Safety Recall #872

Trailer Hitch Reinforcement Brackets

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Date: April 2000

Models: 1998-2000 (BR/BE) Dodge Ram Truck

NOTE: This recall applies only to the above trucks equipped with a trailer tow package (sales code AHC) built from January 1, 1998 through September 29, 1999 (MDH 0101XX through 092919).

NOTE: Also covered are trucks with Mopar Accessory trailer hitch part numbers purchased from Mopar between January 1998 and March 2000. DaimierChrysler does NOT have a record of the vehicles that have had these Mopar hitches installed. Every effort should be made by dealers to review their records and contact owners who have purchased these Mopar trailer hitches or have had these hitches installed by your dealer. Use this recall service procedure and parts information to inspect and repair Mopar accessory trailer hitches.

NOTE: Mopar accessory trailer hitch P/N 82202017 & 82205979 are not affected by 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 trailer hitch assembly on about 357,000 of the above vehicles may fatigue an crack. This can allow a trailer to separate from the truck and, cause an accident without warning.

Repair:

The trailer hitch assembly must be inspected for cracks. Trailer hitch assemblies that are cracked must be replaced. Trailer hitch assemblies without. Cracks must have reinforcement brackets installed.

Parts:

A:   Trailer Hitch Reinforcement Bracket

Part Number CBUB8721 Description Trailer Hitch Reinforcement Bracket Package

Each package contains the following components:
Quantity     Description
     2            Trailer Hitch Reinforcement Brackets
     6            Bolt & Washer Assembly
     6            Nut & Washer Assembly

B:   Trailer Hitch Assembly

Each package contains the following components:
Quantity     Description
     2            Trailer Hitch Reinforcement Brackets
     6            Bolt & Washer Assembly
     6            Nut & Washer Assembly

NOTE: 1998 Vehicles that have a 82205979 Mopar trailer hitch installed must also have the trailer hitch reinforcement bracket package P/N CBUB8721 installed.

Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive one 82205979 trailer hitch. Additional trailer hitch assemblies should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require trailer hitch assembly replacement

C:   Zinc Touch-up Primer

Part Number: 04443636     Description:    Zinc Touch-up Primer

Service Procedure:

A: Inspect the Trailer Hitch Assembly for Cracks

1.    Raise the vehicle on an appropriate hoist.

2.    Clean the side plate area by the trailer hitch mounting nuts (Figure 1).

3.    Inspect the right and left trailer hitch side plates for cracks as shown in Figure 1.

• Trucks with NO cracks on either side of the trailer hitch assembly must have reinforcement brackets installed. Continue with Section "B - Install Trailer Hitch Reinforcement Brackets."
• Trucks with cracks on either side of the trailer hitch assembly must have the trailer hitch assembly replaced. Continue with Section "C - Replace the Trailer Hitch Assembly (PN CBCB8722)." If PN CBCB8722 is not available,, continue with Section "D - Replace the Trailer Hitch Assembly (Mopar 82205979)."

B: Install Trailer Hitch Reinforcement Brackets

1.    Measure and scribe a line on the right side lower frame rail flange 1-3/8 inches (35mm) back from the rear edge of the trailer hitch flange (Figure 2).

2.    Position the front edge of the reinforcement bracket at the scribe line made on the frame rail in Step 1 (Figure 3).

NOTE:    If either of the reinforcement brackets interfere with the bumper brackets, loosen the trailer hitch mounting nuts and center the hitch as required. Tighten mounting nuts to 80 ft. lbs. (108 N.m).

3.    With the reinforcement bracket tight up against the frame rail, clamp the reinforcement bracket to the trailer hitch side plate (Figure 3).

4.    Using the clamped reinforcement bracket as a template, center punch the location for the two holes in the side plate of the trailer hitch assembly.

CAUTION:    Before drilling the left side holes into the side plate, check the trailer wiring harness routing to prevent damaging the harness.

5.    With the bracket still in place, use a 3/16 inch (4.76 mm) diameter drill bit to drill two (2) pilot holes in the side plate. Use the center punch marks as a guide.

NOTE:    To make drilling easier, use hardened drill bits or a 3/16 - 112 inch step drill (UNIBIT, etc.). If using a step drill, a 3/16 inch pilot hole is still required.

6.    Enlarge the two holes to 1/2 inch (12.7 mm) diameter using the pilot holes made in Step 5 as a guide.

7.    Apply a coat of zinc primer (P/N 4443636) to the bare metal inside of the new holes.

8.    Secure the reinforcement bracket to the side plate with two bolt and washer assemblies and two nut and washer assemblies. The bolt heads must be facing toward the outside of the vehicle. Tighten the nuts to 80 ft. lbs. (108 N.m).

CAUTION:    Do not apply any type of lubricant or anti-seize to the bolt threads.

9.    Remove the reinforcement bracket retaining clamp.

10.  Using the reinforcement bracket as a template, center punch the location for the frame rail-to-reinforcement bracket mounting hole (Figure 4).

11.  Using a 3/16 inch (4.76 mm) diameter drill bit, drill a pilot hole using the center punch mark as a guide.

12.  Enlarge the hole to 1/2 inch (12.7 mm) diameter using the pilot hole made in Step 11 as a guide.

13.  Apply a coat of zinc primer (P/N 4443636) to the bare metal inside of the new hole.

14.  Secure the reinforcement bracket to the frame rail with a bolt and washer assembly and nut and washer assembly. Tighten the nut and bolt to 80 ft. tbs. (108 N.m).

15.  Repeat Steps 1 through 14 on the left side of the vehicle. Photo of installed bracket

16.  Lower the vehicle from the hoist.

NOTE:    The bolt head must be against the bottom side of the reinforcement bracket.

C: Replace the Trailer Hitch Assembly (P/N CBCB8722)

NOTE:    Only those trucks that have cracked trailer hitch assemblies, as determined by the inspection in Section "A," require replacement. Very few trucks are expected to require trailer hitch assembly replacement.

1.    Support the trailer hitch with a suitable device.

2.    Remove the trailer wiring and connector from the trailer hitch.

3.    Remove and discard the six (6) original nuts that hold trailer hitch to the frame (Figure 5).

4.    With the help of an assistant, carefully remove and discard the original trailer hitch.

5.    Remove and discard the six (6) original flag bolts that are located in the frame (Figure 5).

6.    Install four (4) new flag bolts (two per side) into the frame rails as shown in Figure 6.

NOTE:    Do not install a new flag bolt in the center hole on the frame rail as there is no hole at this location on the new hitch.
NOTE:    Some hitch packages may contain standard bolts instead of flag bolts.
CAUTION:    Do not apply any type of lubricant or anti-seize to the bolt threads.

7.    With the help of an assistant, lift the new trailer hitch assembly into place and install the new retaining nuts. Tighten the nuts to 80 ft. lbs. (108 N-m).

8.    Using the new trailer hitch as a template, center punch the location for the additional frame rail-to-trailer hitch mounting hole (Figure 7).

9.    Using a 3/16 inch (4.76 mm) diameter drill bit, drill a pilot hole using the center punch mark as a guide.

NOTE:    To make drilling easier, use hardened drill bits or a 3/16 - 1/2 inch step drill (UNIBIT, etc.) If using a step drill, a 3/16 inch pilot hole is still required.
NOTE:    Remember to transfer any receiver/ball, cover, etc. to the new trailer hitch.
CAUTION:    Do not apply any type of lubricant or anti-seize to the bolt threads.

10.  Enlarge the hole to 1/2 inch (12.7 mm) diameter using the pilot hole made in Step 9 as a guide.

11.  Apply a coat of zinc primer (P/N 4443636) to the bare metal inside of the new hole.

12.  Install a flag bolt into the 1/2 inch diameter hole. Install the retaining nut onto the flag bolt and tighten the nut to 80 ft. lbs. (108 N.m).

CAUTION:    Do not apply any type of lubricant or anti-seize to the bolt threads.
NOTE: Hitch packages that contain standard bolts instead of flag bolts will require holding the bolt with a wrench to tighten the retaining nut. 13. Repeat Steps 8 through 12 on the left side of the vehicle

14.  Install the trailer wiring and connector onto the trailer hitch.

15.  Lower the vehicle from the hoist.

D: Replace the Trailer Hitch Assembly (Mopar 82205979)

NOTE: When installing a Mopar trailer hitch (82205979) on a 1998 model yea truck, do not install the center flag bolt. 1998 model year trucks will also require the installation of trailer hitch reinforcement brackets.

NOTE: Only those trucks that have cracked trailer hitch assemblies, as determined by the inspection in Section "A," require replacement. Very few trucks are expected to require trailer hitch assembly replacement.

1. Support the trailer hitch with a suitable device.

2. Remove the trailer wiring and connector from the trailer hitch.

3. Remove and discard the six (6) original nuts that hold trailer hitch to the frame (Figure 5).

4. With the help of an assistant, carefully remove and discard the original trailer hitch.

NOTE: Remember to transfer any receiver/ball, cover, etc. to the new trailer hitch.

5. Remove and discard the six (6) original flag bolts that are located in the frame rails (Figure 5).

6. On 1998 model year trucks only, install four (4) new flag bolts (two per side) into the frame rails as shown in Figure 6.

CAUTION: Do not apply any type of lubricant or anti-seize to the bolt threads.
NOTE: Some hitch packages may contain standard bolts instead of flag bolts.

7. On 1999 and 2000 model year trucks, install six (6) new flag bolts (three per side) into the frame rails.

CAUTION: Do not apply any type of lubricant or anti-seize to the bolt threads.
NOTE: Some hitch packages may contain standard bolts instead of flag bolts.

8. With the help of an assistant, lift the new trailer hitch assembly into place and install the new retaining nuts. Tighten the nuts to 80 ft. lbs. (108 N-m).

NOTE: Hitch packages that contain standard bolts instead of flag bolts will require holding the bolt with a wrench to tighten the retaining nut.

9. On 1998 model trucks only, install trailer hitch reinforcement brackets as shown in Section "B: Install Trailer Hitch Reinforcement Brackets."

CAUTION: The center mounting hole location on 1998 trucks does NOT align with the center hole location on hitch P/N 82205979. As a result, the hitch reinforcement brackets must be installed on 1998 trucks or hitch separation may occur.

10. Install the trailer wiring and connector onto the trailer hitch.

11. Lower the vehicle from the hoist.

Notes:

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

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

Parts Return:    Not Required

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

This page was edited on: May 3, 2004