CHRYSLER NHTSA 13V-252 Rear Structural Reinforcement User Manual

CHRYSLER NHTSA 13V-252 Rear Structural Reinforcement

NOTE: The service procedure for this recall has been updated. Models

Models

1993 – 1998            (ZJ) Jeep® Grand Cherokee

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 rear vehicle structure on about 1,493,000 of the above vehicles may allow fuel leakage during certain low-speed collisions. Fuel leakage in the presence of an ignition source can result in an underbody fire.

Repair

Vehicles equipped with an aftermarket or factory installed trailer hitch must have the hitch inspected and/or replaced. Vehicles without a trailer hitch must have a trailer hitch installed to improve, incrementally, the performance of the vehicle in certain types of low speed collisions.

Safety Recall N45 – Rear Structural Reinforcement

Parts Information

Part Number                Description
CBXTN451AA           Trailer Hitch Package (MSQ = 7)
Each package contains the following components:

Quantity        Description
1                    Hitch, Trailer
4                    Nut and Washer
4                    Stud
2                   Bolt, Hex Head

Each dealer to whom vehicles in the recall were assigned will receive enough Trailer Hitch Packages to service about 20% of those vehicles.

NOTE: A trailer hitch wiring harness is not included and/or part of the installation of the trailer hitch assembly

CBXTN452AA      Trailer Hitch Bolt Kit (bolts missing)
Each kit contains the following components:
Quantity       Description
4                  Nut and Washer
4                  Stud
2                  Bolt, Hex Head

SPECIAL NOTE: There are a small number of trailer hitch packages (CBXTN451AA) that may have been built without providing the necessary bolts to install the trailer hitch. Order the above Trailer Hitch Bolt Kit (CBXTN452AA) only if it is determined that the bolt package is missing from the trailer hitch package.

CBXTN454AA     Thread Repair Kit
Each package contains the following components:
Quantity    Description
1                Bit, 27/64 Cobalt Drill
1                Tap, 1/2 – 13 Taper
2               Bolt, Hex Head (1/2 – 13 x 1.625)

Part Number          Description
04318032                 Compound, Thread Locking

NOTE: Thread Repair kit CBXTN454AA will be superseded to CBXTN454AB in the near future. The original “AA” kit has bolts that do not have thread locking compound on the bolts. The new “AB” kit will contain bolts with thread locking compound already applied to the bolt threads.

If the “AA” kit is used, 04318032 thread locking compound must be applied to the bolt threads. Thread locking compound is not required if the “AB” kit is being used.

Part Number           Description
68266621AA         Label, Trailer Hitch
68264812AA         Bracket, 7-Pin Trailer Hitch Wiring Connector

Special Tools

The following special tools are required to perform this repair:

• 2015800140                Clearance Gauge Set (Figure 1)
• 2019700230                Induction Heating Tool (Figure 1)
• 2019900230                Replacement Induction Heating Tool Coil Kit

NOTE: If a replacement coil is required, an induction heating tool coil kit can be ordered at dealer expense. To order call:855-298-2687 or go online to:
www.MoparEssentialTools.com and click on Equipment Catalog. Then enter item number in the search box or go to Collision Repair / Miscellaneous.

NOTE: Each involved dealer received one Induction Heating Tool, free of charge, through Mopar Essential Tools in July of 2014. Aditional Induction Heating tools can be ordered at dealer expense.

Service Procedure

**A. Inspect Vehicle**

1. Inspect the rear of the vehicle for collision damage:
   ➢ If there is no collision damage, continue to Step 2 of this procedure.
   ➢  If there is minor collision damage, but no apparent frame damage, continue to Step 2 of this procedure.
   ➢  If there is collision induced frame damage, the recall cannot be completed until the collision damage is repaired. Continue with Section H. Document Corrosion and/or Collision Damage.
   NOTE: The cost of collision damage repair is the responsibility of the vehicle owner.
   

2. Inspect for a trailer hitch:
   ➢ If the vehicle is equipped with a factory installed trailer hitch (looks identical to a CBXTN451AA replacement hitch), continue with Section G. Install Trailer Hitch Label.
   ➢  If the vehicle is equipped with an aftermarket trailer h i tch, continue with Section B: Measure and Inspect Aftermarket Trailer Hitch.
   ➢ If the vehicle does not have a trailer hitch, continue with Section C: Inspect Frame Rails for Corrosion.

**B: Measure and Inspect Aftermarket Trailer Hitch**

1. Lift the vehicle on an appropriate hoist.

2. Using Special Tool 2015800140 labeled ZJ, measure the clearance between the fuel tank and the aftermarket trailer hitch in the three locations referenced in Figure 2:
   ➢ If there is adequate clearance between the fuel tank and the aftermarket trailer hitch (Figure 2), continue with Step 3 of this procedure.
   ➢ If there is inadequate clearance between the fuel tank and the aftermarket trailer hitch, continue with Section C: Inspect Frame Rails for Corrosion.
   
   

3. Inspect the aftermarket trailer hitch for sharp edges and/or corners that could puncture the fuel tank in the event of a rear end collision (Figure 3):
   ➢ If there are no obvious sharp edges and/or corners on the aftermarket trailer hitch, continue with Section G. Install Trailer Hitch Label.
   ➢ If there are sharp edges and/or corners on the aftermarket trailer hitch, continue with continue with Section C: Inspect Frame Rails for Corrosion.
   
   

**C: Inspect Frame Rails for Corrosion**

1. Lift the vehicle on an appropriate hoist.
2. Inspect the rear right and left frame rails for corrosion (Figure 4):
   ➢ If there is little or no corrosion of the frame rails (level 1 or 2), continue with Section D. Install Trailer Hitch.
   ➢ If there is light (level 3) to medium (level 4) corrosion of the frame rails (Figures 5 and 6), but no perforation of the frame rail metal, continue with Section D. Install Trailer Hitch.
   ➢ If there is heavy corrosion and/or perforation through the frame rail(s) (level 5 corrosion), the recall cannot be completed until the corrosion damage is repaired (Figure 4). Continue with Section H. Document Corrosion and/or Collision Damage.
   NOTE: The cost of the corrosion damage repair is the responsibility of the vehicle owner.
   
   
   
   

**D. Install Trailer Hitch**

1. If equipped, remove and discard the aftermarket trailer hitch.

2. If equipped, remove and discard the recovery bracket and/or shipping bracket located on the right and/or left rear frame rail (Figure 7).
   

3. For vehicles with damaged trailer hitch mounting studs, continue with Step 3a of this procedure.
   For vehicles without damaged trailer hitch mounting studs, continue with Step 4 of this procedure.
   a. Using two 12 mm x 1.75 nuts, double nut each of the damaged original studs and remove the studs from the frame rail(s) (Figure 8).
   
   NOTE: If any studs and/or bolts are corroded in place, use the induction heating tool (special tool 2019700230) to heat the bolt/stud to aid in removal.
   Follow the instructions provided with the induction heating tool to operate the induction heating tool safely and effectively.
   b. Using Mopar Penetrating spray, apply penetrating spray to the six trailer hitch mounting bolt/stud holes on the frame rails.
   c. Using a 12 mm x 1.75 tapered tap, chase the threads in all six trailer hitch mounting bolt/stud holes on the rear frame rails.
   CAUTION: Be sure to lubricate the thread tap with cutting-oil.
   d. Install new studs in the two rear-most mounting holes in the right and left frame rail (Figure 8).
   e. Using the double nut method, tighten the four studs to 80 ft. lbs. (108 N·m).

4. With the help of an assistant, place and secure the new trailer hitch onto a transmission jack.

5. Using the transmission jack, raise the trailer hitch into position (Figure 9).
   

6. Install the four trailer hitch mounting nuts onto the studs, hand tight.

7. Install the two mounting bolts and tighten them to 65 ft. lbs. (88 N·m).
   CAUTION: If either of the two trailer hitch mounting bolt holes strip-out before reaching the proper tightening specification, continue with Section E. Thread Repair.
   If all bolts achieve the proper tightening specification without stripping out, continue with Step 8 of this procedure.

8. Tighten the mounting stud nuts to 55 ft. lbs. (74 N·m).

9. Remove the transmission jack.

10. For vehicles with trailer hitch wiring, continue with Section F. Trailer Hitch Wiring.

11. Continue with Section G. Install Trailer Hitch Label.

**E. Thread Repair**

1. Remove and discard the original bolt(s) that stripped-out.

2. Using the 27/64 inch drill bit provided in the thread repair kit, drill out the weld nut(s) threads (Figure 10).

3. Using the thread tap provided in the thread repair kit, tap new threads into the weld nut(s) (Figure 11).
   CAUTION: Be sure to lubricate the thread tap with cutting-oil.

4. For thread repair kit CBXTN454AA only , install the provided conical washer onto the bolt with the crowned side towards the bolt head.

5. For thread repair kit CBXTN454AA only, apply three drops of thread locking compound to the bolt threads.

6. Install the provided oversized bolt(s) into the oversized hole and tighten to 65 ft. lbs. (88 N·m).

7. Tighten the mounting stud nuts to 55 ft. lbs. (74 N·m).

8. Remove the transmission jack.

9. For vehicles with trailer hitch wiring, continue with Section F. Trailer Hitch Wiring.

10. Continue with Section G. Install Trailer Hitch Label.
    
    

F. Trailer Hitch Wiring

NOTE: The following procedure is only to be performed on vehicles that had trailer hitch wiring previously installed. Vehicles that did not have a trailer hitch and/or trailer hitch wiring are not eligible for this procedure. If the customer requests trailer hitch wiring, the cost to install wiring is the vehicle owner’s responsibility.

1. For vehicle equipped with a 4-pin electrical connector , secure the wiring as required with plastic tie straps.

2. For vehicles equipped with a 7-pin electrical connector , use the following procedure to install a 7-pin electrical connector bracket:
   NOTE: The installation instructions below are basic guidelines to install a 7-pin connector bracket (P/N 68264812AA) to the trailer hitch. Deviation to these instructions may be required for proper installation.
   a. Place the bracket against the bottom of the hitch cross car beam and position approximately 6 – 8″ to the left of the hitch receiver and the mounting tab pointing towards the front of the vehicle
   b. Using the bracket mounting holes as a template, mark the centers of the holes using the scribe.
   c. Using the centering punch, create a divot at the scribe marks for the drill to center on.
   d. Using the hand drill and #27 drill bit, create two through holes for the mounting screws.
   e. Mount the bracket to the hitch using 2 tapping screws (¼” hex socket) tighten until secure.
   CAUTION: Do not over tighten the tapping or machine screws and nut. Use ¼” hand driver and sockets. The maximum torque should not exceed 26 in. lbs. (3 N·m).
   f. Secured to the 7-way connector to the bracket using 4 screws and 4 nuts included in the kit.

3. Continue with Section G. Install Trailer Hitch Use Label.

**G. Install Trailer Hitch Use Label**

1. Clean the area where the trailer hitch use label will be applied with a clean lint-free cloth.

2. Remove the release paper from the back side of the trailer hitch use label.

3. Install the trailer hitch use label to the trailer hitch as shown in Figure 12.
   NOTE: If the vehicle has an aftermarket hitch, if possible, install the label in the factory trailer hitch label location (Figure 12). If the label does not fit in the factory hitch label location, install the label in a location where the user of the hitch can see and read the label.

4. Lower the vehicle from the hoist and return the vehicle to the customer.
   NOTE: The vehicle should not be driven with the receiver/ball assembly installed in the trailer hitch unless towing. Remove the receiver/ball assembly from the trailer hitch, and secure it in the vehicle, before returning the vehicle to the customer.
   
   

**H. Document Corrosion and/or Collision Damage**

NOTE: The following procedure is only required if the inspection performed in Section “A” or Section “C” determines that the vehicle cannot have a trailer hitch installed.

1. Using a digital camera, take legible image(s) of the affected area (trailer hitch assembly area undercarriage).
2. Print a paper copy of the provided “Level 5 Corrosion/Collision Damage” form.
3. Fill in the required information on the “Level 5 Corrosion/Collision Damage” form.
4. Attach the completed “Level 5 Corrosion/Collision Damage” form and legible image(s) to the recall claim.
5. Lower the vehicle from the hoist and return the vehicle to the customer.

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 Chrysler to record recall service completions and provide dealer payments.

Use the following labor operation numbers and time allowances:

Labor Operation Number

|

Time
Allowance

---|---
13-N4-51-81| 0.4 hours
13-N4-51-82| 0.9 hours
13-N4-51-83| 1.0 hours
13-N4-51-50| 0.2 hours
13-N4-51-51| 0.4 hours
13-N4-51-52| 0.2 hours
13-N4-51-53| 0.1 hours
13-N4-51-54| 0.2 hours
13-N4-51-5Z| 0.9 hours

Inspect the vehicle for a trailer hitch, frame corrosion and/or collision damage and install trailer hitch label
Inspect the vehicle for a trailer hitch, frame corrosion and/or collision damage, install a new trailer hitch and install trailer hitch label
Inspect the vehicle for a trailer hitch, frame corrosion and/or collision damage, remove aftermarket trailer hitch, install a new trailer trailer hitch and install trailer hitch label

Related Operation

Repair one, two, or three threaded hole(s)
Repair four, five, or six threaded holes
Extract bolt(s)/stud(s) with induction heating tool
Document vehicles with “Level 5” frame corrosion and/or collision damage
Install 7-Pin Electrical Connector Bracket 13-N4-51-54 0.2 hours
Weld nut broke during repair, recall could not be completed
Add the cost of the recall parts package plus applicable dealer allowance to your claim.
Refer to Warranty Bulletin No. D-14-14 and follow the detailed instructions in the Warranty Bulletin to process this claim for “Level 5 Corrosion/Collision Damage.
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 Chrysler 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.

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
Chrysler Group LLC

IMPORTANT SAFETY RECALL

This notice applies to your vehicle (VIN: xxxxxxxxxxxxxxxxx).

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Dear John Smith ,

This is a follow up to an earlier communication to remind you that there is a safety recall for certain 1993 through 1998 model year Jeep® Grand Cherokee vehicles. FCA US LLC (“FCA US”) urges you to schedule your service appointment to have the recall remedy completed.

The problem is… The fuel tank on your vehicle has a chance of experiencing a fuel leak during certain types of rear end collisions. Fuel leakage in the presence of an ignition source can result in a fire.

What your dealer will do… 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 inspect your vehicle and install an Original Equipment Manufacturer (OEM) trailer hitch where appropriate, free of charge (parts and labor) to better manage crash forces in low-speed impacts. For your inconvenience, we will provide you with a $100 unrestricted Visa® prepaid card.
   If your vehicle already has an original factory installed FCA US OEM trailer hitch, the area surrounding the hitch will be inspected for damage.
   If your vehicle has an aftermarket trailer hitch, the trailer hitch and the surrounding area will be inspected for any evidence of sharp edges or other puncture risks. If any such evidence is identified, the aftermarket hitch will be removed and a FCA US OEM trailer hitch will be installed free of charge, provided the condition of the vehicle can support proper removal of the existing hitch and installation of a FCA US OEM trailer hitch.
   If it is determined that the condition of your vehicle does not allow the installation of a FCA US OEM trailer hitch or replacement mounting bolts, your vehicle will be returned and you will be advised what, if any, repairs are needed before the installation can be performed.
   The work will take about four hours to complete. However, additional time may be necessary depending on service schedules.
   If your vehicle already had this repair completed on or after July 24, 2015, you are qualified to receive a $100 unrestricted Visa® prepaid card.

2. You can trade-in your vehicle for a new Chrysler/Dodge/Jeep/Ram or Fiat vehicle and receive an additional $1000 trade-in incentive over the fair market value of your vehicle. The combined total of which will be credited towards the purchase of a new FCA US vehicle or FCA US parts or service. To qualify, vehicles must be registered with your State DMV and cannot have a salvage or rebuilt title.

What you must do to ensure your safety… Simply contact your Chrysler, Jeep, or Dodge 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. Please bring this letter with you to your dealer.

FCA US recommends that the trailer hitch ball mount be mounted in the hitch only when your vehicle is towing and be removed at all other times.

_ If you need help… _If you have questions or concerns which your dealer is unable to resolve, please contact the FCA Recall Assistance Center at 1-866-814-1480 or recalls.mopar.com.

If you had your vehicle repaired on or after July 24, 2015, you are entitled to receive the $100 Visa® prepaid card. To request your prepaid card, go to recalls.mopar.com to download the request form and obtain filing instructions.

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 18883274236 (TTY 18004249153), 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.

References

• Lookup FCA Vehicle Recalls by VIN | Official Mopar® Site
• Safer Car Vehicle Safety, Ratings and Recalls | NHTSA
• Contact Us - Reimbursement Form
• Mopar Essential Tools and Service Equipment

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