Recall - Steering and Differential Frame Repair: Overview
May 2002Safety Recall No. 998
Steering and Differential Frame Repair
Models
1996-1999 (SR) Dodge Viper (Coupe and Roadster)
NOTE:
This recall applies only to the above vehicles built through March 1, 1999 (MDH 030110).
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 DIAL VIP System.
Subject
Aggressive driving, such as racing, on about 4,700 of the above vehicles, may lead to cracking and separation of the steering gear crossmember from the frame. This can cause unexpected steering looseness and lag. Aggressive driving can also lead to cracking and separation of a differential mounting bracket winch could cause a loss of vehicle control. Either condition could result in an accident without warning.
Repair
The steering gear crossmember must be inspected for cracks. Vehicles with a cracked steering gear crossmember must have the crossmember replaced. All involved vehicles must have frame gussets and a steering gear crossmember reinforcement bracket installed.
In addition, the left differential mounting bracket must be inspected for cracks. Vehicles that have a cracked mounting bracket must have the bracket installed.
Parts Information
A. Frame Reinforcement Package
NOTE:
Frame reinforcement pages CAAM9981 and CAAP9982 are required to repair each vehicle. Additional parts packages, listed below, may be required depending on the conditions found on a particular vehicle.
Part Number Description
CAAM9981 Steering Reinforcement Package
Each package contains the following components:
Quantity Description
1 Steering Gear Crossmember Reinforcement
1 Right Side Frame Rail Gusset
1 Left Side Frame Rail Gusset
24 Structural Steel Rivets
Part Number Description
CAAP9982 Differential Reinforcement Package
Each package contains the following components:
Quantity Description
1 Differential Support Bracket
1 Differential Bracket "Z" Bracket
1 Differential Support Bracket Bolt
1 Differential Support Bracket Nut
10 Structural Steel Rivets
Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough of each reinforcement package to service about 10% of those vehicles.
B. Steering Gear Crossmember Assembly
Part Number Description
CAAM9983 Steering Gear Crossmember Assembly
C. Differential Frame Bracket Repair Package
Part Number Description
CAAP9984 Differential Frame Bracket Repair Package
Each package contains the following components:
Quantity Description
1 Differential Frame Reinforcement Plate
1 Differential Mounting Bracket
1 Differential Mounting Bracket Gusset
D. Rear Toe Link Bracket Assembly
Part Number Description
CAAP9985 Rear Toe Link Bracket Assembly
E. Fuel Tank Access Panel Package
Part Number Description
CAAP9986 Fuel Tank Access Panel Package
Each package contains the following components:
Quantity Description
1 Service Panel, Fuel Tank
24 Rivets
NOTE:
If individual rivets are required order P/N 06034578.
F. Corrosion Protection
Part Number Description
CAAM9987 Zinc Rich Primer (quart can)
NOTE:
One call of zinc rich primer will repair approximately 10 vehicles.
Part Number Description
CAAM9983 Black Spray Paint
Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive ONE (1) can of zinc rich primer and black spray paint. Additional primer and paint may be ordered as required.
G. Vehicle Curb Height Adjustment Shims
Part Number Description
04709321 Spring Seat Shim, Increase Height
04763943 Spring Seat, Reduced Height
Special Tools
A special air/hydraulic power set riveter tool is required for the installation of the structural rivets and fuel tank access panel rivets. ALL Chrysler and Dodge dealers previously received ONE (1) W-AK175ACH Power Set Riveter, free of charge, through Pentastar Service Equipment (PSE) in December 1998.
In addition, all Chrysler, Dodge and Jeep dealers received ONE (1) W-202145 air/hydraulic power set riveter tool nose piece, free of charge, in April 2002.
Additional power riveters and/or nose pieces may be ordered through Pentastar Service Equipment (PSE) at dealer cost by calling 1-800-223-5623 or faxing 1-800-734-4334. Additional power riveters and/or nose pieces are NOT reimbursable by DaimlerChrysler.
The following existing special tools may be required to perform this recall:
^ # 6632 Adapter, Torque Wrench
^ W-AK175ACH Riveter, Air/Hydraulic Powered
^ W-202145 Nose Piece, Gold Color
^ C-4799-1 Hose, Pressure Release (Part of C-4799-A Gauge Kit)
^ # 6856 Spanner Wrench, Fuel Pump Module
^ C-3894-A Puller, Tie Rod
^ GP-2020-C3.5 Compressor, Coil Spring
^ APS357B or JHW-0-472 Wrench, Spanner
^ # 6914 Height Gages, Suspension
^ # 8396-1 Adapter Height Gage
^ # 6990 Essential Tool Kit, Viper
Kit Contains:
# 6996 - Switch Box, Inclinometer
# 6989 - Inclinometer
# 6916 - Adapter, Rear Caster
# 6915 - Adapter, Front Caster
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 labor operation number and any appropriate related operations as necessary. Related operations must be included in the same condition as the primary repair labor operation.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.
Parts Return
Not required.
Dealer Notification and Vehicle List
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of their involved vehicles.
The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.
DEAL System Functions 53 and VIP
All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD998".
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 included.
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.
Vehicle Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation
CIMS 482-00-85
800 Chrysler Drive East
Auburn Hills, Michigan 48326-2757
If you have any questions or need assistance in completing this action, please contact your Zone Service Office.
Customer Services Field Operations
DaimlerChrysler Corporation