April 2003 Dealer Service Instructions for: Safety Recall No. C11 Blower Motor Wiring Models 2002 (DR) Dodge Ram 1500 Pick-up Trucks 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 DealerCONNECT VIP inquiry process. Subject The blower motor wiring on about 285,000 of the above vehicles contains an undersized terminal. Localized heating from operating the blower motor on high speed may cause the terminal to relax and lose electrical contact. This could cause the blower motor to become inoperative. An inoperative blower motor will not defrost the windshield, which could obstruct the driver s vision and result in an accident. Repair A blower motor wiring overlay harness must be installed. Parts Information Part Number CBT1C110 Description Blower Motor Wiring Harness Each dealer to whom vehicles in the recall were invoiced will receive enough Wiring Harness Packages to service about 5% of those vehicles. Copyright 2003, DaimlerChrysler Corporation, All Rights Reserved
Safety Recall No. C11 -- Blower Motor Wiring Page 2 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. Remove the two (2) knee blocker screws and then remove the knee blocker. 3. Move the steering column to the lowest position and then remove the steering column tilt lever. 4. Remove the upper and lower steering column shrouds. 5. Disconnect the instrument panel (I/P) wiring harness 74-way connector (Figure 1). 6. Release the RED CPA, lift the WHITE lock bar on the top of the 14-way ignition switch connector and then disconnect the connector (Figure 2). 7. Release the four (4) BLUE wedge clips from the back (wire) side of the ignition switch connector and then remove the wedge completely using pliers (Figure 2). 8. Remove the PINK with BLACK tracer wire from the ignition switch connector (Figure 2). Figure 1 74-WAY CONNECTOR Figure 2
Safety Recall No. C11 -- Blower Motor Wiring Page 3 Service Procedure (Continued) 9. Install the PINK with BLACK tracer wire from the overlay harness into the connector cavity (Figure 2). 10. Remove the GREEN wire from the ignition switch connector (Figure 2). 11. Install the GREEN wire from the overlay harness into the connector cavity (Figure 2). 12. Install the BLUE wedge back into the ignition switch connector (Figure 2). NOTE: After initially installing the wedge, push in on the four wedge clips to allow the wedge to be fully seated. 13. Cut off the PINK with BLACK tracer wire and GREEN wire that were removed from the connector as close to the harness wrap as possible. 14. Connect the 14-way ignition switch connector. Ensure that the white lock bar and red CPA are fully engaged. 15. Route the overlay harness along the I/P harness to the 74-way connector. 16. Remove the WHITE cover from the wire side of the 74-way connector. 74-WAY CONNECTOR (WIRE COVER REMOVED) 17. Pull the YELLOW wedge out from the side of the 74-way connector about 1/16 (Figure 3). 18. Remove the PINK with BLACK tracer wire from the 74-way connector (Figure 3). 19. Insert the PINK with BLACK tracer wire from the overlay harness into to 74-way connector cavity. Figure 3 20. Install the YELLOW wedge back into the 74-way connector (Figure 3).
Safety Recall No. C11 -- Blower Motor Wiring Page 4 Service Procedure (Continued) 21. Cut off the PINK with BLACK tracer wire that was removed from the connector as close to the harness wrap as possible. 22. Install the WHITE cover on the wire side of the 74-way connector. 23. Remove the lower bezel at the bottom of the center I/P stack. 24. Route the GREEN overlay harness wire behind the Airbag Control Module (ACM) to the blower motor connector. Tuck the wire behind the carpeting or vinyl floor covering. 25. Disconnect the 2-way blower motor connector located near the right kick panel (Figure 4). 26. Remove the BLUE wedge from the blower motor connector. 27. Remove the GREEN wire from the blower motor connector (Figure 4). 28. Install the GREEN overlay harness wire into the blower motor connector cavity. 29. Install the BLUE wedge back into the blower motor connector. Figure 4 30. Cut off the GREEN wire that was removed from the connector as close to the harness wrap as possible. 31. Connect the 2-way blower motor connector (Figure 4). 32. Tuck any excess wire from the overlay harness behind the carpeting or vinyl floor covering. 33. Install the center lower I/P stack cover. 34. Connect the 74-way I/P harness connector (Figure 1).
Safety Recall No. C11 -- Blower Motor Wiring Page 5 Service Procedure (Continued) 35. Tie strap the overlay harness to the I/P harness near the steering column. 36. Install the upper and lower steering column shrouds. 37. Install the steering column tilt lever handle. 38. Install the knee blocker. Tighten the screws securely. 39. Connect the negative battery cable. 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: Labor Operation Time Number Allowance Install blower motor wiring overlay harness 08-C1-11-82 0.6 hours 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.
Safety Recall No. C11 -- Blower Motor Wiring Page 6 Dealer Notification 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.
Safety Recall No. C11 -- Blower Motor Wiring Page 7 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. A copy of the owner letter is attached. 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. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation
SAFETY RECALL TO INSTALL A BLOWER MOTOR WIRING HARNESS Dear Dodge Ram 1500 Truck Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has determined that a defect, which relates to motor vehicle safety, exists in some 2002 model year Dodge Ram 1500 Pick-up Trucks. The problem is... The blower motor wiring on your Ram Truck (identified on the enclosed form) contains an undersized terminal. Localized heating from operating the blower on high speed may cause the terminal to relax and lose electrical contact. This can cause the blower motor to become inoperative. An inoperative blower motor will not defrost the windshield, which could obstruct the driver s vision and result in an accident. What DaimlerChrysler and your dealer will do... What you must do to ensure your safety... If you need help... DaimlerChrysler will repair your truck free of charge (parts and labor). To do this, your dealer will install a new blower motor wiring harness. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the part for your vehicle or to order it before your appointment. Bring the enclosed form with you to your dealer. It identifies the required service to the dealer. If you have questions or concerns which the dealer is unable to resolve, please contact the DaimlerChrysler Customer Assistance Center at 1-800-853-1403. A representative will assist you. If you have already experienced the problem described above and have paid to have it repaired, you may send your original receipts and/or other adequate proof of payment to the following address for reimbursement: DaimlerChrysler Customer Assistance Center, P.O. Box 1040, St. Charles, MO 63302-1040, Attention: Reimbursement. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590, or call the toll-free Auto Safety Hotline at 1-888-327-4236. We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thank you for your attention to this important matter. Buckle up f Customer Services Field Operations DaimlerChrysler Corporation C11