Safety Recall #B20

Axle Flange Reinforcements

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Date: December 2002

Models: 2002 (DR) Dodge Ram Pick-Up Truck (4WD models only)

NOTE: This recall applies only to the above four wheel drive vehicles built at the:

• Warren Truck Assembly Plant (“S” in the 11th VIN Position) from July 22, 2001 through November 29, 2001 (MDH 072200 through 112910).
• Louis North Assembly Plant (“J” in the 11th VIN Position) from July 22, 2001 through November 29, 2001 (MDH 072200 through 112920).
• Saltillo Assembly Plant ("G" in the 11th VIN position) July 22, 2001 through November 30, 2001(MDH 072200 through 113023).

IMPORTANT: Many 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 rear axle flange welds on about 40,000 of the above trucks may fatigue and allow the brake caliper to rotate. This may cause a rear brake tube to leak, resulting in a partial brake system loss and increased stopping distance. The increased stopping distance can cause an accident without warning.

Repair:

An axle flange reinforcement bracket must be installed on the right and left side of the rear axle.

Parts:

Each package contains the following components:

Each dealer to whom vehicles in the recall were invoiced will receive enough Axle Flange Reinforcement Bracket Packages to service about 10% of those vehicles.

Service Procedure:

1.    Raise the vehicle on an appropriate hoist.

2.    Using Mopar Brake Clean (P/N 04897150AB) or equivalent and a shop towel, remove all dirt, mud and/or rustproofing from the axle tube between the axle flange and the axle U-bolts (Figure 1).

CAUTION: The axle tube area where the reinforcement bracket mounts must be clean before installation. Failure to clean the axle tube may cause reinforcement bracket misalignment.

3.    Remove and discard the two original brake caliper adapter-to-caliper mounting bracket bolts on the left caliper (Figure 2).

4.    Place the axle flange reinforcement bracket body into position and install the two new brake caliper adapter-to-caliper mounting bracket bolts provided in the package (Figure 3). Only tighten the bolts to 75 in. lbs. (9 N·m) at this time.

NOTE: All of the bolts provided in the repair package are interchangeable.

5.    Place the axle flange reinforcement bracket cap into position (Figure 4). Install the two retaining bolts provided and tighten the bolts evenly to 60 ft. lbs. (81 N·m) (Figure 4). Then tighten the bolts to 120 ft. lbs. (162 N·m). Tighten the bolts a second time to 120 ft. lbs. (162 N·m).

CAUTION: The axle flange reinforcement cap retaining bolts must be tightened evenly to maintain equal clamping (gaps) between the axle flange reinforcement body and reinforcement cap.

6.    Tighten the brake caliper adapter-to-caliper mounting bracket bolts to 100 ft. lbs. (135 N·m) (Figure 3).

7.    Repeat steps 2 through 6 on the right rear brake caliper.

8.    Lower the vehicle from the hoist.

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 the following labor operation number and time allowance:

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 applicable.

Dealer Notification and Vehicle List:

All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.

DIAL System Functions 53 and VIP:

All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed.

Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type “53” at the “ENTER FUNCTION” prompt, then type “ORDB20”.

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.

This page was edited on: May 3, 2004