Roof Panel Pop Sound

When driving through an automatic car wash, a loud pop (oil canning) sound may be heard on some 2023-2025 Colorado and Canyon trucks. The pop sound may be the roof panel flexing from the force of the industrial air dryer at the end of the car wash.

There is an updated repair procedure now available that applies to all 2023-2025 Colorado and Canyon models without a sunroof (RPO CAC), built before breakpoint 2/3/25. It addresses the flexing of the roof panel by applying stiffening patches as well as installing a longitudinal roof bow to the underside of the roof panel. (Fig. 9)

 

Fig. 9

 

After completing any paint or body repairs needed to the roof, the stiffening panels should be installed to the underside of the roof panel in five locations at the front of the roof area. (Fig. 10)

TIP: The headliner will need to be dropped, but not removed, for installing the panels and roof bow.

 

Fig. 10

 

If the stiffening patches have been installed as part of an earlier repair, it’s not necessary to remove any of the stiffening panels before installing the roof bow.

Begin installation by pre-drilling the five locations for the rivets on the roof bow. (Fig. 11)

 

Fig. 11

 

The pre-drilled roof bow will be used as a template on the underside of the roof structure. Be sure to properly align the center line of the roof bow to the center line in the roof bars. (Fig. 12)

 

Fig. 12

 

Once all holes are drilled using a depth-control device on the drill bit, apply the appropriate structural adhesive to both ends of the roof bow and panel-vibration control material to the length of the roof bow. (Fig. 13) The roof bow should be installed to the vehicle with the rivets.

 

Fig. 13

 

Once the stiffening panels and roof bow are installed, reinstall the headliner and verify the condition is corrected.

For complete details for the repair procedure, including part numbers, refer to Bulletin 23-NA-209.

– Thanks to Jonathan Johnson