Dash Panel -Cracking/Popping Noise While Turning
NO.: 23-34-92GROUP: Body
DATE: Nov. 30, 1992
SUBJECT:
Dash Panel/Front Rail Welds
MODELS:
1991-1992 (AS) Caravan/GrandCaravan/Caravan CV
Voyager/Grand Voyager/Town & Country
SYMPTOM/CONDITION:
A customer may complain of creaking, popping, or crackling sound at the dash panel area under their feet while turning.
DIAGNOSIS:
With the vehicle raised on a hoist, visually inspect the spot welds on the underside of the vehicle in the kick-up area of the dash panel to front frame rails. Refer to Figure 1.
If a pocket scale can be inserted between the flanges of the frame rail and dash panel, or obvious large gaps are present, or any of the five spot welds per side are missing, then repair is necessary.
PARTS REQUIRED:
12 Structural Rivet 6033688
AR Sealer 4318088
REPAIR PROCEDURE:
This bulletin involves riveting the frame rail flanges to the dash panel.
1. While the vehicle is still raised for inspection, fill the gaps between the rail and the dash panel with sealer (PN 4318088) to prevent squeaking.
2. Return the vehicle to floor level. Pull back the carpet and backing in the dash panel kick-up area. Cut the dash panel silencer at the top to allow access to the dash panel.
3. Inside the vehicle, use an appropriate scraper to remove the sealer around the outboard weld flanges. A heat gun may ease sealer removal.
4. From inside the vehicle, position the template (Figure 2) around the reinforcement plate of the dash panel and mark its outline. Hammer the dash panel down in the area described by the template to eliminate any gap between the dash panel and the frame rail.
5. Use the template to locate and mark the six rivet lucations on each side of the vehicle. Start with the right side first. Mark the locations from inside the vehicle.
6. From inside the vehicle drill 1/8" diameter or less pilot holes at the locations marked with the template. Then drill holes to 17/64" diameter.
!!! CAUTION !!!
WHEN DRILLING HOLES ON THE LEFT FLANGE OF THE RIGHT HAND SIDE OF THE VEHICLE (PASSENGER SIDE) BE EXTREMELY CAREFUL TO AVOID THE FUEL LINES UNDER THE VEHICLE. TAPE THE DRILL BIT SO THAT IT ONLY DRILLS TO A DEPTH OF 1/2
7. Use only 1/4" structural rivets (PN 6033688) to rivet the holes that have been drilled. Do this from inside the vehicle.
8. Apply sealer (PN 2498190 or PN 4318088) over the rivets, both inside and outside the vehicle.
9. Reposition the silencer and install the carpet.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 23-85-80-90 1.2 Hrs.
FAILURE CODE: 7X - Weld Defect