Dash Panel - Cracking Noise
NO.: 23-01-93GROUP: Body
EFFECTIVE DATE: Feb. 22, 1993
SUBJECT:
Dash Panel Crack Repair
MODELS:
1989-1990 (AS) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager/Town & Country
1984-1988 (S) Caravan/Grand Caravan/Caravan CV
Voyager/Grand Voyager
SYMPTOM/CONDITION:
A "cracking" sound coming from the lower center area of the dash panel may be heard on some vehicles. The noise may be induced when turning sharply or rocking the vehicle.
DIAGNOSIS:
With the vehicle raised on a hoist inspect the tunnel area of the dash panel for cracks, particularly in the creases. If cracks are present, perform the repair procedure.
PARTS REQUIRED:
1 Kit, Dash Panel Repair 4741669
The Kit Consists of:
1 Plate, Reinforcement
1 Adhesive, Structural
19 Rivet, Structural
REPAIR PROCEDURE:
This bulletin involves MIG welding of the cracks and installing a reinforcement plate with structural rivets and structural adhesive.
1. Remove the front seats as outlined in the appropriate technical service manual.
2. Remove the console assembly, it is held in place with four screws.
3. Remove the right and left scuff plates.
4. Pull the carpet and floor silencer padding as far rearward as possible.
5. Using a sharp knife, cut the dash panel silencer pad where the right wheelhouse and dash panel meet. Then cut the dash panel silencer pad across to the left 1/2 inch below the bottom of the heater-A/C case until the end of the cut is in-line with the right edge of the accelerator pedal attachment. Then cut the pad straight down the dash panel 1/2 inch from the edge of the accelerator pedal attachment. Place match marks on the pad so it can be reinstalled in the same position. Remove this section of pad and store away from the work area.
6. CAUTION! USE CLOTH TYPE DUCT TAPE TO SEAL THE EDGES OF THE DASH PANEL SILENCER PAD TO THE DASH PANEL. THIS IS TO PREVENT WELDING SPARKS FROM REACHING THE IGNITABLE JUTE MATERIAL ON THE BACK OF THE PAD.
7. Inspect the crack(s) and ensure the edges are as flush to each other as possible. If any holes exist, fit a piece of approximately .035" thick sheet metal to fill the hole.
CAUTION!
PRIOR TO MIG WELDING THE CRACKS, BE SURE TO TAKE ALL OF THE NECESSARY PRECAUTIONS TO PREVENT FIRE HAZARD, ie. REMOVE ANY UNDER COATING THAT MAY HAVE BEEN APPLIED TO THE UNDERSIDE OF THE VEHICLE IN THE AREA TO BE WELDED, PROTECT ANY IGNITABLE MATERIALS INSIDE THE VEHICLE FROM EXPOSURE TO THE HEAT AND SPARKS CREATED BY THE WELDING PROCESS.
HAVE AN ASSISTANT WITH A FIRE EXTINGUISHER WATCH FOR FIRE WHILE THE WELDING IS BEING DONE.
8. From inside the vehicle, MIG weld the full length of all cracks and weld in any necessary hole patches.
9. If necessary, grind the weld and any metal build up that is over 1/4 inch over-flush with the surface of the floor. Be careful not to grind through the metal or the hole will have to be re-welded.
10. Position the reinforcement plate over the welded area so there is no more than a 1/4 inch gap between the plate and the dash panel at any one point.
11. Use the two holes of the reinforcement plate called out in Figure 1 to locate and drill two 17/64 inch holes through the dash panel.
12. Insert (DO NOT CLINCH) a rivet in each hole drilled in step 11 to hold the reinforcement plate in place. Then mark and drill 17/64 inch holes through the dash panel at the remainder of the holes in the reinforcement plate.
13. Remove the reinforcement plate and clean all debris created during the welding and drilling procedures.
14. Remove the tape from around the tube of structural adhesive. Push the plunger rod back and forth through the tube until the contents are thoroughly mixed. Unscrew the plunger rod from the tube. The tube's contents can be dispensed either by putting the tube in a caulking gun or by using the plunger rod to push the plunger disk from the other end of the tube.
15. Apply 1/4 inch beads of structural adhesive per the pattern in Figure 2.
16. Press the plate into place and attach the plate to the dash panel using structural rivets in the holes drilled in steps 11 and 12.
17. Remove the duct tape along the edges of dash panel silencer that was installed in step 6.
18. Reinstall the section of dash panel silencer pad removed in step 5. Use the match marks to ensure the pad is in its original position.
19. Use cloth type duct tape to cover and seal the cuts in the dash panel silencer pad.
20. Return the floor silencer pad and carpet to their original positions.
21. Reinstall the right and left scuff plates.
23. Reinstall the console assembly.
24. Reinstall the front seats.
25. Allow the vehicle to set overnight to allow the structural adhesive to fully cure.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 23-50-01-93 2.2 Hrs.
FAILURE CODE:
01 - Adhesive Bond