Safety Recall #C21

Aluminum Wheels

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Date: June 2003

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

NOTE: This recall applies only to the above trucks equipped with aluminum wheels (Sales Code WD3) built at the Saltillo Assembly Plant (“G” in the 11th VIN Position) from March 24, 2003 through April 7, 2003 (MDH 0324XX through 040717).

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 VIP inquiry process.

Subject:

The aluminum wheels on about 1,000 of the above trucks may have excessive porosity in the center hub area which can cause a wheel to crack. This could cause a loss of vehicle control and result in an accident without warning.

Repair:

The aluminum wheel build codes must be inspected. Wheels that were cast in the affected mold during the suspect period must be replaced.

Alternate Transportation:

Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that wheel replacement(s) is required and the vehicle must be held overnight.

Parts Information:

Due to the small number of involved vehicles expected to require wheel replacement, no parts will be distributed initially. Wheel assemblies should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require wheel replacement.

Service Procedure:

A. Inspect Wheel Build Codes

1.    Raise the vehicle on an appropriate hoist.

2.    Rotate the left front wheel until the valve stem is in the 12 o’clock position.

3.    Looking at the back side of the wheel, locate the mold cavity identification code on the inside of the lower front wheel spoke (Figure 1).

• If the mold cavity code is a number “1”, continue with Step 4.

• If the mold cavity code is any number other than a “1”, the wheel does NOT require replacement. Continue with Step 6.

Figure 1 – Back Side of Wheel Shown

4.    Remove the wheel and tire assembly from the vehicle.

5.    Locate the date codes on the inside of the wheel spokes (Figure 1). With the valve stem at the 12 o’clock position, the MONTH and YEAR are located on the lower right spoke near the mold cavity identification mark. The DAY is located on the lower left spoke near the Pentastar.

• If the combined casting date is “3/17/03” through “4/4/03”, the wheel MUST BE REPLACED. Note the wheel location (i.e. “Left Front”) on the repair order and then continue with Step 6.

• If the combined casting date is BEFORE “3/17/03” or AFTER “4/4/03”, the wheel does NOT require replacement. Install the wheel and tire assembly on the vehicle. Tighten the lug nuts to 135 ft-lbs (183 N·m) and then continue with Step 6.

  IMPORTANT: If the “DAY” code can not be read and the MONTH/YEAR code is 3/03 or 4/03, the affected wheel MUST be replaced OR if the MONTH/YEAR code can not be read and the wheel is from MOLD #1, the affected wheel MUST be replaced.

6.    Repeat Steps 2 through 5 until all four wheels have been inspected.

7.    If ANY wheel requires replacement, continue with Section B.– Replace Wheel Assembly(s).

NOTE: If the replacement wheel assembly is not currently available, temporarily install a spare tire on the vehicle.

If NO wheels require replacement, no further action is necessary. Lower the vehicle and return it to the customer.

B. Replace Wheel Assembly(s)

NOTE: Only wheels that were cast in Mold #1 from March 17, 2003 through April 4, 2003, as determined by the inspection in Section A, require replacement. Very few vehicles are expected to require wheel replacement.

1.    Raise the vehicle to working level on an appropriate hoist (if necessary).

2.    Remove the wheel and tire assemblies that require wheel replacement (if necessary).

3.    Using an appropriate tire machine, remove the tire from all affected wheels.

NOTE: Be sure to follow the tire machine manufacturer’s instructions.

4.    Damage the wheel or using a ¼” drill bit, drill a hole in the air section of the affected wheel(s) to insure that a new tire can not be mounted on the wheel(s). Discard the old wheel(s).

5.    Install a new valve stem (P/N 52057949AB) into the new wheel(s).

6.    Using an appropriate tire and balancing machine, mount and balance the original tire(s) on the new wheel(s) and then inflate the tire to the recommended tire inflation pressure specified in the table below (Figure 2).

Figure 2 – Tire Inflation Pressures for 17x8 Wheels

NOTE: Be sure to follow the tire machine and tire balancer manufacturer’s instructions.

7.    Install the wheel and tire assembly(s) on the vehicle. Tighten the lug nuts to 135 ft-lbs (183 N·m).

8.    Lower the vehicle and return it to the customer.

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 wheel(s), if necessary, 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. However, all removed wheels MUST be damaged or have a hole drilled in the air section to insure that the old wheels do not get installed on any other vehicle.

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