Safety Recall No. C35

Headlamp and Dash Wiring Harness

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Date: October 2003

Models: 2001-2003 (AN) Dodge Dakota

NOTE: This recall applies only to the above vehicles equipped with a manual transmission (Sales Code DDK or DDC).

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 VIP inquiry process.

Subject:

The headlamp and dash wiring harness on about 49,000 of the above vehicles may be chafed by the actuation of the clutch pedal. This could result in abnormal operation of the wipers, horn, turn signals and/or lighting systems.

Repair:

The headlamp and dash wiring harness must be rerouted. Any harness wires that are chafed must be repaired as necessary.

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:

No parts are required to perform this service procedure.

Service Procedure:

1.    Disconnect the negative battery cable.

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

2.    Using a 10mm socket, back out the bolt that attaches the 74-way headlamp and dash connector to the instrument panel (I/P) harness connector (Figure 1).

Figure 1

3.    Disconnect the 74-way headlamp and dash-to-I/P harness connector.

4.    Temporarily move the white I/P harness connector out of the way by placing it up over the hood release cable.

5.    Press the release tab on the black 74-way connector surround sleeve and then pull the gray connector and sleeve assembly off of its steel mounting bracket.

6.    Inspect the headlamp and dash wiring harness take-out that is routed near the clutch pedal for evidence of chafing from contact with the pedal assembly (Figure 1). Wrap any wires that have exposed copper wire strands with high quality electrical tape.

7.    Re-route the headlamp and dash wiring harness take-out by moving it under the gray 74-way connector and black surround sleeve assembly and then positioning it to the LEFT side of the connector (move harness from inboard to outboard side of connector/bracket).

8.    Install the gray 74-way connector and black surround sleeve assembly back on to its mounting bracket. A “Click” will be heard when it is locked into position.

9.    Connect the white 74-way I/P harness connector to the gray 74-way connector and black surround sleeve assembly.

10. Tighten the 74-way connector bolt to 31 in-lbs (3.5 N•m).

11. Actuate the clutch pedal and inspect the harness routing to ensure that the headlamp and dash harness take-out is positioned away from the clutch pedal and linkage. Also ensure that the harness does not interfere with or touch any part of the park brake assembly.

12. Connect the negative battery cable.

Completion Reporting and Reimbursement

Claims for vehicles that have been serviced must be submitted on the DIAL System or on the DealerCONNECT claim entry screen located on the Service tab. 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 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 applicable.

Owner Notification and Service Scheduling

All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT and the MDS2 will be updated to include this recall in the near future.

Vehicle Lists, Global Recall System, VIP and Dealer Follow up

All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter.

GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner’s name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission.

To use this system, click on the “Service” tab and then click on “Global Recall System.” Your dealer’s VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence.

Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair.

Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use.

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