Recall - Transaxle Ring Gear to Carrier Bolts May Break
90chrysler19 No. 497December, 1990
ADVANCED RECALL INFORMATION
To: All Dodge, Plymouth and Chrysler Dealers
Subject: Recall No. 497 -- Transaxle Differential Ring Gear Bolts
Models: 1991 Front Wheel Drive Cars and Mini-Vans as follows:
^ Equipped with automatic transaxle (3-speed or 4-speed).
^ Built during months of August, September and October, 1990 -- MDH 0801XX through 1031XX.
^ Still in dealer inventory.
^ Imports, Monaco and Laser models are not involved.
Problem:
Some of the bolts used to attach the transaxle differential ring gear to its carrier may break during vehicle operation.
Action:
Immediate service is required to inspect for, and replace if necessary, suspect ring gear bolts. This service must be performed on the above model vehicles in dealer inventory before retail delivery.
The following summarizes the instructions and requirements of the required service:
Identification of Suspect Transaxles
4-Speed Automatic (A-604)
1) From the driver's side (underhood), inspect the transaxle differential fins next to the extension housing for a pink paint mark. If there is a pink mark present, the transaxle has been cleared and no further action is required. The vehicle may be delivered.
If a pink mark is not present then proceed with steps 2 through 4.
2) Locate the transaxle identification label. This label is located on the transaxle case next to the solenoid assembly (see page 21-126 of the 1991 FWD Car Engine, Chassis and Body Service Manual). The label can be viewed from the front of the vehicle looking down between the transmission fluid dipstick and the battery; under the battery.
3) Read the build date on the label. Printing on the label is:
K XXX 0633 XXXX
(Plant) (Part Number) (Build Date Example) (Sequence No.)
All 12 characters may not be visible, but the last 8 digits will be. The important data is the Build Date (first grouping of 4 digits).
4) If the build date is before 0594 or after 0626, no further action is required and the vehicle may be delivered.
If the Build Date falls within the range 0594 through and including 0626, the ring gear bolts must be inspected. Proceed to the Inspection/Repair portion of this letter for instructions.
3-Speed Automatic (A-404)
1) From the driver's side (underhood), inspect the transaxle differential fins next to the extension housing for a pink paint mark. If there is a pink mark present, the transaxle has been cleared and no further action is required. The vehicle may be delivered.
If a pink mark is not present, then proceed with steps 2 through 4.
2) Locate the transaxle identification number. This number is stamped on the left (driver's) side transaxle oil pan rail, forward of the transaxle rear end-cover. It can be viewed from the left front wheel housing. The inner wheel house splash shield may need to be pulled back slightly to view the number.
3) Read the build date portion of the number as follows:
K XXXXXX 0633 XXXX
(Plant) (Part Number) (Build Date Example) (Sequence No.)
The important data is the Build Date (first grouping of four digits, as shown above).
4) If the build date is before 0594 or after 0626, no further action is required and the vehicle may be delivered.
If the Build Date falls within the range 0594 through and including 0626, the ring gear bolts must be inspected.
Proceed to the Inspection/Repair portion of this letter for instructions.
Inspection/Repair
1) With vehicle on hoist, support the front of the engine with a jack stand.
2) Remove the front engine mount through-bolt and nut.
Note: On AWD S-body vehicles, also remove the bracket from the power transfer unit to the differential cover.
3) Lift the jack stand to rotate the engine to gain better access to the differential cover attaching bolts.
4) Remove the differential cover bolts.
5) Partially loosen the cover to drain fluid, then completely remove cover.
6) Inspect the markings on the heads of all 12 ring gear bolts.
^ Any bolts that have a letter "E" marking on the bolt head must be replaced.
^ Replace bolts having "E" on the head with PN 6501240 and torque to 70 ft.lbs. (95 N-m). Order PN 6501240 bolts from the parts depot as required.
CAUTION: When replacing a suspect bolt, use a hand wrench to remove the bolt. Use of an impact wrench for removal may result in bolt failure.
^ If none of the 12 ring gear bolts has "E" marking on the bolt head, no further service is required.
7) Complete the service by following steps 1 through 5 in reverse. (Be sure to clean the differential and cover mating surfaces thoroughly and use new RTV sealant when reinstalling the cover).
8) Add fluid to the proper fill level.
NOTE: If a ring gear bolt is already failed or fails during removal, contact your Zone Technical Advisor for further service instructions.
Reimbursement:
Use one of the following labor operation numbers and time allowances for reimbursement.
Labor Operation Time
Number Allowance
Inspect transaxle build date code 21497181 0.2 Hour
Inspect build date, remove differential cover and inspect ring gear bolts (none require replacement)
- with 3-speed transmission 21497182 0.5 Hour
- with 4-speed transmission 21497183 0.6 Hour
Inspect build date, remove differential cover, inspect for and replace suspect ring gear bolt(s)
- with 3-speed transmission 21497184 0.8 Hour
- with 4-speed transmission 21497185 1.0 Hour
Add the cost of replacement bolts to the claim.
This action requires your immediate attention. Normal recall instruction letters will be sent to all dealers in the near future. If you have any questions regarding this action, contact your Zone Service Office.