Recall - Transmission Crossmember Reinforcement Brackets
NO849
DATE
January 2000
CUSTOMER SATISFACTION NOTIFICATION NO. 849 TRANSMISSION CROSSMEMBER REINFORCEMENT BRACKETS
Effective immediately, all repairs on involved vehicles are to be performed according to this notification. service action #99-32 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification.
MODELS
2000 (AN) Dodge Dakota 4-Wheel Drive
NOTE:
This notification applies only to the above trucks built through August 19, 19999 (MDH0819XX)
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 transmission crossmember support brackets on about 2,400 of the above vehicles may crack and separate from the frame under severe operating condition.This will cause the rear portion of the transmission to move out of positian and contact the torsion bar anchor reinforcement.
REPAIR
All vehicles must be inspected for the presence of transmission crossmember reinforcement brackets. Vehicles without the reinforcement brackets must have them installed.
PARTS INFORMATION
Each dealer, to whom vehicles in the notification were invoiced (or the current dealer at the same street address), will receive enough Transmission Crossmember Reinforcement packages to service about 25% of those vehicles.
Parts Information:
PARTS INFORMATION
SERVICE PROCEDURE
A. Transmission Crossmember Reinforcement Bracket Inspection:
1. Raise vehicle on an appropriate hoist.
Figure 1:
2. Inspect the right and left side of the transmission crossmember for the presence of crossmember reinforcement brackets (Figure 1). The brackets are located at each end of the transmission crossmember, at the frame rail.
> If transmission crossmember reinforcement brackets are present, lower the vehicle and return it to the owner. No further action is required.
> If there are no transmission crossmember reinforcement brackets, proceed to Section "B". Transmission Crossmember Reinforcement Bracket Installation."
B". Transmission Crossmember Reinforcement Bracket Installation:
NOTE
If there are no transmission crossmember reinforcement brackets, proceed to Section "B". Transmission Crossmember Reinforcement Bracket Installation."
1. If so equipped, remove the front and rear skid plates.
2. Place a jack stand under the transfer case housing and raise the transmission/transfer case assembly so that there is no weight on the transmission crossmember.
3. Remove the transmission crossmember-to-frame attaching bolts on the left side of the vehicle.
Figure 2:
4. position the relief cut depth gauges as shown in Figure 2 and clamp in place using locking pliers.
5, Using a high speed cut-off tool, cut a relief in the front and rear L-bracket. The relief is cut at a 45-degree angle to the L-Bracket in the radius area where the bracket is attached to the frame (Figure 3). The relief should be cut to a depth where the cut-off wheel just touches the relief cut depth gauge.
6. Remove both relief cut depth gauges from the frame.
Figure 3:
7. Temporarily position the new transmission crossmember reinforcement bracket onto the frame (Figure 4).
NOTE:
Use the transmission M1O crossmember attaching bolts to keep the bracket in place while center punching the bottom of the frame (Figure 4).
Figure 4:
8. Hold the reinforcement bracket tight against the bottom of the frame. Using the supplied transfer punch and reinforcement bracket lower holes as a template, center punch the bottom of the frame for the two (2) lower Riv-Nut locations (Figure 4).
CAUTION:
Do not center punch the frame side Riv-Nut locations at this time.
9. Remove the reinforcement bracket.
10. Using the center punch marks as a guide, drill two (2) V4 inch pilot holes through the lower frame.
11. Enlarge the two (2) � inch pilot holes in the lower frame with the 45/64 inch drill bit supplied.
12. Clean off any burrs around the two (2)45/64 inch holes with a flat file and apply a coat of zinc primer (PN 4443636) or equivalent to cover the edges of all drilled holes.
Figure 5:
13. Assemble the Riv-Nut installation tool by installing the hex head spacer onto the M12 x 4Srnmghex flange bolts. Then install the locking star washer onto the bolt. Screw the installation tool into one of the Riv-Nuts (Figure 5).
CAUTION:
A light coat of motor oil must be applied to the hex flange bolt head, hex head spacer and the hex flange bolt threads before installing each Riv-Nut (Figure 5). Failure to apply oil to these components will cause false torque readings and incorrect Riv-Nut crush.
NOTE:
One of the M12 x 45mm hex flange bolts is provided and must be used as the tool to install all of the Riv-Nuts. Do not use any of the other eight bolts to install Riv-Nuts.
14. Place the Riv-Nut (with installation tool) into one of the 45/64 inch holes drilled into the lower section of the frame.
15. While holding the hex head spacer with an open-end wrench, tighten the M12 bolt with a torque wrench to 45 ft. lbs. (61 N.m) (Figure 6).
16. Remove the installation tool from the Riv-Nut.
17. Repeat steps 13 through 16 to install the second Riv-Nut into the other 45/64 inch hole that was drilled into the lower section of the frame.
18. Temporarily mount the reinforcement bracket onto the frame using the two M1 0 transmission crossmember bolts and two M12 x 45mm bolts. Do not tighten any bolts until all four bolts are in their proper position.
19. Tighten the two M12 x 45mm bolts to 15 ft. lbs. (20 N.m).
20. Using the reinforcement bracket as a template, center punch the side of the frame for two side Riv-Nut locations (Figure 7).
21. Remove the reinforcement bracket from the frame.
22. Using the center punch marks as a guide, drill two (2) � inch pilot holes through the side of the frame.
23. Enlarge the two (2) � inch pilot holes in the side of the frame with the 45/64 inch drill bit supplied.
24. Clean off any burrs around the two (2)
45/64 inch holes that were drilled in the frame with a flat file and apply a coat of zinc primer (PN 4443636) or equivalent to cover the edges of all drilled holes.
25. Screw the installation tool into one of the Riv-Nuts as shown in Figure 5 and apply motor oil to the tool.
26. Place the Riv-Nut into one of the 45/64 inch holes in the side of the frame.
27. While holding the hex head spacer with an open-end wrench, tighten the M1 2 bolt with a torque wrench to 45 ft. lbs. (61 N.m) (Figure 8).
28. Remove the installation tool from the Riv-Nut.
29. Repeat steps 25 through 28 to install the second Riv-Nut into the other 45/64 inch hole that was drilled into the side of the frame.
30. Assemble the reinforcement bracket onto the frame using four (4) M12 x 45mm bolts at the lower and side Riv-Nut locations (Figure 9). Do not tighten the bolts at this time.
31. Attach the reinforcement bracket to the transmission crossmember using two M10 bolts and nuts (Figure 10). Do not tighten the bolts/nuts at this time.
32. Torque the four M12 x 45mm bolts to 45 ft. lbs. (61 N.m) (Figure 10).
33. Torque the two M1O bolts and nuts to 65 ft. lbs. (88 N.m) (Figure 10).
34. Repeat steps 3 through 33 on the other side of the vehicle.
35. Lower the weight of the transmission onto the transmission crossmember by removing the jack stand.
36. If so equipped, install the front and rear skid plates. Torque all of the skid plate attaching bolts to 17 ft. lbs. (23 N.m).
37. Lower the vehicle.
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 Customer Satisfaction Notification service completions and provide dealer payments.
Use one of the following labor operation numbers and time allowances:
Add to the cost of the parts package plus applicable dealer allowances to your claim.
NOTE:
See the warranty administration manual, recall claim processing section, for complete claim processing instructions.
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 MD52 will be updated to include this Customer Satisfaction Notification 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 FUNCTION" prompt, then type "0RD849".
OWNER NOTIFICATION AND SERVICE SCHEDULING
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by 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 notification is an Owner Notification Form. The involved vehicle and Customer Satisfaction Notification are identified on the form for owner or dealer reference as needed.
VEHICLE NOT AVAILABLE
If a vehicle is not available for service for a known reason, 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