Exhaust System - Rattle or Clunk Sound While Driving
NUMBER: 11-004-07GROUP: Exhaust
DATE: October13, 2007
SUBJECT:
Exhaust Rattle or Clunk
OVERVIEW:
This bulletin involves checking for proper clearance of exhaust and installing updated hangers.
MODELS:
2008 (RT) Town & Country/Caravan/Grand
Caravan/Voyager (U.S. and International
Markets)
NOTE:
This bulletin applies to vehicles built at the Windsor Assembly Plant before August 31, 2007 (MDH 0831 XX) and the St. Louis Assembly Plant before September 14, 2007 (MDH 0914XX).
DIAGNOSIS:
The resonator at the rear of the vehicle may come in contact with the body when turning left and/or going over bumps. If the vehicle operator complains of a rattle or clunk at the rear of the vehicle. Raise the vehicle on a suitable hoist and check for a witness mark at the right rear corner of the resonator on the body sheet metal. This witness mark can be up to 12 mm in length due to exhaust expansion when hot. If the resonator has come in contact with the body, perform the Repair Procedure.
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Check the exhaust and surrounding components for any misaligned or damaged hanger brackets/rods or any bent shields. Replace or repair any damaged components as necessary.
2. Replace the hanger isolators on the front muffler inlet (2nd from front) and on the resonator inlet (rearmost) with p/n 04578340AA. Do NOT replace the first or third hanger isolators. See (Fig. 1 ) # 2 below.
CAUTION:
When replacing hanger isolators, do not use oil or grease (petroleum based) lubricants to aid in the removal and installation. Use only Rubber Bushing Installation Lube p/n 05010319AA (or liquid hand soap) to aid in removal and installation of hanger isolators.
3. After installing hanger isolators, check the clearance between the right rear corner of the resonator and the body sheet metal. Is the clearance between the resonator and the body sheet metal at least 13 mm (.5 in)? (Fig. 2)
a. YES >> Repair is complete.
b. NO >> Proceed to step # 4
NOTE:
If the resonator has been in contact with the body, a witness mark should be visible and may be up to 12 mm (.5 in.) long due to exhaust expansion. See # 3 below.
4. Loosen the rearmost hanger rod attached to the body near the resonator.
5. Rotate hanger rod counterclockwise until 13 - 16 mm (.5 - .62 in) of clearance is achieved. (Fig. 3)
NOTE:
Do not exceed 16 mm (.62 in.) of clearance by rotating hanger rod as this may result in excessive hanger isolator load or lack of clearance elsewhere in system.
6. Tighten the hanger rod fastener while holding in the proper position. Torque to 28 N-m (250 in. lb).
7. If noise persists, the issue may not be exhaust related and further diagnosis is required.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.