Customer Satisfaction Notice #B28

Tighten Diesel Engine Cooling Fan

Visit Geno's Garage for Truck accessories.

Date: October 2002

Models: 2003 (DR) Dodge Ram 2500/3500 Trucks

NOTE: This recall applies only to the above vehicles equipped with a 5.9L Cummins Turbo Diesel engine ("6" or "C" in the 8th VIN Position) built at the Saltillo Assembly Plant ("G" in the 11th VIN Position) through September 10, 2002 (MDH 091016).

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

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

Subject:

The engine cooling fan assembly on about 13,000 of the above trucks may loosen and separate from the pulley. This may cause the engine to overheat.

Repair:

The engine cooling fan assembly must be tightened to the proper specification.

Parts Information:

No parts are required to perform this service procedure.

Service Procedure:

1. Open the hood.

2.  Obtain a 36 mm fan clutch wrench that is approximately 14" long and that has a square ½" drive hole to attach a torque wrench (OTC P/N 7204E2, Snap-on P/N YA9325-1, K-D P/N 3136-76 or MAC P/N FCW3260A). If one of the listed fan clutch wrenches is not readily available, modify the fan clutch wrench from the Cummins Diesel Essential Tool Kit (P/N SP346) as follows:

a. Remove the red plastic handle cover. b. Mark and center punch a point on the handle that is 12" (300 mm) c. Using a 7/16" drill bit, drill a hole at the marked location. d. Install a 10-mm bolt and nut combination (PN 06506019AA and PN 06502696 or equivalents) in the handle hole (Figure 1). Tighten the bolt and nut to 75 ft-lbs (102 N·m).

3. Using the fan clutch wrench, rotate the radiator cooling fan until the tool
handle is approximately vertical.

4. Connect a "clicker" torque wrench to the fan clutch wrench so that the torque wrench and the fan clutch wrench are in a straight line. Set the torque wrench to 42 ft-lbs (57 N·m). (This will achieve 85 ft-lbs at the cooling fan nut.)

IMPORTANT: The torque wrench and the fan clutch wrench MUST be in a straight line to achieve the proper torque measurement.

NOTE: If using the modified special tool SP346, attach the torque wrench to the bolt that was installed in the handle, with a socket.

5. Place a large screwdriver or small pry bar across two of the pulley bolts as shown in Figure 2.

6. While holding the pulley in place with the screwdriver, tighten the cooling fan nut with the torque wrench/fan clutch wrench set to 42 ft-lbs (57 N·m) (Figure 3). This will achieve 85 ft-lbs at the cooling fan nut.

NOTE: Turn the nut clockwise, as viewed from the front of the vehicle to tighten.

CAUTION: The pulley must be held in place. Belt friction alone will not allow the nut to be tightened sufficiently.

7. Remove the torque wrench/fan clutch wrench assembly and the screwdriver.

8. 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 Customer Satisfaction Notification service completions and provide dealer payments.

Use the following labor operation number and time allowance:

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

Parts Return

Not Applicable

This page was edited on: May 3, 2004