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TSB 08-30-99

Outside Power Mirror Pivot Arm Rotates With Little Resistance

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Models: 1996 - 1997 (BR) Ram Truck

NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH OUTSIDE POWER MIRRORS.

Discussion:

This bulletin involves replacing the outside power mirror mounting bracket,  

Symptoms:

The outside power mirror is loose on its mounting bracket.  

Diagnosis:

Position the mirror into its detent position. Then, move the mirror fore and aft to check for looseness in the detent. If the outside power mirror moves easily past its detent, perform the Repair Procedure.  

Parts:

AR (1)    05016568AA   Mounting Kit, Outside Power Mirror, Right Side
AR (1)    05016957AA   Mounting Kit, Outside Power Mirror, Left Side
AR (1)    05010901AA   Reinforcement Bracket, Left (Driver Side) Outside Power Mirror
AR (3)    00153912        Screw, 0. 1 90-16 X 0.50 in. Self Tapping
AR (1)    82300234        Mopar RTV Sealant  

Repair:

1.    Disconnect and isolate the battery negative cable(s).
2.    Swing the outside power mirror forward (Figure 1).

3.    Open the door.  
4.    Remove the two screws in the door pull cup that secure the cup to the inner door panel (Figure 2) and remove the cup.

5.    If equipped, remove the manual window regulator crank handle with a removal tool (Figure 3).

6.    Remove upper trim panel screw.
7.    Using a trim panel removal tool such as Snap-on Al 61 B, gently pry the trim panel away from the door around the perimeter to release the retainers. Support the door trim panel by allowing it to hang on the door handle.
8.    Unplug the power mirror motor wire harness connector (Figure 4).

9.     Remove the foam stuffer from the mirror-mounting opening.
10.   Remove the three nuts that secure the power mirror to the door panel.
11.   From the outside of the door, pull the mirror loose. As the mirror is being pulled from the door, feed the wire harness, grommet, and connector through the hole in the outer door panel.
12.   Remove the mirror-mounting gasket by peeling the gasket off the mounting bracket.
13.   Remove the three mounting bracket cover screws (Figure 5).

14. Rotate the mounting bracket cover approximately 180 degrees to expose the mirror's mounting clamp (Figure 6).

15.   Remove the four mounting bracket clamp retaining screws (Figure 6) and remove the clamp.

16.   Separate the mirror support arm from the mounting bracket assembly (Figure 7).

17.   Slide the friction sleeve off the support arm and wipe the arm and sleeve clean.
18.   Slide the friction sleeve back into place ove rthe support arm.
19.   Install the new plunger (supplied in Outside Power Mirror Mounting Kit - see Parts Required section) into the new mounting bracket assembly (Figure 8).

20.   Position the mirror support arm into the new mounting bracket assembly making sure that the detent plunger is aligned with the slot in the support arm and friction sleeve (Figure 9).

21. In addition, the mirror pivot stop must be positioned properly in the groove provided on the mirror support arm (Figure 10) when assembling the pivot arm to the mounting bracket.

22.   Position the new clamp over the mirror support arm and align the holes in the clamp to the mounting bracket.

NOTE: STEPS 23 AND 24 ARE CRITICAL FOR PROPER OPERATION OF THE MIRROR PIVOT ARM AND DETENT ASSEMBLY.

23.   Install the four new mounting bracket clamp attachment screws taking care to tighten the screws alternately while maintaining an even gap that is about the thickness of a penny, all the way around the clamp. To ensure that gap is even, slide the penny into the gap and adjust the clearance until the penny has a slight amount of resistance when the penny is removed from the gap (Figure 11).

24. With the penny removed, tighten the attachment screws further using the following tightening sequence:

• Tighten the screws to 6.2 N*m (55 in. lbs.) evenly in a crisscross pattern.
• Tighten the screws to 6.8 N*m (60 in. lbs.) evenly in a crisscross pattern

NOTE: THE CLAMP SHOULD NOT BOTTOM AGAINST THE MOUNTING BRACKET. A 0.250 - 0.510 MM (0.010 - 0.020 IN.) GAP BETWEEN THE CLAMP AND MOUNTING BRACKET IS NORMAL AND WILL PERMIT THE CLAMP TO APPLY THE CORRECT AMOUNT OF FORCE ON THE SUPPORT ARM.

25. Place the mirror assembly in a vise with the mounting studs facing away from you as shown in Figure 12. Swing the mirror 180 degrees to the right for the right mirror or to the left for the left mirror.

26. Remove the mirror from the vise then, position the mounting bracket cover onto the mounting bracket making sure that the power mirror's wiring harness does not get pinched during the assembly process (Figure 13.)

27. Attach the mounting bracket cover to the mounting bracket using three new screws. Tighten the screws to 2 Nm (16 in. lbs.).

28. Apply a new mounting gasket to the mounting bracket taking care to align the clearance holes to the mounting studs. Press firmly into place.

29. If the left mirror is being service, proceed to the next step. If the right mirror is being service, proceed to Step 35.

NOTE: THE REINFORCEMENT BRACKET MAY HAVE BEEN PREVIOUSLY INSTALLED. IF THE REINFORCEMENT BRACKET HAS ALREADY BEEN INSTALLED, PROCEED TO STEP 35.

30. Place reinforcement bracket p/n 05010901 AA in position as shown in Figure 14.

NOTE: THE REINFORCEMENT BRACKET MAY REQUIRE SOME FORCE TO INSTALL DUE TO THE LACK OF CLEARANCE PROVIDED.

31. Feed the mirror's wiring harness, grommet, and connector through the hole in the outer door panel. Secure the wiring harness grommet.

32. Install the mirror onto the door attaching the mirror to the door with the three nuts/washers. Only hand tighten the nuts at this time.

33. Drill three (3) 3 mm (1/8 in.) pilot holes into the door that correspond with the holes in the reinforcement bracket (Figure 14).

34. Tighten the mirror attachment nuts to 7.3 Nom (65 in. lbs.). Apply a small amount of Mopar RTV Sealant p/n 82300234 to the three self tapping screws p/n 001 53912. Install the screws then proceed to Step 37.

35. Feed the mirror's wiring harness, grommet, and connector through the hole in the outer door panel. Secure the wiring harness grommet.

36. Using the three attachment nuts, attach the mirror to the door. Tighten the mirror attachment nuts to 7.3 Nom (65 in. lbs.).

37. Connect the power mirror motor wiring harness connector.

38. Install the foam stuffer into the mirror-mounting opening.

39. Install the door trim panel.

40. Install the upper trim panel screw.

41. If equipped, install the manual window regulator handle.

42. Install the door pull cup securing it with the two screws.

43. Connect the battery,negative cable(s). Reset the clock on the radio.

Notes:

POLICY:        Reimbursable within the provisions of the warranty.

TIME ALLOWANCE.
Labor Operation No:
              23-04-21-97 Mirror, Outside Power, Pivot Arm Rotates With little Resistance,
                          Left Side ................................................. 1.0 Hrs.
              23-04-21-98 Mirror, Outside Power, Pivot Arm Rotates With little Resistance,
                          Right Side ............................................... 0.9 Hrs.

FAILURE CODE: P8 - New Part