” screen via WebDCS to identify open campaigns.

Description: This bulletin provides information to replace the outer tailgate handle switch due to a
defective rubber injection which allows water to leak into the switch, potentially hindering proper
tailgate opening.

Applicable Vehicles (Certain):.
• 2023MY Kona (OS) produced 5/12/2023–8/17/2023
• 2023MY Kona Electric (OS EV) produced 5/24/2023–7/26/2023

Parts Information:
Model

Part Name

Part Number

Figure

Remarks
Handle Switch (Qty. 1)

Kona
(OS)
Kona
Electric
(OS EV)

Outer Tailgate
Handle Switch
Assembly Kit

Pull Handle (Qty. 1)
81260-J9000-QQH
Joint Terminal (Qty. 3)

Heat Shrink Tube (Qty. 3)

Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair

SUBJECT:

OUTER TAILGATE HANDLE SWITCH REPLACEMENT (SERVICE CAMPAIGN TBQ)

Warranty Information:
Model

Op. Code

Kona (OS)
Kona Electric 40D008R0
(OS EV)

Operation

Op.
Time

Outer Tailgate Handle
0.5 M/H
Switch Replacement

Causal Part

Nature
Code

Cause
Code

81260-J9000

B19

ZZ7

NOTE 1: Submit claim on Claim Entry Screen as “Campaign” type.
NOTE 2: If a part is found in need of replacement while performing this service campaign and the
affected part is still under warranty, submit a separate claim using the same repair order. If the
affected part is out of warranty, submit a Prior Approval request for goodwill consideration prior to
performing the work.
NOTE 3: This TSB includes Repair validation photos. Op times include VIN, Mileage, and Repair
validation photo(s) as outlined in the Digital Documentation Policy.
NOTE 4: The incident parts are subject to callback through the normal Warranty Technical Center
(WTC) parts return process. Claim is subject to debit if the part is not returned.
NOTE 5: Dealer will be reimbursed $0.18 for 2 zip ties under the labor op code.

Service Procedure:

STUI
This TSB includes Repair validation photos. Refer to the latest Digital Documentation Policy for
requirements.
1.

Open the tailgate.

2.

Disconnect the negative (–) battery terminal.

3.

Use a plastic trim tool to remove and replace
the pull handle (A).

A

NOTICE
Do NOT use metal tools to avoid damage
to the pull handle or body.

TSB #: 24-01-033H

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4.

OUTER TAILGATE HANDLE SWITCH REPLACEMENT (SERVICE CAMPAIGN TBQ)

! CAUTION

C

Wear gloves to avoid injuries to hands.
After removing the mounting screws (B) and
fasteners (C), use a plastic trim tool to remove
the tailgate trim panel assembly (D).

NOTICE
Do NOT use metal tools to avoid damage
to the lower trim of the tailgate.

B
B

i

Information

Replace damaged clips or pin-type
retainers.

D

D

5.

Remove the 4 garnish mounting nuts (E) from
the tailgate.

E

TSB #: 24-01-033H

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6.

OUTER TAILGATE HANDLE SWITCH REPLACEMENT (SERVICE CAMPAIGN TBQ)

Disconnect the outer handle connector (F)
from the tailgate harness.

F

7.

Detach exterior garnish by pinching both fixing
fasteners (G) and gently pushing outwards.

i

Information

Replace any damaged fasteners.

G

G

TSB #: 24-01-033H

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OUTER TAILGATE HANDLE SWITCH REPLACEMENT (SERVICE CAMPAIGN TBQ)

8.

Detach the wiring grommet (H) from the
tailgate panel assembly and gently pull out the
harness with garnish from the outside of the
panel.

9.

Remove the 2 mounting screws (I) from the
switch.

H

I

I

TSB #: 24-01-033H

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10.

OUTER TAILGATE HANDLE SWITCH REPLACEMENT (SERVICE CAMPAIGN TBQ)

Cut the ends (J) of the wires connected to the
outer tailgate handle switch and remove the
switch (K).
K

J

K

11.

Remove about 5 mm (roughly 1/4 inch) of
cladding (L) from the ends of the wires.

L

TSB #: 24-01-033H

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12.

OUTER TAILGATE HANDLE SWITCH REPLACEMENT (SERVICE CAMPAIGN TBQ)

Remove about 5 mm (roughly 1/4 inch) of
cladding (M) from the ends of the wires on the
NEW outer tailgate handle switch.

M

M

13.

Slide 2 heat shrink tubes (N) onto the wires of
the outer tailgate handle switch as shown in
the image.

TSB #: 24-01-033H

N

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14.

OUTER TAILGATE HANDLE SWITCH REPLACEMENT (SERVICE CAMPAIGN TBQ)

Use a proper crimping tool (O) to connect the
joint terminals (P).

i

O

Information

Verify the connection of the joint
terminals by gently pulling the wires in
opposite directions.

P

TSB #: 24-01-033H

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15.

OUTER TAILGATE HANDLE SWITCH REPLACEMENT (SERVICE CAMPAIGN TBQ)

Slide the heat shrink tubes over the crimped
joint terminals. Use a heat gun to blow hot air
onto the heat shrink tubes (Q) to release the
resin.

Q

16.

Secure wire harness with zip ties (R).

R

17.

STUI
Using STUI, take a photo of the
completed heat shrink tubing with the
last 6 digits of the VIN and the date of
repair on a piece of paper.
Upload the photo to STUI.

18.

Reinstall all parts in the reverse order of the
removal.

TSB #: 24-01-033H

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