DodgeRam.info > TSB's > Recalls > Recall 861

Safety Recall #861

Front Axle Assembly
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Date: March 2000

Effective immediately,. all repairs on involved vehicles are to be performed according to this recall service procedure. Service Action #99-41 is being cancelled. Those vehicles that have already had this repair performed as determined by our warranty records, have been excluded-from this recall.

Models: 2000 (BR/BE) Dodge Ram 2500/3500 Series Four Wheel Drive Trucks

NOTE: This recall applies only to the above vehicles built at the St. Louis North Assembly Plant ("J" in the 11th VIN Position) from August 3; 1999 through November 6, 1999 (MDH 080322 through 110609)

IMPORTANT:    Most of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall.

IMPORTANT:    Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System.

Subject:

The right lower control arm bracket may separate from the front axle assembly on 51 of the above vehicles due to a poor quality weld. Bracket separation may cause reduced steering control and/or,cause the vehicle to pull when braking, which can cause an accident without warning.

Repair:

The front axle assembly must be replaced.

Parts:

No parts will be distributed initially. Dealers should determine which axle assembly is required for each vehicle at the time the appointment is scheduled to assure that the correct parts are available when the customer arrives. The appropriate axle assembly for the vehicle to be serviced may be determined by:

Parts Information:

No parts will be distributed initially. Dealers should determine which axle assembly is required for each vehicle at the time the appointment is scheduled to assure that the correct parts are available when the customer arrives. The appropriate axle assembly for the vehicle to be serviced may be determined by:

Using the part code in the third column of the VIN list along with the following table (involved dealers);
Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or
Entering the VIN to the DIAL VIP System Function (sales code information) along with the following table (all dealers).

Axle Ratio   Sales Code   Part Code    Original Axle PN     Replacement Axle PN  
3.55 DMD 1 52070136AG,
52070138AH or
52070148AB
05015195AA
4.10 DMF 2 52070137AG,
52070139AG or
52070152AB
05015243AA

In addition, each vehicle requires 8.5 pints of axle lubricant to be added to the axle assembly. Dealers should order enough axle lubricant to service vehicles as necessary.

Quantity      Part Number   Description
5 04874468 Axle Lubricant (80W-90/GL-5) - One Quart

Service Procedure:

A. Remove the Front Axle Assembly:

1. Raise the vehicle to a working level on an appropriate hoist.

2. Remove the front wheel and tire assemblies.

3. Remove the right brake caliper adapter assembly and set the assembly aside.

NOTE: Do not allow the brake hose to support the weight of the caliper adapter assembly.

4. For 3500 series trucks, remove the right hub extension mounting nuts and remove the extension from the brake rotor (Figure 1).

5. Remove the right brake rotor.

6. Back off the right hub/bearing mounting bolts 1/4" each, then tap the bolts with a hammer to loosen the hub/bearing from the steering knuckle (Figure 2).

 

7. Remove the right hub/bearing mounting bolts and then remove the hub/bearing and axle shaft assembly (Figure 2).

8. Remove the right brake shield and spacer from the steering knuckle.

9. Remove the right ABS wheel speed sensor from the steering knuckle, if equipped.

10. Using Special Tool C-3 894-A, disconnect the tie rod/drag link from the right steering knuckle (Figure 3).

11. Remove the right upper and lower ball joint nuts. Strike the steering knuckle with a brass hammer to loosen the ball joints and then remove the right steering knuckle.

12. Remove the right brake hose mounting bracket from the axle assembly.

13. Disconnect the steering damper from the axle assembly (Figure 4).

14. Disconnect the right stabilizer bar link from the axle bracket (Figure 5).

fig 3 fig 4 fig 5

15. Disconnect the right stabilizer link from the stabilizer bar and remove the link (Figure 5).

16. Remove the left brake caliper adapter assembly and set the assembly aside.

NOTE: Do not allow the brake hose to support the weight of the caliper adapter assembly.

17. For 3500 series trucks, remove the left hub extension mounting nuts and remove the extension from the rotor (Figure 1).

18. Remove the left brake rotor.

19. Back off the left hub/bearing mounting bolts 1/4" each, then tap the bolts with a hammer to loosen the hub/bearing from the steering knuckle (Figure 2).

20. Remove the left hub/bearing mounting bolts and then remove the hub/bearing and axle shaft assembly (Figure 2).

21. Remove the left brake shield and spacer from the steering knuckle.

22. Remove the left ABS wheel speed sensor from the steering knuckle, if equipped.

23. Using Special Tool C-3 894-A, disconnect the tie rod from the left steering knuckle (Figure 3).

24. Remove the left upper and lower ball joint nuts. Strike the steering knuckle with a brass hammer to loosen the ball joints and then remove the left steering knuckle.

25. Remove the left brake hose mounting bracket from the axle assembly.

26. Disconnect the left stabilizer bar link from the axle bracket (Figure 5).

27. Disconnect the left stabilizer link from the stabilizer bar and remove the link (Figure 5).

28. Fully raise the vehicle.

29. Drain the fluid from the front axle differential.

30. Disconnect the axle vent hose.

31. Disconnect the electrical connector and vacuum hose from the axle shift motor housing.

32. Remove the axle vacuum shift motor housing (Figure 6).

33. Remove the right intermediate axle shaft and shift collar.

34. Disconnect the driveshaft from the axle yoke. Use a plastic tie strap or equivalent to support the drive shaft.

35. Support the axle with a hydraulic jack under the differential.

CAUTION: Use a chain or strap to secure the axle to the hydraulic jack.

36. Disconnect the track bar from the axle bracket.

37. Disconnect the left and right upper and lower suspension arms from the axle brackets (Figure 7).

38. Disconnect the right and left lower shock absorber bolts from the axle bracket (Figure 8).

fig 6 fig 7 fig 8

39. Using the hydraulicj ack, lower the axle enough to allow the removal of the front coil springs.

40. Remove the front coil spring s from the 9 axle brackets.

41-. Lower the axle assembly and remove it from under the vehicle.

B. Install Front Axle Assembly:

1. Place the new front axle assembly on the hydraulic jack and install the front coil springs onto the axle brackets.

CAUTION: Use a chain or strap to secure the axle to the hydraulic jack.

2. Raise the axle into position with the hydraulic jack while aligning the coil springs onto the coil spring pads.

3. Position the upper and lower suspension arms into the axle bracket (Figure 7). Loosely install the bolts and nuts. Do not tighten at this time.

CAUTION: The front coil springs must be supporting the full weight of the vehicle when the suspension fasteners are tightened or premature bushing wear may occur.

4. Install the left and right lower shock absorber bolts. Tighten the bolts to 100 ft-lbs (136 N-m) (Figure 8).

5. Connect the track bar to the axle bracket and install the bolt. Do not tighten fastener at this time.

6. Remove the hydraulic jack.

7. Install the right intermediate axle shaft and shift collar.

8. Connect the left stabilizer bar link to the stabilizer bar and the axle bracket (Figure 5). Tighten the stabilizer link nuts to 50 ft-lbs (68 N-m).

9. Install the left brake hose bracket onto the axle assembly.

10. Install the left steering knuckle.

a. Tighten the lower ball joint nut to 35ft-lbs(47 N-m).

b. Tighten the upper ball joint castle nut to 70 ft-lbs (94 N.m). NOTE: Remember to install the ABS wheel speed sensor wiring bracket on the upper ball joint, if equipped.

c. Install a new cotter pin through upper ball joint nut. Tighten the nut if necessary to line up the cotter pin hole.

d. Tighten the lower ball joint nut to 150 ft-lbs (203 N-m).

11. Connect the tie rod to the left steering knuckle (Figure 4). Tighten the nut to 65 ft-lbs (88 N-m).

12. Clean any dirt and rust off of the steering knuckle and hub mounting surfaces.

13. Install the left brake shield and spacer.

14. Install the left hub, bearing and@ axle assembly into the axle housing (Figure 2). Tighten the hub flange bolts to 125 ft-lbs (170 N-m).

15. Install the left ABS wheel speed sensor, if equipped. Tighten the sensor bolt to 11 ft-lbs (14 NM).

16. Install the left brake rotor.

17. For 3500 series trucks, install the left wheel hub extension (Figure 1). Tighten the hub extension nuts to 135 ft-lbs (183 N-m).

18. Install the left brake caliper adapter assembly. Tighten the adapter bolts to 210 ft-lbs (285 NM).

19. Connect the right stabilizer bar link to the stabilizer bar and the axle bracket (Figure 5). Tighten the stabilizer link nuts to 50 ft-lbs (68 N-m).

20. Install the right brake hose bracket onto the axle assembly.

21. Install the right steering knuckle.

a. Tighten the lower ball joint nut to 35ft-lbs(47 N-m).

b. Tighten the upper ball joint castle nut to 70 ft-lbs (94 N-m).

NOTE: Remember to install the ABS wheel speed sensor wiring bracket on the upper ball joint, if equipped.

c. Install a new cotter pin through upper ball joint nut. Tighten the nut if necessary to line up the cotter pin hole.

d. Tighten the lower ball joint nut to 150 ft-lbs (203 N-m).

22. Connect the steering damper to the axle bracket (Figure 4). Tighten the bolt to 70 ft-lbs (95 NM).

23. Connect the tie rod to the right steering knuckle (Figure 4). Tighten the nut to 65 ft-lbs (88 N-m).

24. Clean any dirt and rust off of the steering knuckle and hub mounting surfaces.

25. Install the right brake shield and spacer.

26. Install the right hub, bearing and axle assembly into the axle housing (Figure 2). Tighten the hub flange bolts to 125 ft-lbs (170 N-m).

27. Install the right ABS wheel speed sensor, if equipped. Tighten the sensor bolt to 11 ft-lbs (14 N-m).

28. Install the right brake rotor.

29. For 3500 series trucks, install the right wheel hub extension (Figure 1). Tighten the hub extension nuts to 135 ft-lbs (180 NM).

30. Install the right brake caliper adapter assembly. Tighten the adapter bolts to 210 ft-lbs (285 N-m).

31. Install the axle vacuum shift motor housing (Figure 6).

32. Attach the vacuum hose and the electrical connector to the shift motor housing.

33. Connect the axle vent hose to the tube fitting.

34. Connect the drive shaft to the axle yoke. Tighten the U-joint clamp bolts to 14 ft-lbs (19 N-m).

35. Add 8.5 pints of differential lubricant (Mopar PN 04874468 or equivalent) to the axle assembly. Check the lubricant level and adjust as necessary.

36. Install the right and left wheel and tire assemblies.

> On 2500 series trucks, tighten the lug nuts to 135 ft-lbs (I 80 N-m).
> On 3500 series trucks, tighten the lug nuts to 145 ft-lbs (195 NM).

37. Lower the vehicle.

38. With the full weight of the vehicle on the suspension, tighten the left and right upper suspension arm nuts at the axle to 89 ft-lbs (121 N-m).

39. With the full weight of the vehicle on the suspension, tighten the left and right lower suspension arm nuts at the axle to 62 ft-lbs (84 NM).

40. With the full weight of the vehicle on the suspension, tighten the track bar bolt at the axle bracket to 130 ft-lbs (176 NM). Place the vehicle on a suitable alignment rack. Install the wheel alignment equipment onto the vehicle per the alignment equipment manufacturer's instructions and align the front suspension. Refer to the appropriate service manual for alignment specifications.

Completion Reporting and Reimbursement

Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments.

Use one of the following labor operation numbers and time allowances:

Replace front axle assembly and align      Labor Operation  
Number
Time
  Allowance  
  > 2500 Series Trucks 02861182 4.7 hours
  > 3500 Series Trucks 02861183 4.9 hours

Add the cost of the recall parts package and switch assembly, if necessary, plus applicable dealer allowance to your claim.

Parts Return

Removed front axle assemblies must be returned to the Warranty Material Return Center.

NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing and material return instructions.


Thanks to Bob Bergevin for supplying this Recall information.

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This page was edited on: May 3, 2004