Safety Recall #B04

Power Distribution Center Cable Connections

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Date: May 2001

Models: 2001 (BR/BE) Dodge Ram Truck

NOTE: This recall applies only to the above vehicles built through August 28, 2000 (MDH 082800)

IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System.

Subject:

The Power Distribution Center (PDC) generator cable connection on about 268,000 of the above vehicles may loosen. A loose generator cable connection can cause an underhood fire.

Repair:

The generator and battery cable terminals in the PDC must be inspected and repositioned if necessary. If electrical arcing at the generator cable connection has occurred, the PDC stud, nut and buss bar may need to be replaced.

Parts Information:

Power Distribution Center Repair Package

Part Number     Description
CBSIB040       Power Distribution Center Repair Package

Each package contains the following

Each dealer to whom vehicles in the recall were invoiced will receive ONE (1) Power Distribution Center Repair Package. Additional Power Distribution Center Repair packages may be ordered as required. Very few vehicles are expected to require Power Distribution Center stud replacement.

Service Procedure:

A. Power Distribution Center Inspection

1.    Open the hood.

2.    With the ignition key in the "OFF" position, disconnect the negative battery cable(s).

CAUTION: Vehicles equipped with a diesel engine have two batteries. The negative battery terminal on both batteries must be disconnected.

NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure.

3.    Remove the cover from the Power Distribution Center (PDC). The PDC is located on the left (driver's) side of the engine compartment, next to the battery (Figure 1).

4.    Inspect the black generator cable connection and the surrounding area on the Power Distribution Center for signs of previous electrical arcing (Figure 2).

> If there are no signs of a previous electrical arcing condition at the Power Distribution Center generator connection, continue with Step 5 of this procedure.

> If there are signs of a previous electrical arcing condition at the Power Distribution Center generator connection and the buss bar, stud and/or nut require replacement, continue with Section "B - Power Distribution Center Stud Repair." Very few vehicles are expected to require Power Distribution Center stud repair.

5.    Inspect the black generator cable and red battery cable (B+) terminals. They both must be oriented so that the cable crimp openings are facing upward, away from the PDC housing (Figure 3). If either (or both) of the terminals are installed with the crimp opening facing downward, remove the retaining nut, lift the terminal off of the stud and reinstall the cable terminal(s) onto the stud with the crimp facing up as shown in Figure 3.

6.    Install the cable terminal retaining nut(s). Tighten the nut(s) to 80 in. lbs. (9 N-m).

7.    If the generator and battery cable terminals are oriented correctly, verify that both retaining nuts are tight. Tighten both retaining nuts to 80 in. lbs. (9 N-m).

8.    Install the PDC cover onto the PDC housing.

9.    Connect the negative battery cable(s).

> On trucks equipped with a gas engine, tighten battery clamp nut to 35 in. lbs. (4 N-m).

> On trucks equipped with a diesel engine, tighten the battery clamp nuts to 80 in. lbs. (9 N-m).

10.  Close the hood.

11.  Return the vehicle to the customer, no further action is required.

B. Power Distribution Center Stud Repair

NOTE: The following procedure is required if the PDC buss bar, stud and/or nut for the generator cable require replacement per the inspection in Section "A." Very few vehicles are expected to require this repair.

1.    Remove the black generator cable retaining nut.

2.    Lift the black generator cable terminal up off of the stud.

3.    Remove the two fuse retaining screws. Save the screws for use during installation.

4.    Remove the fuse (Figure 3). Save the fuse for reinstallation.

5.    Carefully pry the buss bar from the PDC housing. Discard the old buss bar.

6.    Slide the generator cable stud out of the PDC housing and discard stud (Figure 4).

7.    Slide the new generator cable stud into the PDC housing.

8.    Snap the new bus bar into place.

9.    Position the fuse across the battery bus bar and the generator bus bar and install the retaining screws. Tighten the fuse retaining screws to 30 in. tbs. (3.5 NM). Place the generator cable terminal over the stud and install the retaining nut (Figure 3).

10.  Tighten the generator cable terminal nut to 80 in. lbs. (9 NM).

11.  Tighten the generator cable terminal nut to 80 in. lbs. (9 NM).

12.  Verify that the red battery cable (B+) terminal crimp opening is facing upward (Figure 3). Remove the retaining nut and reposition the cable terminal if required. Verify that the retaining nut is tight by torquing the retaining nut to 80 in. lbs. (9 NM).

13.  Install the PDC cover onto the PDC housing.

14.  Connect the negative battery cable(s).

> On trucks equipped with a gas engine, tighten battery clamp nut to 35 in. lbs. (4 NM).

> On trucks equipped with a diesel engine, tighten the battery clamp nuts to 80 in. lbs. (9 NM).

15.  Close the hood.

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 number and time allowance:

Add the cost of the part 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.

Owner Notification and Service Scheduling

All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers.

Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.

Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair.

This page was edited on: May 3, 2004