Recall - Fuel Tank Straps and Rear Brake Tube
NO841
DATE
02/17/00
SAFETY RECALL 841
Fuel Tank Straps and Rear Brake Tube
MODELS
1998 ,(DN) Dodge Durango
ATTENTION:
Service Manager
RECALL MATERIAL ENCLOSED
IMMEDIATE ACTION REQUIRED
The envelope contains one copy of the dealer recall service instruction letter. In addition, a VIN listing is included for those dealers to whom involved vehicles were invoiced.
The owner notification mailing for this recall will begin in about one week. Please advise the appropriate dealer personnel to forward the orange bordered recall envelope to your service manager as soon as it is received. Doing so will insure that our dealership is ready to schedule and repair involved vehicles soon as possible.
Additional copies of the recall notification letter will be forwarded via DCMMS mail and the MDS2 in the near future.
The entire dealer recall notification letter (excluding graphics) is provided below for your information.
February 2000
Dealer Service Instructions for:
SAFETY RECALL No. 841
FUEL TANK STRAPS AND REAR BRAKE TUBE.
NOTE:
This recall applies only to the above vehicles built through May 21, 1998 (MDH 0521XX).
NOTE:
Safety Recall No. 842 also involves fuel tank strap replacement but applies to later built vehicles that do not require the brake tube inspection.
ATTENTION: Service Manager
Recall material enclosed immediate action required
require the brake tube inspection.
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 DIAL VIP System.
SUBJECT
The fuel tank straps on about 96,OOO of the above vehicles may fatigue and separate. If this occurs, the fuel tank will loosen and could leak fuel. Fuel leakage in the presence of an ignition source can result in an underbody fire.
In addition, the rear brake tube may contact an underbody crossmember. Prolonged brake tube contact may cause the tube to rub through and leak, resulting in a partial brake system loss and increased stopping distance. The increased stopping distance can cause an accident without warning.
REPAIR
The front and rear fuel tank straps must be replaced, and the rear brake tube must be inspected on all involved vehicles. ~7ehicles without brake tube contact must have a brake tube isolator installed. Vehicles that exhibit contact but have no signs of red rust AND have less than 45,000 miles must have an isolator installed with RTV silicone. Vehicles that exhibit contact and have red rust OR have more than 45,000 miles must have a new brake tube and isolator installed.
Parts Information:
Parts Information
Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Fuel Tank Strap Packages to service about 25% of those vehicles.
In addition, each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive ONE (1) Rear Brake Tube, PN 52102243AC. Additional brake tubes should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require rear brake tube replacement.
SERVICE PROCEDURE
A. Inspect Rear Brake Tube:
1. Raise the vehicle on an appropriate hoist.
2. For vehicles equipped with a fuel tank skid plate:
a. Place a transmission jack under the fuel tank skid plate and support the skid plate.
b. Remove the inboard screws that attach the skid plate to the frame crossmember (Figure 1)
c. Remove the bolts that attach the skid plate to the frame rail (Figure 1).
d. Lower the skid plate and remove it from under the vehicle.
3. Remove the three (3) bolts that attach the evaporative canister bracket to the fraim rail and body. set the evaporative canister aside.
4. Using a mirror and flashlight, inspect the top of the rear brake tube where it is routed near the body crossmember just above the front of the fuel tank (Figure 2).
5. If there is evidence of brake tube contact and there is red rust on the brake tube, the brake tube must be replaced. Continue with Section "C" - Replace Fuel Tank Straps and Rear Brake Tube. Tubes with white powder or other residue/discoloration do not require replacement.
If there is evidence of contact with NO RED RUST on the brake tube but the vehicle has MORE than 45,000 miles, the brake tube must be replaced. Continue with Section "C" - Replace Fuel Tank Straps and Rear Brake Tube.
If there is evidence of contact with no red rust on the brake tube but the vehicle has less than 45,000 miles, the brake tube does NOT require replacement. Continue with Section "B" - Replace Fuel Tank Straps and Install Isolator.
If there is no evidence of brake tube contact, the brake tube does not require replacement. continue with section "B" - replace fuel tank straps and install isolator.
B. Replace Fuel Tank Straps and Install Isolator:
1. Clean the area of the brake tube shown in Figure 3 with Brake Clean, PN 04897150AA.
2. If the inspection in Section "A" determined that there was brake tube contact with the body crossmember and there was no red rust, coat the brake tube contact area with RTV Sealant (Mopar PN 82300234 or equivalent).
3. Fill the cavity of the provided brake tube rubber isolator with RTV Sealant (Mopar PN 82300234 or equivalent).
4. Snap the isolator over the brake tube. Center the isolator over the area of the tube that is closest to the body crossmember (Figure 3). Position the isolator with the slit toward the ground.
NOTE:
It is acceptable, and likely, that the rubber isolator will be in contact with the body crossmember. Do NOT bend the brake tube to avoid contact with the body crossmember.
5. Place a transmission jack under the fuel tank and support the fuel tank.
6. Remove the front tank strap mounting nut and remove the front tank strap (Figure 4).
NOTE:
Lower the fuel tank slightly to ease removal of the strap.
7. Install the provided front tank strap (Figure 4). Tighten the strap mounting nut to 30 ft-lbs (41 Nm).
8. Remove the rear tank strap mounting nut and remove the rear tank strap (Figure 2).
NOTE:
Lower the fuel tank slightly to ease removal of the strap.
9. Install the provided rear tank strap (Figure 2). Tighten the strap mounting nut to 30 ft-lbs (41 Nm).
10. Remove the transmission jack.
11. Install the evaporative canister and bracket assembly. Tighten the three (3) bolts that attach the evaporative canister bracket to the frame rail and body to 90 in-lbs (10 Nm).
12. For vehicles equipped with a fuel tank skid plate:
a. Position the skid plate under the vehicle and support it with a transmission jack.
b. Install the inboard screws that attach the skid plate to the frame crossmember (Figure 1). Tighten the screws to 30 ft-lbs (41 Nm)
c. Install the bolts that attach the skid plate to the frame rail (Figure 1). Tighten the bolts to 17 ft-lbs (23 Nm).
d. Remove the transmission jack.
13. Lower the vehicle.
C. Replace Fuel Tank Straps and Rear Brake Tube:
NOTE:
Only those vehicles that have damaged brake tubes, as determined by the inspection in Section "A", require replacement. Very few vehicles are expected to require brake tube replacement.
1. Lower vehicle.
Depress and hold the brake pedal using a brake pedal prop rod.
NOTE:
Keeping the brake pedal in the "applied" position makes bleeding the brakes faster and easier since only the rear brakes will require bleeding.
3. Raise vehicle on hoist.
4. Disconnect the fuel tank fuel filler vent hose from the vent tube. Do not disconnect vent hose from fuel tank.
5. Insert a siphon hose through the~ vent hose and drain the fuel into an approved gasoline container.
6. Place a transmission jack under the fuel tank and support the fuel tank.
7. Remove the front tank strap mounting nut, then remove and discard the front tank strap (Figure 5).
NOTE:
Lower the fuel tank slightly to ease removal of the straps.
8. Remove the rear tank strap mounting nut, then remove and discard the rear tank strap (Figure 5).
9. Lower the fuel tank approximately six inches (6") and move it inboard to allow access to the rear brake tube.
10. Disconnect the rear brake tube from the junction block at the front of the vehicle.
11. Remove the rear brake tube from the clips along the frame rail.
12. Disconnect the rear brake tube from the rear brake hose.
13. Remove and discard the rear brake tube by sliding it forward.
14. Install the new brake tube along the frame rail. Make sure that the tube is routed behind the evaporative canister lines and above the fuel tube.
15. Connect the brake tube to the brake hose. Tighten the fitting to 170 in-lbs (19 Nm)
16. Connect the brake tube to the junction block at the front of the vehicle. Tighten the fitting to 145 in-lbs (16 Nm)
17. Clean the area of the brake tube shown in Figure 6 with Brake Clean, PN 04897150AA.
18. Install the brake tube into the clips along the frame rail.
19. Fill the cavity of the provided brake tube isolator with RTV Sealant (Mopar PN 82300234 or equivalent).
20. Snap the isolator over the brake tube. Center the isolator over the area of the tube that is closest to the body crossmember (Figure 6). Position the isolator with the slit toward the ground.
NOTE:
It is acceptable, and likely, that the rubber isolator will be in contact with the body crossmember. Do NOT bend the brake tube to avoid contact with the body crossmember.
21. Raise the fuel tank into position.
22. Install the provided front tank strap (Figure 5). Tighten the strap mounting nut to 30 ft-lbs (41 Nm).
23. Install the provided rear tank strap (Figure 5). Tighten the strap mounting nut to 30 ft-lbs (41 Nm)
24. Connect the fuel vent hose to the vent tube. Tighten the hose clamp to 25 in-lbs (3 Nm)
25. Bleed both rear brake circuits as follows:
a. Fill the master cylinder reservoir with clean brake fluid that conforms to DOT-3 specifications.
b. Attach a clear plastic hose to both rear bleeder screws and feed the hoses into a clear jar containing enough fresh brake fluid to submerge the end of the hose.
c. Have a helper pump the brake pedal three or four times and then hold it in the down position.
d. With the pedal in the down position, open the right bleeder screw at least one full turn.
e. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal.
f. Alternating between the right and left side, repeat steps "C" through "E" until all trapped air is removed from the rear brake circuits (usually four or five times).
26. Top off the master cylinder, then inspect the brake tube connections to ensure that there are no leaks.
27. Install the evaporative canister and bracket assembly. Tighten the three (3) bolts that attach the evaporative canister bracket to the frame rail and body to 90 in-lbs (10 Nm).
28. For vehicles equipped with a fuel tank skid plate:
a. Position the skid plate under the vehicle and support it with a transmission jack.
b. Install the inboard screws that attach the skid plate to the frame crossmember (Figure 1). Tighten the screws to 30 ft-lbs (41 Nm)
c. Install the bolts that attach the skid plate to the frame rail (Figure 1). Tighten the bolts to 17 ft-lbs (23 Nm)
d. Remove the transmission jack.
29. Lower the vehicle.
30. Refill the fuel tank and ensure that there are no leaks.
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 one of the following labor operation numbers and time
Allowances:
Add the cost of the recall parts package and brake tube, if necessary, 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 required.
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 MD52 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) 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 FUNCTION1' prompt, then type 110RD84111.
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. A copy of the owner notification letter is attached.
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.
Vehicle Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation
CIMS 482-00-85
800 Chrysler Drive East
Auburn Hills, Michigan 48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone Service Office.
Customer Services Field Operations
DaimlerChrysler Corporation