Exhaust System - Drone or Rattle Sound At Idle
NUMBER: 11-005-11 REV AGROUP: Exhaust System
DATE: November 12, 2011
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 11-05-11, DATED OCTOBER 18, 2011, WHICH SHOULD BE REMOVED FROM YOUR FILES THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS
SUBJECT:
Rattle Sound At Idle Or Drone/Vibration Between 60 And 65 MPH (96 And 104 KPH)
OVERVIEW:
This bulletin involves diagnosing the condition and only if necessary making adjustments to the exhaust system or installing a right halfshaft as required.
MODELS:
2008 - 2010 RT Dodge Grand Caravan/Chrysler Town & Country
NOTE:
This bulletin applies to vehicles equipped with the 3.3L or 3.8L engine (Sales Code EGV or EGL)
SYMPTOM/CONDITION:
Vehicles may exhibit a drone sound on 3.3L engines that may be present when the vehicle is driven between 60 & 65 MPH (96 & 104 KPH) (steady state driving) and is more pronounced while driving up a slight grade.
A rattle sound may also be noticed at all RPM ranges idle or driving.
RATTLE DIAGNOSIS:
1. Inspect for witness marks or contact between the exhaust system and the underbody.
2. Are there witness marks or contact between the exhaust system and the underbody?
a. Yes >>> Proceed to Step # 1 of ALIGN EXHAUST REPAIR PROCEDURE.
b. No >>> Proceed to Step # 3.
3. Using a rubber mallet hit the muffler and listen for rattle.
4. Is rattle sound heard?
a. Yes >>> Replace muffler. Refer To Group 11 - Exhaust > Muffler Exhaust Removal and Installation procedures.
b. No >>> Proceed to Step # 5.
5. Is vehicle equipped with a 3.8L engine?
a. Yes >>> Proceed to Step # 6.
b. No >>> This Service Bulletin does not apply further diagnosis required.
6. Locate the bottle resonator directly behind the catalytic converter. Using a rubber mallet hit the resonator.
7. Is rattle sound heard?
a. Yes >>> Replace the catalytic converter/bottle resonator. Refer To Group 11 - Exhaust > Converter Catalytic Removal and Installation procedures.
b. No >>> This Service Bulletin does not apply further diagnosis required.
DRONE DIAGNOSIS:
1. Is vehicle equipped with 3.3L engine?
a. Yes >>> Proceed to Step # 2.
b. No >>> This Service Bulletin does not apply further diagnosis required.
2. Drive Vehicle at a constant speed between 60 MPH (96 KPH) to 65 MPH (104 KPH).
3. Is drone present between 60 & 65 MPH (96 & 104 KPH) (steady state driving)?
a. Yes >>> Replace the right halfshaft. Refer To Group 03 - Differential & Driveline > Half Shaft Removal and Installation procedures.
b. No >>> This Service Bulletin does not apply further diagnosis required.
PARTS REQUIRED:
ALIGN EXHAUST REPAIR PROCEDURE:
1. Loosen the all exhaust mounts.
2. Adjust away from contact point.
3. Re-torque all fasteners. Refer To Group 11 - Exhaust System > Specifications and inspect again for clearance.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.