Recall - Frame Rail to Floor Pan Welds
No. 587October, 1993
To: All Chrysler-Plymouth and Dodge Dealers
Subject:
Safety Recall # 587 -- Frame Rail-To-Floor Pan Welds
Models:
All 1992 and Early - 1993 Model Year Dodge Daytona (AG-Body) Vehicles Built Through November 2, 1992.
The welding attachment of the front frame rails-to-floor pan sheet metal may not be properly welded. This could cause body panel flexing and sheet metal cracking, possibly resulting in structural damage. To correct the condition, these areas must be strengthened by installing nut and bolt attachments to the inboard and outboard flanges of each rail.
IMPORTANT:
Some of the involved vehicles may be in dealer inventory Federal law requires you to complete this recall service on these vehicles before retail delivery.
Details of this service action are explained in the following sections.
Service Procedure Videotape
No videotape of the service procedure for this recall will be provided.
Dealer Notification & Vehicle List
Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by Certified Mail.
Important:
Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible dealership personnel should be instructed to sign for this Certified Mall without hesitation as it concerns urgent safety recall information.
The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.
All dealers: Each Chrysler-Plymouth and Dodge dealer will receive a copy of this dealer recall notification letter by first class mail.
DIAL System Function 70
All involved vehicles will be entered to DIAL System Function 70 at the time of recall implementation for dealer inquiry by VIN as needed.
Parts
Important:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand.
Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Nut and Bolt Packages, Recall PN C3905870, to service 25% of those vehicles.
Each parts package contains the following components:
Quantity Description
18 Nuts, Flanged
18 Bolts, Flanged
1 Instruction Sheet
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is included.
Enclosed with each owner notification is an Owner Recall Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.
Service Procedure
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To ensure customer satisfaction, record all radio settings before disconnecting the battery and reset the electronic memory when you have completed the repair procedure.
2. Move both front seats to the full rear position. Remove the door opening sill plate, lower trim kick panel and console cover from both sides of the vehicle.
3. Pull carpet back on both sides of the vehicle.
4. Cut the passenger side floor insulation pad down the center and fold each side back to expose the floor pan kick-up area.
5. Locate and draw a line between the center of the large raised dimple and the small recessed dimple on the passenger side of the floor pan. Measure 3 inches up from the center of the large raised dimple, then center punch and drill 1/4 inch diameter hole as shown in figure 1.
Note:
Body sealer may have to be removed to locate small dimple.
6. Cut the driver side insulation pad down to the right of the brake pedal, then fold each side back to expose floor pan kick-up area.
7. Locate and draw a line between the center of the large raised dimple and the small recessed dimple on the driver side of the floor pan. Measure 3 inches up from the center of the large raised dimple, then center punch and drill one 1/4 inch diameter hole as shown in figure 2. Be sure to tape the drill bit about 1/2 inch from the end to prevent contact with brake tubes.
Note:
Body sealer may have to be removed to locate small dimple.
8. From under the vehicle, measure, center punch and drill five 1/4 inch diameter holes along the outboard side of each frame rail flange as shown in figure 3.
Note:
Make sure all holes are drilled on the centerline of the outboard flange.
9. From under the vehicle, measure, center punch and drill three 1/4 inch diameter holes along the inboard side of each frame rail flange as shown in figure 3.
Caution:
Use care not to damage brake tubes (left side) and fuel tubes (right side) when drilling holes.
Note:
Make sure all holes are drilled on the centerline of the inboard flange.
10. Use primer, Mopar PN 4443636 or equivalent, to cover the edges of all (18) drilled holes.
11. From inside the vehicle, insert the 18 supplied bolts into the drilled holes.
Note:
Bolt heads must be on inside of vehicle with bolt threads pointing down.
12. From under the vehicle, apply a generous amount of Silicone Rubber Adhesive Sealant (RTV), PN 4318025, around the entire circumference of each hole and the underside of each bolt head to completely seal all attachments.
13. With an assistant, install the 18 supplied nuts onto the bolts and torque nuts to 230 +/- 10 in.lbs.
Caution:
Make sure top inboard bolt is clear of brake tubes on driver side of vehicle.
14. Coat all nuts and bolts by applying Mopar Rustproofing and Sealant PN J8993799, or equivalent.
15. Place insulation pad into proper position and use duct tape over cut areas.
16. Place carpet into proper position.
Caution:
Make sure carpet is properly placed and does not interfere with brake or accelerator pedals.
17. Install console side covers, lower trim kick panels and sill plates.
18. Reconnect battery.
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments.
Use the labor operation number and time allowance:
Add the cost of the recall parts package plus applicable dealer allowance to your claim.
Note:
See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing instructions.
Parts Return
Not applicable.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to:
Chrysler Corporation 429-10-04
P.O. Box 1919
Detroit, Michigan 48231-1919
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone Service Office.
SAFETY RECALL -- FRAME RAIL-TO-FLOOR PAN WELDS
Dear Chrysler Corporation Vehicle Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1992 and 1993 model Dodge Daytona vehicles. The frame rail-to-floor pan welds may not be adequate.
Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange for service to correct the condition without delay. The service and required parts as described in this letter will be provided free of charge.
The welding attachment of the front frame rails-to-floor pan sheet metal may not be properly welded. This could cause body panel flexing and sheet metal cracking, possibly resulting in structural damage. If the attachments are not strengthened, the vehicle impact protection capability may be compromised. This could increase the likelihood of injury to occupants if the vehicle is involved in a collision accident.
To correct the condition, your dealer will strengthen the area by bolting both frame rails to the floor pan.
The work will take about two and one-half hours to complete. However, additional time may be required depending on how dealer appointments are scheduled and processed. To obtain this free service:
^ Contact your dealer as soon as possible to schedule an appointment for the service.
^ Take the enclosed Owner Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and the service that is required.
If you have any problem obtaining the needed repair, please contact the Chrysler Zone Service Office in your area. (it is listed under "Service Assistance" in your Owner's Manual.) A Zone representative will arrange for prompt attention to your vehicle.
We regret any inconvenience which this action may cause you. However, we are concerned about your safety. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington D.C. area residents may call 366-0123.)
Thank you for your attention to this important matter.