NUMBER: GROUP: 02-04-00 Rev. A Suspension DATE: May 12, 2000 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without written permission of DaimlerChrysler Corporation. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-04-00, DATED MAR. 17, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CORRECTION TO A PART NUMBER. SUBJECT: Squeaking/Clicking Noise From Rear Leaf Springs OVERVIEW: This bulletin involves replacing the spring tip liners and installing spring clinch clip isolators. MODELS: 1994-2000 (AB) Ram Van/Wagon 1994-2001 (BR/BE) Ram Truck SYMPTOM/CONDITION: Squeaking/clicking noise coming from the rear of the vehicle. DIAGNOSIS: If the customer indicates that the vehicle has a squeaking/clicking noise coming from the rear of the vehicle, verify that the noise is coming from the rear springs as the vehicle s suspension goes through jounce and rebound. If a squeaking/clicking noise is coming from the rear springs, perform the Repair Procedure. NOTE: NOTE: PERFORM THE REPAIR PROCEDURE ON ANY VEHICLE THAT HAS MISSING TIP LINERS OR MISSING CLINCH CLIP ISOLATORS AND A SQUEAKING/CLICKING NOISE IS COMING FROM THE REAR SPRINGS. RAM TRUCKS WERE NOT ORIGINALLY EQUIPPED WITH SPRING CLINCH CLIP ISOLATORS. PARTS REQUIRED: 8 52113142AA Isolators, Spring Clinch Clip AR (8) 52113136AA Liner, Spring Tip, 2.5 in. Diameter (1500 Series Ram Truck And Ram Vans With Spring P/N 52106156AD) AR (12) 52113137AA Liner, Spring Tip, 3.0 in. Diameter (2500/3500 Series Ram Truck) AR (12) 52113135AA Liner, Spring Tip, 2.5 in. Diameter, (All Ram Van/Wagon Except Vehicles Equipped With Spring P/N 52106156AD) AR (1) 05018626AA Lubricant Form TSB-003 Rev. 1.08 February 3, 2000
02-04-00 Rev. A -2- EQUIPMENT REQUIRED: Large C-Clamp (5-6 in.) Large Pry Bar Large Adjustable Pliers REPAIR PROCEDURE: 1. Raise the vehicle on an appropriate frame support style lift (rear axle must be allowed to extend fully) 2. On Ram Vans, remove both rear tire/wheel assemblies. 3. Position a large C-Clamp adjacent to the spring clinch clip and clamp the leaves of the spring together 4. Use an appropriate pry bar to bend open the rear spring clinch clip (Figure 1). If necessary, remove the existing spring clinch clip isolators. 1 - REAR LEAF SPRING CINCH CLIP 2 - PRY BAR 3 - C-CLAMP FIGURE 1 5. Use the pry bar to spread apart the leaf (Figure 2). The clearance between the leaves should be enough to remove the old liner (if necessary) and install the replacement liner. 6. If necessary, remove the old spring tip liner (Figure 3). 7. With the prybar still inserted between the leaves, install a new spring tip liner (see Parts Required section) onto the leaf.
-3-02-04-00 Rev. A 1 - REAR LEAF SPRING 2 - PRY BAR FIGURE 2 1 - SPRING TIP LINER FIGURE 3 8. Firmly seat the spring tip liner onto the leaf. A C-Clamp can be used to compress the adjacent leaves together (Figure 4) which will seat the liner retaining pin into the hole.
02-04-00 Rev. A -4- NOTE: THE SPRING TIP LINER IS PROPERLY INSTALLED WHEN THE RETAINING PIN IS POINTING TOWARD THE PAVEMENT AND THE WEAR PAD IS CONTACTING THE LEAF SPRING. FIGURE 4 9. Apply a small amount of lubricant p/n 05018626AA onto the tip liner wear pad. 10. Repeat Steps 5 through 9 to remove and install all rear spring tip liners. 11. Place one spring clinch clip isolator p/n **52113142AA** onto the outboard side of the spring clinch clip (Figure 5) and one isolator on the inboard side of the spring clinch clip. 1 - SPRING CINCH CLIP ISOLATOR 2 - C-CLAMP FIGURE 5
-5-02-04-00 Rev. A 12. Using large adjustable pliers, close the spring clinch clip until the isolator contacts the leaf spring (Figure 6). CAUTION: DO NOT USE A HAMMER TO CLOSE THE SPRING CLINCH CLIP. DAMAGE TO THE ISOLATOR MAY RESULT. 1 - SPRING CINCH CLIP 2 - ADJUSTABLE PLIERS 3 - C-CLAMP FIGURE 6 13. Use an appropriate pry bar to bend open the front spring clinch clip. If necessary, remove the existing spring clinch clip isolators. 14. Perform Steps 5 through 12 to the front portion of the rear leaf spring assembly. 15. Perform Steps 4 through 14 to the other side of the vehicle. 16. On Ram Van/Wagons, install the tire wheel assemblies. 17. Lower the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 02-30-02-96 Liner, Spring Tip/Isolator, Clinch Clip - Install Both Sides - 1500 models (AB) Ram Van...0.6 Hrs. (BR/BE) Ram Truck...0.4 Hrs.
02-04-00 Rev. A -6-02-30-02-97 Liner, Spring Tip/Isolator, Clinch Clip - Install Both Sides - 2500 models (AB) Ram Van...0.7 Hrs. (BR/BE) Ram Truck...0.6 Hrs. 02-30-02-98 Liner, Spring Tip/Isolator, Clinch Clip - Install Both Sides - 3500 models (AB) Ram Van...0.7 Hrs. (BR/BE) Ram Truck...0.8 Hrs. FAILURE CODE: P8 - New Part