DodgeRam.info > TSB's > Recalls > Recall 828

Safety Recall #828

Hydraulic Clutch

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Date: December 1999

Models: 1994-1999 (BR/BE) Dodge Ram Four-Wheel Drive (4X4) (4WD) Trucks

Note: This recall applies only to the above vehicles equipped with an 8.0L engine ("W" in the 8th VIN Position) and a manual transmission (Sales Code - DXX) built through April 21, 1999 (MDH 0421xx)

Subject:

The hydraulic clutch line on some 8,800 of the above vehicles MAY melt and spray fluid on the exhaust system under certain operating conditions. Hydraulic fluid leakage in the presence of an ignition source (such as the exhaust system) can result in an underbody fire.

There are two parts packages, one for 1994-97 and another for '98-99. See your dealer...no charge for any recalls anytime.

If you did not get informed by DC, call your dealer as he will perform the recall for you. He may want to order the correct parts, as he gets only a first shipment to cover 25% of that model he sold. All in that identified group get the change, no dealer decisions unless your model has already had it done.

Repair:

The hydraulic clutch master cylinder, slave cylinder and clutch line must be replaced.

Parts:

Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Hydraulic Clutch Packages to service about 25% of those vehicles.

The appropriate clutch package for the vehicle to be serviced may be determined by model year as follows:

Model Year
10" VIN Position
Character
Part Code
Part Number
1994,1995,
1996, 1997
R, S, T, V
1
CAAM8281
1998, 1999 W, X
1
CAAA8282

Each package contains the following components:

         Quantity    Description
 
1
  Clutch Master Cylinder
 
1
  Clutch Slave Cylinder
 
1
  Clutch Pedal Clip
 
1
  Clutch Pedal Bushing (94-97 package only)
 
2
  Clamps
 
2
  Screws
 
3
  Plastic Rivets

 

Service Procedure:

1.    Raise the vehicle on an appropriate hoist.

2.    Remove the nuts that attach the clutch slave cylinder to the clutch housing (Figure 1).

3.    Remove the slave cylinder from the clutch housing.

4.    Remove the clutch line clip(s) from the lower body flange (Figure 1).

5.    Push the slave cylinder up around the exhaust pipe and into the engine compartment.

6.    Lower the vehicle.

7.    Inside the passenger compartment, disconnect the clutch pedal interlock switch wiring connector.

8. For 1994-1997 vehicles, remove the locating pin that secures the master cylinder to the dash panel (Figure 2).

9.    Remove the retaining clip, and on 1994-1997 vehicles, remove the plastic bushing that attaches the clutch master cylinder push rod to the clutch pedal pivot pin. Discard the clip and bushing.

10.   Disconnect the clutch master cylinder push rod from the clutch pedal pivot pin.

11.   Inside the engine compartment, verify that the clutch reservoir cap is tight.

12.   Remove the two (2) clutch reservoir mounting screws (Figure 1).

13.   Remove the clutch master cylinder as follows (Figure 1):

For 1994 through 1997 model year vehicles: Rotate the master cylinder 45 degrees counter-clockwise to unlock it and then remove the master cylinder from the dash panel.

For 1998 and 1999 model year vehicles: From inside the passenger compartment, remove the master cylinder bracket nuts that attach the master cylinder to the dash panel. In the engine compartment, remove the master cylinder from the dash panel.

14.   Remove the hydraulic clutch assembly (master cylinder, slave cylinder, reservoir and hydraulic line) from the vehicle. Discard the hydraulic clutch assembly.

15.   Verify that the reservoir cap on the new clutch master cylinder is tight.

16.   Connect the new clutch slave cylinder portion of the clutch line to the new master cylinder portion by connecting the quick connect fitting. Pull back on the fitting to ensure that the connection is secure.

17.   Position the new clutch master cylinder into the vehicle so that the clutch line quick connect fitting is located downward against the lower dash panel and rearward of the inner fender (Figure 3).

18.   Install the clutch master cylinder as follows:

For 1994 through 1997 model year vehicles: Install the master cylinder into the dash panel and then rotate the master cylinder 45 degrees clockwise to lock it in place.

For 1998 and 1999 model year vehicles: Install the master cylinder into the dash panel and then, from inside the passenger compartment, install the master cylinder bracket nuts to attach the master cylinder to the dash panel. Tighten the bracket nuts to 40 ft-lbs (54 N-m).

19.   Install the clutch reservoir onto the dash panel. Tighten the reservoir screws to 60 in-lbs (7 N.m).

20.   Inside the passenger compartment, apply a light coating of grease to the clutch pedal pivot pin.

21.  Slide the master cylinder push rod onto the clutch pedal pivot pin, install the plastic pivot bushing into the push rod eyelet (1994-1997 vehicles only), and then secure the push rod to the pivot with the provided retaining clip.

22.   For 1994-1997 vehicles, install the original locating pin to secure the master cylinder to the dash panel (Figure 2). NOTE: If a new pin is required, order P/N 06029645.

23.   Connect the clutch pedal interlock switch wiring connector.

24.   Raise the vehicle.

25.   Route the flexible clutch line along the REAR side of the lower body flange and OVER the fuel line (Figure 3).

26.   Install the new slave cylinder into the clutch housing but do NOT remove the push rod shipping strap. Tighten the slave cylinder nuts to 17 ft-lbs (23 N.m).

27.   Remove the fuel line heat shield located on the inside of the left frame rail (Figure 4). Slide the heat shield rearward to access the lower body flange.

28.   Remove the rearmost three (3) plastic rivets from the left front wheel well splash shield. Pull the splash shield forward to access the lower body flange.

29.   Drill two (2) '/s" pilot holes through the lower body flange as shown in Figure 3.

30.   Install the provided clamps over the clutch line heat wrap convolute and attach the clamps to the lower body flange with the provided screws. Tighten the screws to 60 in-lbs (7 N.m).

NOTE: Install the inboard clamp first. Make sure that the clutch line is routed through the lower body flange cutout (Figure 3).

31.   Install the left front wheel well splash shield using the new plastic rivets.

32.   Install the fuel line heat shield (Figure 4).

33.   Lower the vehicle.

34.   Cycle the clutch pedal several times to assure proper operation.

35.   Check all hydraulic clutch connections to ensure that there are no leaks.

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 following labor operation number and time allowance:

Replace hydraulic clutch
  1994-1997 model years        06828182     0.8 hours
  1998-1999 model years        06828183     0.9 hours

Add the cost of the recall parts package 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.

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:

DaimlerChrysler Corporation
CIMS 482-00-85
800 Chrysler Drive East
Auburn Hills, Michigan 48326-2757

If you have any questions or need assistance in completing this action, please contact your Zone Service Office.


Thanks to Bob Bergevin and Barry Drodge for supplying this Recall information.

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This page was edited on: May 3, 2004