Dealer Service Instructions for: Safety Recall R16 / NHTSA 13V-527 Steering Linkage May 2015 NOTE: Safety Recall N63 is being cancelled. All vehicles involved in Safety Recall N63 must have this recall performed. Models 2008 2010 (DM) RAM Truck (4500/5500 Cab Chassis) 2011 2012 (DP) RAM Truck (4500/5500 Cab Chassis) NOTE: This recall applies only to the above vehicles built from February 20, 2007 through December 22, 2012 (MDH 022009 through 122210). 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 left tie rod ball stud on about 35,900 of the above vehicles may fracture under certain driving conditions. This could cause a loss of directional control and/or a crash without warning. Repair The steering linkage must be replaced. Copyright 2015, FCA US LLC, All Rights Reserved (wah)
Safety Recall R16 Steering Linkage Page 2 Parts Information Part Number CBEMN631AA Description Linkage, Steering Each dealer to whom vehicles in the recall were assigned will receive enough Steering Linkage Packages to service about 20% of those vehicles. Parts Return No parts return required for this campaign. Special Tools The following special tool is required to perform this repair: 8677 Separator, Tie Rod
Safety Recall R16 Steering Linkage Page 3 Service Procedure 1. Lift the vehicle on an appropriate hoist. 2. Remove and save the steering damper nut and bolt at the steering linkage bracket (Figure 1). 3. Remove and save the drag link castle nut at the right tie rod end (Figure 1). 4. Using special tool 8677 or equivalent, separate the drag link from the right tie rod end. CAUTION: Do not allow the drag link to free-fall from the right tie rod end once disconnected. Damage to the rod end at the pitman arm may result. 5. Remove and save the right side tie rod-to-knuckle arm castle nut (Figure 1). 6. Using special tool 8677 or equivalent, separate the right tie rod end from the right knuckle arm. RIGHT TIE ROD END CASTLE NUT DRAG LINK STEERING LINKAGE RIGHT TIE ROD END DRAG LINK CASTLE NUT STEERING DAMPER NUT STEERING LINKAGE BRACKET FRONT AXLE TUBE STEERING DAMPER Figure 1 Original Steering Linkage
Safety Recall R16 Steering Linkage Page 4 Service Procedure (Continued) 7. Remove and save the left tie rod-to-knuckle arm castle nut. 8. Using special tool 8677 or equivalent, separate the left tie rod end from the left knuckle arm. 9. Remove and discard the steering linkage assembly. 10. Using brake clean or equivalent, clean the tapered holes in the steering knuckles of all grease and dirt (Figure 2). 11. Place the new steering linkage into position. CAUTION: Use care not to damage the rubber boots during installation. 12. Install the left and right tie rod castle nuts hand tight. 13. Install the original drag link to the right tie rod end and hand tighten the castle nut. CLEAN TAPERED HOLE IN STEERING KNUCKLE ARM NEW STEERING LINKAGE STEERING KNUCKLE Figure 2 Clean Tapered Holes in Steering Knuckle Arms (right side shown)
Safety Recall R16 Steering Linkage Page 5 Service Procedure (Continued) 14. Place the steering damper end into the steering linkage bracket and install the retaining nut and bolt hand tight (Figure 3). 15. Tighten the left tie rod end castle nut to 75 ft. lbs. (101 N m). 16. Install a cotter pin through the left tie rod end castle nut. CAUTION: If the castle nut slot does not align with the cotter pin hole in the steering linkage stud, continue tightening the castle nut until the next slot aligns with the cotter pin hole in the steering linkage stud. Never loosen the nut to align the slot in the nut with the cotter pin hole in the steering linkage stud. TIGHTEN THE RIGHT TIE ROD END CASTLE NUT TO 75 FT. LBS. (101 N M) DRAG LINK TIGHTEN THE DRAG LINK-TO-TIE ROD CASTLE NUT TO 100 FT. LBS. (140 N M) RIGHT SIDE TIE ROD END TIGHTEN THE STEERING DAMPER NUT AND BOLT TO 86 FT. LBS. (117 N M) TIGHTEN THE TIE ROD END ADJUSTER CLAMP BOLTS TO 44 FT. LBS. (60 N M) Figure 3 New Steering Linkage Fastener Torque Specifications
Safety Recall R16 Steering Linkage Page 6 Service Procedure (Continued) 17. Tighten the right tie rod end castle nut to 75 ft. lbs. (101 N m) (Figure 3). 18. Install a cotter pin through the right tie rod end castle. CAUTION: If the castle nut slot does not align with the cotter pin hole in the steering linkage stud, continue tightening the castle nut until the next slot aligns with the cotter pin hole in the steering linkage stud. Never loosen the nut to align the slot in the nut with the cotter pin hole in the steering linkage stud. 19. Tighten the drag link-to-tie rod castle nut to 100 ft. lbs. (140 N m) (Figure 3). 20. Install a cotter pin through the drag link-to-tie rod castle nut. CAUTION: If the castle nut slot does not align with the cotter pin hole in the drag link stud, continue tightening the castle nut until the next slot aligns with the cotter pin hole in the drag link stud. Never loosen the nut to align the slot in the nut with the cotter pin hole in the drag link stud. 21. Tighten the steering damper nut and bolt to 86 ft. lbs. (117 N m) (Figure 3). 22. Using a grease gun, grease both outer tie rod ends and the drag link ends. 23. Lower the vehicle from the hoist. 24. Place the vehicle on an alignment rack. Set the toe and center the steering wheel following the wheel alignment machine manufacturer s instructions. NOTE: Toe should be set to +0.20º total toe on all models. 25. After toe is set, tighten the tie rod end adjuster clamp bolts to 44 ft. lbs. (60 N m). 26. Align the drag link ends so they are square with the right tie rod end boss and pitman arm boss and then tighten the adjuster clamp bolts to 44 ft. lbs. (60 N m). 27. Remove the vehicle from the alignment rack and return it to the customer.
Safety Recall R16 Steering Linkage Page 7 Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by FCA to record recall service completions and provide dealer payments. Use the following labor operation number and time allowance: Labor Operation Number Time Allowance Replace steering linkage (includes setting toe) 19-R1-61-82 1.0 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. Dealer Notification To view this notification on DealerCONNECT, select Global Recall System on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to FCA are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is attached. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable.
Safety Recall R16 Steering Linkage Page 8 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. 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. 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 FCA US LLC
STEERING LINKAGE IMPORTANT SAFETY RECALL R16 / NHTSA 13V-527 This notice applies to your vehicle (VIN: xxxxxxxxxxxxxxxxx). This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Dear: (Name) FCA has decided that a defect, which relates to motor vehicle safety, exists in certain 2008 through 2012 model year RAM 4500/5500 Cab Chassis trucks. This is a follow up to an earlier communication. FCA urges you to schedule your service appointment to have the recall remedy completed. The problem is... What your dealer will do... The left tie rod ball stud on your truck may fracture under certain driving conditions. This could cause a loss of directional control and/or a crash without warning. In an effort to remedy this condition and to satisfy our requirements under a Consent Order with the National Highway Traffic Safety Administration, FCA US offers you one of the following options: 1. FCA US will repair your vehicle free of charge (parts and labor). To do this, your dealer will inspect the steering linkage on your truck and replace steering linkage if required. The inspection will take less than ½ hour. If linkage replacement is required, the work will take an additional 1 hour to complete. However, additional time may be necessary depending on service schedules. For your inconvenience, we will provide you with a $100 unrestricted gift card. This option is available now. 2. FCA US will repurchase your vehicle per the terms of the Consent Order. We are currently developing a repurchase process that will determine the fair market value of your vehicle based on mileage and condition. If you elect this option, you will be entitled to the fair market value (less any modifications) plus 10%. Please visit www.fcarecall.com for information on calculating a preliminary estimate of the fair market value of your vehicle. We expect this calculator to be available by September 1, 2015. You may contact your local dealer on or after October 1, 2015 to arrange for a final appraisal of your vehicle. This option will be available beginning October 1, 2015. 3. Through January 4, 2016, you can trade in your vehicle for a new Chrysler / Dodge/ Jeep / Fiat or Ram vehicle and receive an additional incentive offer of $2,000 towards the purchase of a new Ram Truck or $1,000 towards the purchase of a new Dodge / Jeep / Chrysler or Fiat vehicle. This offer will be in addition to all other incentives available at the time of purchase. This option is available now through January 4, 2016. What you must do to ensure your safety... If you need help... Simply contact your Chrysler, Jeep, Dodge or Ram dealer immediately to schedule a service or sales appointment for Options 1 or 3 above. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. For Option 2, please contact your Chrysler, Jeep or Dodge dealer on or after October 1, 2015 to arrange for a final appraisal of your specific vehicle. Please bring this letter with you to your dealer. If you have questions or concerns which your dealer is unable to resolve, please contact the FCA Group Recall Assistance Center at either recalls.mopar.com or 1-800-853-1403.
Please help us update our records by filling out the attached prepaid postcard if any of the conditions listed on the card apply to you or your vehicle. If you have further questions go to recalls.mopar.com. If you have already experienced this specific condition and have paid to have it repaired, you may visit www.fcarecallreimbursement.com to submit your reimbursement request online or you can mail your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-8004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement. Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. If you ve had previous repairs and/or reimbursement you may still need to have the recall repair performed on your vehicle. 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, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to safercar.gov. We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thank you for your attention to this important matter. Customer Services / Field Operations FCA US LLC Note to lessors receiving this recall: Federal regulation requires that you forward this recall notice to the lessee within 10 days.