TSB #24-033-03

Date: May 23,2003

Models: 1990 -2004     All Chrysler Group Products

Discussion:

NOTE: NO REFRIGERANT BLENDS OR HYDROCARBON-BASED REFRIGERANTS ARE TO BE USED.

NOTE: A/C SYSTEMS FOUND TO BE CONTAMINATED WITH A/C SYSTEM SEALERS, A/C STOP-LEAK PRODUCTS, SEAL CONDITIONERS, COMPRESSOR OIL OR REFRIGERANTS NOT APPROVED BY CHRYSLER VOIDS THE WARRANTY FOR THE A/C SYSTEM.

Equipment Available:
S-EEAC-312C A/C Refrigerant identifier
  Numerous UV (Black Light) Lamps are available through PSE
04798219 MOPAR R-134A Leak Detection Dye
05010044AA MOPAR R-12 Leak Detection Dye

NOTE: PSE A/C refrigerant recovery equipment found to be contaminated with A/C system sealers, A/C stop-leak products, seal conditioners, compressor oil or refrigerants not approved by Chrysler voids the warranty for the A/C refrigerant recovery equipment.

Policy:    Information only

 

ROTOR TBS #05-008-03

Date: Nov. 28, 2003

Models: 2003 (DR) Ram Truck

Overview:
This bulletin involves installing brake pads, calipers, resurfacing the rotors and checking rotor runout.

Symptom/Condition:
The vehicle may exhibit pulsation or vibration in the brake pedal and/or steering wheel when the brakes are applied. The Condition is most noticeable at speed over 50 MPH but can occur at lower speeds.

Diagnosis:
If the customers indicate that the condition is present, perform the Repair Procedure.

Parts Required:
Qty. Part No. Description
1 05080556AF Brake Pads - Vehicles built prior to March 6, 2003 (MDH 0603XX)
1 05139733AA Brake Pads - Vehicles built after March 6, 1 2008 (MDH 0603XX)
1 05134582AB Caliper , Right
1 05134583AB Caliper, Left

Special Tools/Equipment Required:

 
  ProCut Hunter
One of the Following
DaimlerChrysler
Approved On Car Disc   
Rotor Lathes:    		 PC-610, PC-CHRYSLER,
PC-TRUCK, PC-CROSTRTJCK,
PC-PFMTRUCK,
PC-PFMCHRYSLER, PC-PFM900,
PC-PFMCHRYSLER-95,
PC-PFMTRUCK-95, PC-PFM900-95,    
PC-PFM90.2, PC-PFM90.4,
PC-PFM90		 H-OCL360,
H-OCL360-LT-PRO,
H-OOL360-LT-PSE,
H-OCL360A,
H-OCL36OA-LT'-PRO,    
H-OCL36OA-LT-PSE,
H-OCL360S,
H-OCL36OS-LT-PRO,
H-OOL36OS-LT-PSE

Repair Procedure: 
1.    Inspect the front brakes for any signs of abnormal wear or damage. Repair as necessary.
2. Resurface the front brake rotors with a DaimlerChrysler approved on-car brake lathe. If an on-car lathe is not available at the dealership, the rotor resurfacing must be sublet to a facility with an approved on car lathe.
3. Remove the calipers.
4. Clean the caliper adapter and lubricate the adapter and anti-rattle springs with MOPAR brake grease.
5. Install new calipers, p/n's 05134582AB and 05134583AB.
6. Replace the front pads and anti-rattle springs with the appropriate part number listed in the Parts Required Section above.
7. Bleed the system.
8. Mark one wheel stud on each side with a dab of paint or suitable marker.

 

NOTE: Wheel stud torque is critical to the success of the repair. the following procedure is intended to identify excessive rotor distortion which could be caused by improper wheel stud torque.

 
9. Install the wheel and pre-tighten the lug nuts in a cross pattern to: 70 NM (50 ft. lbs.) then final the lug nuts in a cross pattern to: 135 Nm (100 ft, lbs.) and mark the wheel at the same location as the marked wheel stud.
10. Set up a dial indicator to measure mounted rotor runout . Place the dial indicator plunger against the inner machined rotor- face, visible between the brake caliper and the front splash shield. Rotate the wheel and tire assembly two turns and take runout measurement. If the measurement is less than .050 mm (.002 in.) no further action, is required. If the measurement is greater than .050 mm (.002 in.) remove the lug nuts and relocate the wheel one stud clockwise, tighten the lug nuts as described in step 6 and check the runout again. Do not remove any brake parts. Repeat step 7 for each wheel location until you achieve the lowest mounted runout. Minimum mounted rotor runout will be achieved by moving the wheel, not the rotor.

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:

 
Labor Operation No:   Description Amount
05-81-01-93 Replace Brake Pads, Calipers, Resurface
Rotors and Check Rotor Run Out		 2.3 Hrs.

Failure Code:

 
2X        Vibration or Chatter

 

DaimlerChrysler Motors Corporation                             INTER COMPANY CORRESPONDENCE

 

                                                                                         October 21, 2003
______________________________________________________________
To - Name & Department                                                 Cims Number
BUSINESS CENTER MANAGERS                               

From - Name & Department                                             Cims Number
J. E. Hilger Vice President, Global Service                     485-10-10
______________________________________________________________

Subject:   RAPID RESPONSE TRANSMITTAL #03-017

Roof Seam May Lack Sufficent Body Sealer - 2004 DR Ram Truck

This should be a top priority. All sold and unsold vehicles Included in this service action will require repair. Dealers are to contact the owners of any sold units and complete the repair.

Approximately 64 suspect vehicles, built on August 23, 2003 (MDH 0823XX) through and including August 25, 2003 (MDH 0825XX), may have a passenger side roof body seam that is not sealed completely. The body seam may allow water to leak into the right rear passenger compartment and be seen on the right grab handle, or the customer may find that the carpeting is wet.

The body sealer application may have been less than the required amount to seal the body seam. The body seam is located on the right side roof to quarter panel joint. The joint runs from the rear corner of the roof to the back window. The seam must be sealed.

The body seam that requires sealer can be seen once the right side roof quarter joint trim molding is removed. Refer to the graphics available in TechCONNECT or the 2004 DR Ram Truck Service Manual CD (publication no. 81-370-04059CD) in Section 23 Body, Body Structure, Sealer Locations.

The attached DMAIL and VIN List will be sent to all affected Dodge dealers later today requesting that they reseal the roof to quarter joint seam on the passenger side and replace the quarter joint trim molding. The dealers receiving the DMAIL are the "Ship To" dealers, and the VIN's listed on their DMAIL are specific to their dealership.

Please ensure that all Business Center personnel are aware of this information. If you have any questions, please contact Bob Silveri in Dealer Technical Operations on T/L 733-2051.

J. E. Hilger

Form ASI-002 Rev. 1.25 Jan. 7, 2003

 

                                                DMAIL

October 21, 2003

TO: ALL DODGE DEALERS

FROM: J. E. HILGER

SUBJECT: SERVICE ACTION #03-017

ROOF SEAM MAY LACK SUFFICENT BODY SEALER

THIS SHOULD BE A TOP PRIORITY. ALL SOLD AND UNSOLD VEHICLES INCLUDED IN THIS SERVICE ACTION WILL REQUIRE REPAIR. DEALERS ARE TO CONTACT THE OWNERS OF ANY SOLD UNITS AND COMPLETE THE REPAIR.

INVOLVED VEHICLES:      2004 DR Ram Truck

NOTE: THIS SERVICE ACTION APPLIES TO VEHICLES BUILT ON AUGUST 23, 2003 (MDH 0823XX) THROUGH AND INCLUDING AUGUST 25, 2003 (MDH 0825XX). (VIN LIST HERE -  Microsoft Excel file)

SYMPTOM/CONDITION:

A number of vehicles, built on August 23, 2003 (MDH 0823XX) through and including August 25, 2003 (MDH 0825XX), may have a passenger side roof body seam that is not sealed completely. The body seam may allow water to leak into the right rear passenger compartment and be visible on the right grab handle or the customer may find that the carpeting is wet.

The body sealer application may have been less than the required amount to seal the body seam. The body seam is located at the right side roof to quarter panel joint. The joint runs from the rear corner of the roof to the back window. The seam must be sealed.

PARTS REQUIRED:

AR  04318026        Paintable Repair Sealer (1 tube will service multiple vehicles)
1     55275794AA   Molding, Roof Quarter Joint, Right - Standard Cab
1     55275796AA   Molding, Roof Quarter Joint, Right - Quad Cab

REPAIR PROCEDURE:

The body seam that requires sealer can be seen once the right side roof quarter joint molding is removed. Refer to the service information and graphics available in TechCONNECT or the 2004 DR Ram Truck Service Manual CD (publication no. 81-370-04059CD) in Section 23 Body, Body Structure, Sealer Locations.

1.   Use a trim stick and heat gun set at moderate temperature to remove and then discard the right roof quarter joint molding. DO NOT REUSE.

2.   Clean the seam surfaces of all dirt, oil, grease.

3.   Apply sealant (p/n 04318026 or equivalent) flowing into the seam. Remove excess sealant immediately.

4.   Allow sealant to dry for at least 30 minutes.

5.   Install new right roof quarter joint molding (p/n 55275794AA Quad cab or 55275796 Standard cab). The vehicle should be at room temperature to ensure proper adhesion.

POLICY:    Reimbursable within the provisions of the warranty.

NOTE: USE OF THE LABOR OPERATION INCLUDED WITH THIS SERVICE ACTION ON VEHICLES OTHER THAN THOSE INVOLVED MAY BE SUBJECT TO CHARGE BACK.

TIME ALLOWANCE:
Labor Operation No:
23-50-57-90     Seam, Right Side Roof Quarter Joint - Standard Cab and Quad Cab - Reseal 0.4 Hrs.

FAILURE CODE:  D1 - Missing

If you have any questions, contact your Business Center office.

 

Date: December 2002    #B-33                       Models: 2003 (DR) Dodge Ram Pick-up Truck

NOTE: This notification applies only to the above vehicles equipped with a 5.9L Cummins Turbo Diesel engine ("C" or "6' in the 8th VIN position) and an automatic transmission (Sales Code - DGP) built at the:

IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System.

Subject:

The torque converter drain back valve on about 10,000 of the above listed vehicles may contain a check ball that swells. A swollen check ball will restrict fluid flow to the cooler and cause the transmission to overheat. This could cause transmission damage.

Repair:

The torque converter drain back valve assembly must be replaced.

Parts Information:

A. Torque Converter Drain Back Valve

Part Number Description
50010185AA      Torque Converter Drain Back Valve and Hose Assembly

Since the required torque converter drain back valve assembly is likely already in dealer inventory, no parts will be distributed initially. Additional Torque Converter Drain Back Valve and Hose assemblies may be ordered as necessary to support scheduled repairs.

B. Automatic Transmission Fluid

Part Number Description
05013457AA      Mopar ATF+4 (MS-9602) Automatic Transmission Fluid (Quart bottle)

Service Procedure:

1.   Open the hood.

2.   Remove the three (3) left front wheelhouse splash shield screws from the fender (Figure 1).

3.   Remove the electrical connector push pin fastener from the splash shield.

4.   Remove the five (5) remaining splash shield screws and then remove the wheelhouse splash shield (Figure 1).

5.   Loosen the charge air cooler-to-intake manifold boost tube clamp on the driver?s side of the charge air cooler (Figure 2).

 

Figure 1 Figure 2

6.   Loosen the boost tube clamp at the intake manifold (Figure 3).

7.   Remove the boost tube and set it aside.

8.   Using Miller Special Tool #8218, disconnect the transmission cooler line quick-connect fitting from the air-to-oil cooler at the lower driver's side of the radiator (Figure 4).

 

Figure 3 Figure 4

9.   Disconnect the torque converter drain back valve and hose assembly from the metal cooler line coming from the water-to-oil cooler. The water-to-oil cooler is located above the starter on the rear driver's side of the engine (Figure 4).

10. Discard the drain back valve and hose assembly.

11. Connect the new drain back valve and hose assembly to the metal cooler line coming from the water-to-oil cooler (Figure 4). Tighten the valve to 275 in-lbs (31 N-m).

12. Connect the quick connect fitting on the drain back valve assembly to the air-to-oil cooler (Figure 4). Pull back on the fitting to ensure that it is fully connected.

13. Install the boost tube assembly.

14. Tighten the boost tube clamp at the intake manifold connection to 95 in-lbs (11 N-m) (Figure 3).

15. Tighten the boost tube clamp at the charge air cooler connection to 95 in-lbs (11 N-m) (Figure 2).

16. Install the front left wheelhouse splash shield. Position the front edge of the splash shield into the support bracket on the bumper (Figure 1).

17. Install the five (5) inner splash shield screws (Figure 1).

18. Install the three (3) splash shield-to fender screws (Figure 1).

19. Connect the electrical connector push pin fastener to the splash shield.

20. Check the transmission fluid level and add additional ATF+4 transmission fluid (Mopar P/N 05013457AA) as required and recheck level

Completion Reporting and Reimbursement

Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments.

Use the following labor operation number and time allowance:

 
    Labor Operation  
Number		 Time
  Allowance  
Replace torque converter drain back valve    21-B3-31-82 0.5 hours

Add the cost of the parts package plus applicable dealer allowance to your claim.

Parts Return

Not Applicable

Dealer Notification and Vehicle List

All dealers will receive a copy of this Customer Satisfaction Notification letter by mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this notification in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.

 

Date: March 2003      RECALL #C02

Models: 2003 (DR) Dodge 2500 and 3500 Pick Up Truck

NOTE: This recall applies only to the above trucks equipped with a 5.9L turbo diesel engine (sales code ETC or ETH), a manual transmission and speed control (sales code NHM) built at the St. Louis Assembly Plant ("J" in the 11th VIN Position) through December 24, 2002 (MDH 1224XX) or the Saltillo Assembly Plant ("G" in the 11th VIN Position) through December 29, 2002 (MDH 1229XX).

IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by determined by using the VIP inquiry process.

Subject:

The Engine Control Module (ECM) on about 19,900 of the above trucks may cause an increased engine idle speed after extended speed control usage. This could increase the truck's stopping distance and cause an accident without warning.

Repair:

The ECM must be reprogrammed (flashed).

CAUTION: Failure to follow the attached service procedure may result in a no-start condition on vehicles equipped with a Sentry Key Immobilizer Module (SKIM).

Parts Information:

Since the required labels are likely already in dealer inventory, no labels will be distributed initially. Additional Labels may be ordered as necessary to support scheduled repairs.

Each vehicle requires application of the following labels:

 
Part Number    Description 
04669020     Authorized Software Update Label
04275086AB   Authorized Modifications Label

Service Procedure:

The MDS2 (Mopar Diagnostic System) with the DRB III (Diagnostic Readout Box scan tool) operating at CIS CD2127 or higher is required to perform this repair.

A. Reprogram the ECM:

 
1. Open the hood, install a battery charger and verify battery state is above 11.5 volts.
2.     

With the ignition switch in the "RUN" position, determine and record the "ECM part number of the ECM currently in the vehicle. Using the DRBIII select:

a.    Select 1. "DRBIII Standalone" from Main Menu screen.
b. Select 1. "1998 - 2003 Diagnostics" from Standalone Main Menu screen.
c. Select 1. "All (Except Below)" from 1998 - 2003 Diagnostics screen.
d. Select 8. "System Monitor" from Select System screen.
e. On 1998 1/2 - 2003 vehicles, select "Cummins". 2004 and later vehicles, proceed to next step.
f. Select 3. "J1850 Module Scan" from Select Monitor screen.

If the vehicle is equipped with SKIM obtain the vehicle PIN (Personal Identification Number) before continuing with step 3. This information is available from the original selling invoice, the Dial System - Function 13, or by contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997.

WARNING: Failure to install the SKIM PIN number into the module after flashing the ECM will cause a no-start condition. The flash procedure erases the original PIN number stored in the ECM.

If the vehicle is not equipped with SKIM then continue with step 3.
3.

Using the DRB III, page back to the Main Menu and connect the MDS2 to the DRB III, use your service I.D. to log onto the MDS2 and verify "DRB III Status: Connected" in the upper right corner of the MDS2.
4.

Verify that the VIN displayed on the MDS2 screen is correct. If the VIN is not displayed or is not correct, then manually enter the VIN. Select "OK".
5. Enter the information requested by the "New Session Setup" window. Select "OK".
6. Select the "Flash" tab.
7. Select "Read part number from vehicle".
8. Select "Show updates" on the MDS2, follow the instruction listed on the DRB III.
9. Select "OK" for "Flash update information".
10. Select the new ECM calibration to be updated.
11. Select "Update Controller Software".
12. Monitor the "Status" window on the MDS2 and follow the instructions.
13.

Follow the instructions on the DRB III to complete the calibration download process.
14. Return to Main Menu and select 1. "DRB III Standalone".
15. Select 1. "1998 - 2003 Diagnostics".
16. Select 1. "All (Except Below)"
17.

If the vehicle is equipped with a SKIM module proceed to Step 18. If the vehicle is not equipped with a SKIM module, proceed to Step 24.
18. Select 7. "Theft Alarm" in Select System.
19. SSelect 2. "SKIM" in Anti-Theft Systems.
20. Select 9. "Miscellaneous" in Select Function.
21. Select 1. "Cummins ECM Replaced" in Select Miscellaneous Function.
22. Follow the DRB III instructions to proceed.
23.

Enter the previously obtained PIN number and follow the instructions to complete PIN entry in DRB III. Verify that the Secret Key and VIN transfer to ECM is successful. ECM calibration is complete, proceed to Step 29.
24. Select 1. "Engine" in Select System.
25.

Select 1. "Cummins (ECM/Engine)"
26. On the Select Function screen, proceed to page 2 of 2 and Select 1. "Miscellaneous".
27. On the Select Miscellaneous screen, Select 3. "CM845 Check VIN"
28. Enter in VIN as requested by DRB III.
29 Clear all diagnostic trouble codes from all modules before returning the vehicle to the customer.
30. Disconnect the DRB III from the vehicle, disconnect the battery charger and continue with Section "B - Install Authorized Software Update Label."

B. Install Authorized Software Update Label:

 
Type or print (with a ballpoint pen) the part
number, dealer code and date on the
Authorized Software Update Label (Figure 1)
and attach it to the PCM. Cover the label with
the clear plastic portion of the label.
Figure 1

C. Install the Authorized Modifications Label:

 
Type or print (with a ballpoint pen)
the recall number, dealer code and
date on the Authorized Modifications

Completion Reporting and Reimbursement

Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments.

Use one of the following labor operation number and time allowance:

 
   Labor Operation Number   Time Allowance 
ECM Update Previously Performed 08-C0-21-81 0.2 hours
Reprogram ECM (without SKIM) 08-C0-21-82 0.5 hours
Reprogram ECM (with SKIM) 08-C0-21-83 0.2 hours

NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

Parts Return: Not Applicable

Dealer Notification and Vehicle List

All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.

DIAL System Functions 53 and VIP

All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed.

Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "ORDC02".

Owner Notification and Service Scheduling

All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers.

Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.

Recall #C10

Date: March 2003

Models: 2002 (DR) Dodge Ram 1500 Pick-up Truck

NOTE: This recall applies only to the above trucks equipped with manual side view mirrors (sales code GPU) or power side view heated mirrors (sales code GTS) built built at the:

IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.

Subject:

A retainer in the side view mirrors on about 173,000 of the above vehicles may separate and allow the mirror(s) to rotate out of position. This can cause a loss of rearward vision and result in an accident.

Repair:

A mirror retainer package must be installed in both side view mirrors.

Parts:

A. Mirror Retainer Package

 
Part Number    Description 
CBN1C100     Mirror Retainer Package

NOTE: One mirror retainer package will repair two mirror assemblies.

Each package contains the following components:

 
Quantity    Description 
2     J-Hook
2          Plastic Retainer
2   Nut
2   Lock Nut

Each dealer to whom vehicles in the recall were invoiced will receive enough Mirror Retainer Packages to service about 10% of those vehicles.

B. Thread Locker

 
Part Number    Description 
04318032     Mopar Stud N’ Bearing Mount Adhesive

NOTE: One tube of adhesive will repair approximately 10 vehicles.

Service Procedure:

1.    Lower both front windows.

2.    With the mirror glass tilted in the downward position, place a plastic trim stick or equivalent between the bottom of the mirror glass and the mirror housing (Figure 1). Apply a twisting motion to the trim stick to “pop” the mirror glass upward and disengage the mirror glass from the mirror adjuster head.

3.    Carefully remove the mirror glass from the adjuster head, disconnect the heated mirror wires (if equipped) and set the mirror glass aside.

4.    Disengage the three (3) tabs that hold the back cover of the mirror to the mirror head (Figure 2).

       

5.    Remove the back half of the mirror cover from the mirror head to expose the mirror head retainer and mirror post (Figure 3).

CAUTION: There is a small hidden back cover retaining nub on the inside edge of the mirror cover (Figure 3). Use care when separating the back cover to avoid breaking the retaining nub receiver slot.

6.    Apply Mopar “Stud N’ Bearing Mount Adhesive” (PN 04318032) or equivalent to the threads of one of the supplied J-hooks.

7.    Assemble the new mirror retainer as shown in Figure 4 using the nut with the spinning washer.

       

 
8.     On mirror heads where the retainer has not separated from the mirror post, insert the J-hook through the post on the mirror base so that it hooks under the base (Figure 5). Using a torque wrench, tighten the J-hook nut to 35 in. lbs. (4 N·m).
  On mirror heads where the retainer has separated from the mirror post, insert the J-hook through the retainer and the post on the mirror base so that it hooks under the base (Figure 5). Align the original retainer clip and slowly tighten the nut on the J-hook. Carefully guide the original retainer onto the post of the mirror base while tightening the nut on the J-hook. Using a torque wrench, tighten the nut on the J-hook to 35 in. lbs. (4 N·m).

CAUTION: Verify that the plastic cap is properly seated into the mirror post and do not over tighten the J-hook nut, damage to the mirror base may occur.

CAUTION: On vehicles equipped with power mirrors, the wire harness must be routed through the channel provided on the new plastic retainer. Make sure the J-hook does not pinch the mirror wiring harness.

9.   While holding the nut on the J-hook with an open-end wrench, install the lock nut with the nylon patch onto the J-hook. Tighten the lock nut to 40 in. lbs. (5 N·m).

10. Snap the back cover onto the mirror head.

CAUTION: Verify that all the retaining tabs, including the hidden nub (Figure 3), on the back cover are fully engaged (Figure 2).

11. If equipped, connect the heated mirror wires to the mirror glass.

12. Place the mirror glass onto the retaining studs on the mirror adjuster head.

13. Place a plastic trim stick between the mirror glass and the top of the mirror housing (Figure 6). Using a twisting motion on the trim stick, engage the mirror glass to the mirror adjuster head.

NOTE: A snapping sound will be heard when the mirror glass retainers are fully engaged.

      

CAUTION: Verify that the mirror glass is fully engaged onto the mirror adjuster head by lifting up on the mirror glass.

14. Clean any finger prints from the mirror glass and housing.

15. Repeat steps 2 through 14 for the mirror on the other side of the vehicle.

NOTE: Both mirror assemblies must have a retainer installed.

Completion Reporting and Reimbursement

Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments.

Use the following labor operation number and time allowance:

 
   Labor Operation Number   Time Allowance 
Install mirror retainer package    23-C1-01-82 0.4 hours

Add the cost of the recall parts package plus applicable dealer allowance to your claim.

NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

Parts Return: Not applicable.

Dealer Notification and Vehicle List:

All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and Dealer Connect/MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.

DIAL System Functions 53 and VIP:

All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed.

Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type “53” at the “ENTER FUNCTION” prompt, then type “ORDC10”.

Owner Notification and Service Scheduling

All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers.

Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.

Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair.

RECALL # C11  This is LARGE I. E.  285.000  vehicles

 

Date: April 2003

Models: 2002 (DR) Dodge Ram 1500 Pick-up Trucks

IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DealerCONNECT VIP inquiry process.

Subject:

The blower motor wiring on about 285,000 of the above vehicles contains an undersized terminal. Localized heating from operating the blower motor on high speed may cause the terminal to relax and lose electrical contact. This could cause the blower motor to become inoperative. An inoperative blower motor will not defrost the windshield, which could obstruct the driver’s vision and result in an accident.

Repair:

A blower motor wiring overlay harness must be installed.

Parts:

 
Part Number    Description 
CBT1C110     Blower Motor Wiring Harness

Each dealer to whom vehicles in the recall were invoiced will receive enough Wiring Harness Packages to service about 5% of those vehicles.

Service Procedure:

1.    Disconnect the negative battery cable.

2.    Remove the two (2) knee blocker screws and then remove the knee blocker.

3.    Move the steering column to the lowest position and then remove the steering column tilt lever.

4.    Remove the upper and lower steering column shrouds.

5.    Disconnect the instrument panel (I/P) wiring harness 74-way connector (Figure 1).

6.    Release the RED CPA, lift the WHITE lock bar on the top of the 14-way ignition switch connector and then disconnect the connector (Figure 2).

7.    Release the four (4) BLUE wedge clips from the back (wire) side of the ignition switch connector and then remove the wedge completely using pliers (Figure 2).

       

8.   Remove the PINK with BLACK tracer wire from the ignition switch connector (Figure 2).

9.   Install the PINK with BLACK tracer wire from the overlay harness into the connector cavity (Figure 2).

10. Remove the GREEN wire from the ignition switch connector (Figure 2).

11. Install the GREEN wire from the overlay harness into the connector cavity (Figure 2).

12. Install the BLUE wedge back into the ignition switch connector (Figure 2).

NOTE: After initially installing the wedge, push in on the four wedge clips to allow the wedge to be fully seated.

13. Cut off the PINK with BLACK tracer wire and GREEN wire that were removed from the connector as close to the harness wrap as possible.

14. Connect the 14-way ignition switch connector. Ensure that the white lock bar and red CPA are fully engaged.

15. Route the overlay harness along the I/P harness to the 74-way connector.

16. Remove the WHITE cover from the wire side of the 74-way connector.

17. Pull the YELLOW wedge out from the side of the 74-way connector about 1/16” (Figure 3).

18. Remove the PINK with BLACK tracer wire from the 74-way connector (Figure 3).

19. Insert the PINK with BLACK tracer wire from the overlay harness into to 74-way connector cavity.

20. Install the YELLOW wedge back into the 74-way connector (Figure 3).

21. Cut off the PINK with BLACK tracer wire that was removed from the connector as close to the harness wrap as possible.

22. Install the WHITE cover on the wire side of the 74-way connector.

23. Remove the lower bezel at the bottom of the center I/P stack.

24. Route the GREEN overlay harness wire behind the Airbag Control Module (ACM) to the blower motor connector. Tuck the wire behind the carpeting or vinyl floor covering.

      

25. Disconnect the 2-way blower motor connector located near the right kick panel (Figure 4).

26. Remove the BLUE wedge from the blower motor connector.

27. Remove the GREEN wire from the blower motor connector (Figure 4).

28. Install the GREEN overlay harness wire into the blower motor connector cavity.

29. Install the BLUE wedge back into the blower motor connector.

30. Cut off the GREEN wire that was removed from the connector as close to the harness wrap as possible.

31. Connect the 2-way blower motor connector (Figure 4).

32. Tuck any excess wire from the overlay harness behind the carpeting or vinyl floor covering.

33. Install the center lower I/P stack cover.

34. Connect the 74-way I/P harness connector (Figure 1).

35. Tie strap the overlay harness to the I/P harness near the steering column.

36. Install the upper and lower steering column shrouds.

37. Install the steering column tilt lever handle.

38. Install the knee blocker. Tighten the screws securely.

39. Connect the negative battery cable.

Completion Reporting and Reimbursement

Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments.

Use the following labor operation number and time allowance:

 
   Labor Operation Number   Time Allowance 
Install blower motor wiring overlay harness    08-C1-11-82 0.6 hours

Add the cost of the recall parts package plus applicable dealer allowance to your claim.

NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

Parts Return: Not applicable.

Dealer Notification and Vehicle List:

All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT and the MDS2 will be updated to include this recall in the near future.

Vehicle Lists, Global Recall System, VIP and Dealer Follow up:

All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter.

GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner’s name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission.

To use this system, click on the “Service” tab and then click on “Global Recall System.” Your dealer’s VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence.

Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair.

Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use.

Owner Notification and Service Scheduling

All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers.

Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.

Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair.

 

Recall  # C17

Date: May 2003

Effective immediately, all repairs on involved vehicles are to be performed according to this recall. Technical Service Bulletin #18-036-02 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this recall.

Models: 2003 (DR) Dodge Ram Pick-up Trucks

NOTE: This recall applies only to the above trucks equipped with California Emissions (sales code NAE) 5.9L Cummins turbo diesel engine (sales code ETC or ETH) and 47RE automatic transmission (sales code DGP) built at:

IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.

Subject:

The Powertrain Control Module (PCM) on about 440 of the above vehicles was programmed with errors in the automatic transmission diagnostic information. As a result, the PCM will not detect a transmission governor pressure sensor problem, or illuminate the Malfunction Indicator Light (MIL) if this sensor fails in the future.

Repair:

The Powertrain Control Module (PCM) must be reprogrammed (flashed).

Parts Information:

Due to the small number of vehicles involved in this recall and the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following labels may be ordered as needed.

Each vehicle requires application of the following labels:

 
Part Number    Description 
04669020     Authorized Software Update Label
04275086AB   Authorized Modifications Label

Service Procedure:

The MDS2 (Mopar Diagnostic System) with the DRB III (Diagnostic Readout Box scan tool) operating at CIS CD2123 or higher is required to perform this repair.

A. Reprogram the ECM:

 
1. Log onto the MDS2 system.
2.     

Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO “ON”.

NOTE: The MDS2 and DRB III should begin to “Auto Connect” within a few seconds after all connections have been made
3.

If the “Auto Connect” does not initialize, use the arrow keys and select #2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN.

NOTE: Once MDS2, DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the “OK” button to request a MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the “OK” button when asked to begin the session.
4.

Push the FLASH TAB on the MDS2.
5.

Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the “OK” button.

NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says “Part number (updated part number is displayed) is up to date and does not require any new updates.” Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS. Press the “OK” button, then continue with Section C.
6. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE.
7.

The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process.

NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC’s) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC’s may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC’s relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased.
8. Select "Show updates" on the MDS2, follow the instruction listed on the DRB III.
9. Select "OK" for "Flash update information".
10. Select the new ECM calibration to be updated.
11. Select "Update Controller Software".
12. Monitor the "Status" window on the MDS2 and follow the instructions.
13.

Follow the instructions on the DRB III to complete the calibration download process.
14. Return to Main Menu and select 1. "DRB III Standalone".
15. Select 1. "1998 - 2003 Diagnostics".
16. Select 1. "All (Except Below)"
17.

If the vehicle is equipped with a SKIM module proceed to Step 18. If the vehicle is not equipped with a SKIM module, proceed to Step 24.
18. Select 7. "Theft Alarm" in Select System.
19. SSelect 2. "SKIM" in Anti-Theft Systems.
20. Select 9. "Miscellaneous" in Select Function.
21. Select 1. "Cummins ECM Replaced" in Select Miscellaneous Function.
22. Follow the DRB III instructions to proceed.
23.

Enter the previously obtained PIN number and follow the instructions to complete PIN entry in DRB III. Verify that the Secret Key and VIN transfer to ECM is successful. ECM calibration is complete, proceed to Step 29.
24. Select 1. "Engine" in Select System.
25.

Select 1. "Cummins (ECM/Engine)"
26. On the Select Function screen, proceed to page 2 of 2 and Select 1. "Miscellaneous".
27. On the Select Miscellaneous screen, Select 3. "CM845 Check VIN"
28. Enter in VIN as requested by DRB III.
29 Clear all diagnostic trouble codes from all modules before returning the vehicle to the customer.
30. Disconnect the DRB III from the vehicle, disconnect the battery charger and continue with Section "B - Install Authorized Software Update Label."

B. Install Authorized Software Update Label:

 
Type or print (with a ballpoint pen) the part
number, dealer code and date on the
Authorized Software Update Label (Figure 1)
and attach it to the PCM. Cover the label with
the clear plastic portion of the label.
Figure 1

C. Install the Authorized Modifications Label:

 
Type or print (with a ballpoint pen)
the recall number, dealer code and
date on the Authorized Modifications

D. Complete Proof of Correction Form for California Residents:

This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration.

Completion Reporting and Reimbursement

Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments.

Use one of the following labor operation number and time allowance:

 
   Labor Operation Number   Time Allowance 
PCM Update Previously Performed 08-C1-71-81 0.2 hours
Reprogram Powertrain Control Module 08-C1-71-82 0.5 hours

NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

Parts Return: Not Applicable

Dealer Notification and Vehicle List

All dealers will receive a copy of this dealer recall notification letter by Dmail and by first class mail. Two additional copies will be sent through the DCMMS, DealerCONNECT and the MDS2 will be updated to include this recall in the near future.

Vehicle Lists, Global Recall System, VIP and Dealer Follow up

All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter.

GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner’s name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission.

To use this system, click on the “Service” tab and then click on “Global Recall System.” Your dealer’s VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence.

Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair.

Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use.

Owner Notification and Service Scheduling

All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers.

Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.

WARRANTY  #D 03- 23- STUPID but I sent it

To: Dealer Principal, Service Mgr, and Claims Admin Mgr.

Date: October, 2003

Purpose:

To clarify the Basic Limited Warranty coverage on Chrysler, Dodge and Jeep vehicles for light bulbs and
lamps.

Timing:

Effective immediately.

Action:

Based upon a Dealer Council request in September, an explanation of bulb and lamp coverage is listed below.

Additional Information:

A bulb or light bulb is a device that produces light through electrical energy by heating a filament. A lamp or housing is a fixture, such as a tail lamp, side marker lamp, headlamp housing or a high intensity discharge lamp (HID) where the light emitting bulb and lamp/housing are an assembly.

To verify exact bulb/lamp coverage for a specific vehicle, run a DealerCONNECT VIP inquiry with the vehicle’s current mileage and enter the 8 digit Labor Operation for the bulb/lamp in question. Hit the “View” key and then select the “LOP COV” tab to see if the bulb/lamp is covered.

Should you have any additional questions concerning coverage, please use the Warranty Information Center (WIC) in DealerCONNECT. See WPA Bulletin D-03-21, dated September 2003 for details.

2003024       WARRANTY PLANNING & ADMINISTRATION