Recall - Brake Return Check Valve
No. 574July, 1993
To: All Dodge Truck Dealers
Subject:
Safety Recall # 574 -- 4 Wheel ABS - Brake Return Check Valve
Models:
The Following Vehicles Equipped With Optional 4-Wheel Anti-lock Brakes:
^ 1993 Model Year Dodge Dakota (AN-Body) Vehicles Built Through March 13, 1993 (MDH 03-13-11)
^ 1994 Model Year Dodge Ram Van/Wagon (AB-Body) Vehicles Built Through March 15, 1993 (MDH 03-15-08)
The front Hydraulic Control Unit (HCU) on some of these vehicles may contain an undersized Brake Return Check Valve (BRCV) which could become stuck in the bypass mode. If the valve becomes stuck, the front ABS function will be defeated and brake pedal travel will increase during ABS stops.
To correct this condition, the BRCV must be removed from the HCU and replaced with the proper size valve.
Important:
Some of the involved vehicles may still be in dealer inventory. Federal law requires you to complete the recall service on these vehicles before retail delivery.
Details of this service action are explained in the following sections.
Service Procedure Videotape
No videotape of the service procedure for this recall will be provided.
Dealer Notification & Vehicle List
Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by Certified Mail.
Important:
Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible dealership personnel should be instructed to sign for this Certified Mail without hesitation as it concerns urgent safety recall information.
The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.
All dealers: Each Dodge dealer will receive a copy of this dealer recall notification letter by first class mail.
DIAL System Function 70
All involved vehicles will be entered to DIAL System Function 70 at the time of recall implementation for dealer inquiry by VIN as needed.
Parts
Important:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand.
Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Brake Return Check Valve Packages, Recall PN C3905740, to service 50% of those vehicles.
Each parts package PN C3905740 contains the following components:
Quantity Description
1 Brake Return Check Valve (BRCV)
1 Lint Free Cloth
1 Instruction summary for convenient reference by the servicing technician.
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 the service with their dealers at the earliest possible date. A copy of the owner notification letter is attached.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.
Service Procedure
This procedure involves thoroughly cleaning the front Hydraulic Control Unit (HCU), and replacing the internal Brake Return Check Valve (BRCV). By using the following procedure, only the front brake system will need to be bled.
1. Locate the front HCU under the hood on the left (driver) side of the engine compartment (Figure 1).
2. On RAM VAN/WAGON (AB-BODY) ONLY the following components must be removed for access.
2a. Set aside engine coolant reserve/overflow bottle and windshield washer reservoir (Figure 2).
2b. Remove HCU protective cover (Figure 1).
3. Thoroughly clean the top rear outboard surface of the HCU (the BRCV allen plug area) using Mopar Brake Parts Cleaner PN 4318037 (Figure 3).
Note:
The BRCV is mounted on the back side of HCU (facing the rear of the vehicle) and is not visible from the working area (front of the engine compartment) on AB-body models. While the procedure for BRCV replacement is the same on all models, a mirror will be required on AB-body models to assure that the correct 3/8 inch allen plug is removed and that the area is properly cleaned prior to valve replacement.
4. Remove the top outboard 3/8 inch allen plug (this plug is flush with surface) on the rear side of the HCU (Figure 3).
Caution:
There are two 3/8 inch allen plugs on the rear side of the HCU. Make sure that you remove the smaller top outboard allen plug.
DO NOT remove the larger 3/8 inch recessed allen plug.
5. Thoroughly clean the allen plug bore thread of the HCU using Mopar Brake Parts Cleaner PN 4318037 and shop air. Inspect the entire area to ensure it is free of all debris.
6. Place a shop towel over the HCU to avoid potential brake fluid spray and keep fingers clear of valve area.
7. Using an assistant, apply moderate pressure on the brake pedal until the large end of the BRCV is forced out of the HCU bore. Remove and discard the original valve. As brake fluid is lost, a slight amount of brake pedal drop will be experienced when the valve unseats.
Caution:
The assistant must hold the brake pedal until the BRCV is removed and the new BRCV is installed. Releasing pedal pressure before the BRCV is removed may pull the BRCV back into the bore along with air, making BRCV removal more difficult.
Note:
The original BRCV has a hole in the large end of the valve. This hole was removed from the new valve as a means of positive identification.
8. Insert the small end of the new BRCV into the HCU bore until the O-ring meets the lead-in chamfer of the bore. Using a socket or other blunt tool, apply additional force on the large end of the valve until a snap occurs, indicating the valve is fully seated. The assistant may now release the brake pedal.
Caution:
Cleanliness is critical for proper operation. Handle the new valve with the provided lint free towel to avoid contamination (order additional towels PN 4636968 as necessary). The new valve is prelubricated and ready for installation. If the BRCV becomes contaminated, do not attempt to clean it. Order a new service package.
9. Reinstall the 3/8 inch allen plug and torque to 1 60 inch pounds.
10. Bleed front brakes only using the service manual procedure and inspect for leaks.
11. Verify proper brake operation before moving vehicle.
12. On RAM VAN/WAGON (AB-BODW O-NL-Y the following must be reinstalled.
12a. Install HCU protective cover (Figure 1).
12b. Install engine coolant reserve/overflow bottle and windshield washer reservoir (Figure 2).
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments.
Use one of the labor operation numbers and time allowances (see illustration).
Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing instructions.
Parts Return
Not required.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to:
Chrysler Corporation 415-03-18
P.O. Box 1919
Detroit, Michigan 48231-1919
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone Service Office.
SAFETY RECALL -- 4 WHEEL ABS - BRAKE RETURN CHECK VALVE
Dear Chrysler Corporation Vehicle Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1993 model year Dodge Dakota and 1994 model year Dodge Ram Van/Wagon vehicles. An undersized brake return check valve may have been installed in the front ABS hydraulic control unit of your vehicle.
Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange for service to correct the condition without delay. The service and required parts as described in this letter will be provided free of charge.
An undersized valve could stick inside the control unit, which would disable the front ABS function and cause increased brake pedal travel during hard stops. The driver may be warned of this condition by illumination of the ABS light on the instrument panel. Complete loss of braking will not occur because the normal braking system will continue to operate. However, the increased brake pedal travel occurs unexpectedly and a vehicle crash can occur if the driver is alarmed and does not continue to apply the brake pedal.
To correct this condition, the undersized valve must be removed and replaced with a new valve.
The work will take less than one hour to complete. However, additional time may be required depending on how dealer appointments are scheduled and processed. To obtain this free service:
^ Contact your dealer as soon as possible to schedule an appointment for the free service.
^ Take the enclosed Owner Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and the service that is required.
If you have any problem obtaining the needed repair, please contact the Chrysler Zone Service Office in your area. (It is listed under "Service Assistance" in your Owner's Manual.) A Zone representative will arrange for prompt attention to your vehicle.
We regret any inconvenience which this action may cause you. However, we are concerned about your safety. 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, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington D.C. area residents may call 366-0123.)
Thank you for your attention to this important matter.