| DISCUSSION: 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 first class mail.
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 other dealers: Each Dodge and Chrysler-Plymouth dealer who does not
receive a Vehicle List will receive a copy of this dealer recall notification letter by
first class mail DIAL System Functions 53, 70 and VIP
All involved vehicles will be entered to DIAL System Functions 53, 70 and VIP at the time
of recall implementation for dealer inquiry as needed. The fourth character of the recall
number(formerly used to identify truck notifications with a "T") will be
utilized to indicate whether the vehicle is located in the salt belt (7051) or non-salt
belt (7052) according to Chrysler's records.
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 Retainer Clip Packages,
Recall PN CAS27055,to service 100% of those vehicles.
Each Retainer Clip parts package contains the following components:
Quantity Description
1 Retainer Clip
1 Screw
4 Tie Strap (required for ABS equipped vehicles only)
1 Instruction Sheet
In addition, involved dealers will receive the following tube parts packages:
Initial Distribution
Salt Belt Non-Salt Belt
Part Number QTY* Description Recall #7051 Recall #7052
CAJ27051 LT 1 * Left rear ABS brake tube 75% 10%
CAJ27051 RT 1 * Right rear ABS brake tube 75% 10%
CAN27052LT 1 * Left rear NON-ABS brake tube 75% 10%
CAN27052RT 1 * Right rear NON-ABS brake tube 75% 10%
CAS27053 1 * Fuel vapor tube 25% 5%
CAS27054 1 * Fuel supply tube 5% None
" " 1* SOHC Fuel Hose
" " 1* DOHC Fuel Hose
*All of the above Part Number packages containing either a brake or fuel tube have
a minimum sales quantity of 5.
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. A copy of the owner notification letter is attached.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle
and four digit recall number (7051 for salt belt or 7052 for non-salt belt) are identified
on the form for owner or dealer reference as needed.
Service Procedure
A. Inspect Tubes For Corrosion and Install Retaining Clip:
1. With ignition switch in the off position, raise vehicle on a hoist.
2. Remove and discard the under body bracket and rubber isolator retaining the rear brake
tubes, fuel vapor tube and fuel supply tube (Figure 1).
3. Carefully inspect all four tubes in the area that was covered by the rubber
isolator as shown in figure 2. If
any one of the four tubes have any RED CORROSION, the tube(s) must be replaced. Proceed
to section "B. Replace Corroded Tube(s) and Install Retaining Clip". Tubes
with white powder or other residue/discoloration do not require replacement.
4 If no red corrosion is present on any of the four tubes, reinstall the two outboard
bolts into the frame rail and cross member holes and torque to 250 in-lbs (28 N m) (Figure
3 - not available)
Note: The two outboard bolts must be installed to assure the structural integrity of
the frame rail.
5 Snap the provided clip onto the four tubes so that the nipple on bottom of clip is
in the outboard position. The clip should be positioned at the forward edge of the center
crossmember as shown in figure 3
6. Using the screw hole in the clip as a template, center punch, then drill a 3/16 inch
(4.8mm) hole in the cross member for the clip retaining screw (Figure 3).
7. Secure clip to the cross member and torque the provided retaining screw to 30 in-lbs
(3N m) (Figure 3).
8. Lower vehicle from hoist.
B. Replace Corroded Tube(s) and Install Retaining Clip:
Note: Only those tubes with RED CORROSION, as determined by the inspection in
section "A" require replacement. Tubes with white powder or other
residue/discoloration do not require replacement. The brake tubes are the most susceptible
to corrosion. Very few fuel vapor tubes and even fewer fuel supply tubes are expected to
require replacement. Therefore, the following procedure replaces brake tubes, then if
necessary, the fuel vapor and supply tubes.
1. Lower vehicle from the hoist.
2. Remove air inlet tube, air cleaner housing and coolant over flow bottle.
3. Remove brake lamp fuse from the Power Distribution Center (PDC).
4. Install a brake pedal fixture tool to keep the master cylinder in the applied position,
such as an alignment tool or prop rod from the brake pedal to the drivers seat.
Note: Keeping the master cylinder in the "applied" position makes bleeding
the brakes faster and easier since only the REAR brakes will require bleeding.
5. Disconnect the left rear and right rear brake tubes from the:
_ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles
or;
_ proportioning valves on the Hydraulic Control Unit (HCU) on ABS equipped vehicles.
Caution: Be sure to disconnect only the REAR brake tubes or the entire brake system
must be bled.
6. Remove tubes from dash panel rubber and plastic retainers and if equipped, cut tie
straps retaining ABS wiring.
Note: To assure that wiring and tubes are properly positioned during re assemble, note
tie strap locations and each tubes position in each retainer.
7. If fuel supply tube requires replacement, release fuel system pressure, then
disconnect fuel tube from engine compartment fuel hose quick-connect.
8. Raise vehicle on hoist.
9. Remove the splash shield located at fuel tank sending unit and fuel filter.
10. Disconnect fuel vapor tube from rear hose and allow rear end of tube to drop.
11. Remove bolt retaining fuel filter and lower fuel filter.
12. Disconnect fuel tank sending unit wiring connector.
13. Position transmission jack under fuel tank and remove fuel tank support strap bolts(Figure 4).
Caution: It is not necessary to drain the fuel tank. However, make sure that
jack-to-tank contact surface is adequate and that jack is properly positioned.
14. Slowly lower fuel tank about 2 inches and move tank rearward about two
inches (Figure 4).
Caution: DO NOT lower or move the tank rearward more than two inches or damage to fuel
system components or sheet metal at fuel filler tube may occur.
15. Disconnect rear brake tubes from all under body plastic clips.
Note: Leave clips attached to body. Clips may break if removal is attempted.
16. Disconnect left and right rear brake tubes from the brake hoses at the rear frame
rails.Remove and discard the corroded brake tube(s) (Figure 5).
Note: To ease tube removal, the left tube should first be moved inboard of fuel supply
and vapor tubes, then lowered.
17. If fuel vapor tube requires replacement, disconnect tube from front vapor
hose.Remove and discard corroded vapor tube.
18. If fuel supply tube requires replacement, disconnect tube from fuel filter
quick-connect. Remove and discard corroded supply tube.
19. If fuel supply tube required replacement, feed front of new tube into position
in the engine compartment, then attach rear of tube to the fuel filter quick connect.
20. If fuel vapor tube required replacement,feed front of new tube into position,
but do not connect to either hose.
21. Feed front of new left brake tube into position, then attach the rear of the
tube to the three retaining clips forward of the fuel tank and to the clip at the left
rear brake hose.
Note: ABS wiring must be clipped to the top frame clip positions.
22. Feed front of right brake tube into position, then attach the rear of the
tube to the retaining clip at the right rear brake hose.
Note: ABS wiring must be clipped to the top clip position. Also, make sure fourway
oxygen sensor connector and wiring (located at generator) is routed inboard of all brake
and fuel tubes.
23. If fuel vapor tube required replacement, attach front of vapor tube to the
front vapor hose and attach tube to bottom clip position (right front brake tube should be
in top clip position).
24. Transfer any retaining clips from old tubes to new ones and attach all tubes to all
remaining underbody retaining clips. The left rear brake tube must be in the
inboard clip position with the fuel supply (largest tube) next to it. The right rear
brake tube must be in the outboard clip position with the fuel vapor tube next to it. The
ABS wiring, if equipped, must be attached outboard of the tubes.
25. Reinstall the two outboard bolts into the frame rail and cross member holes and torque
to 250 in-lbs (28 N m) (Figure 3)
Note: The two outboard bolts must be installed to assure the structural integrity of
the frame rail.
26. Snap the provided clip onto the four tubes so that the nipple on bottom of clip is
in the outboard position. The clip should be positioned at the forward edge of the center
crossmember as shown in figure 3.
27. Using the screw hole in the clip as a template, center punch, then drill a 3/16
inch(4.8mm) hole in the cross member for the clip retaining screw (Figure 3).
28. Secure clip to the cross member and torque the provided retaining screw to 30 in-lbs
(3 Nm) (Figure 3).
29. Attach left and right rear brake tubes to rear brake hoses and torque fittings to 145
in-lbs (17N m) (Figure 5).
30. Raise fuel tank into position. Install two fuel tank support straps and torque fuel
tank strap bolts to 250 in-lbs. (28 N m).
31. Attach rear end of vapor tube to the vapor hose at the fuel tank.
32. Attach fuel tank sending unit wiring connector.
33. Install fuel filter and torque fuel filter mounting bolt to 85 in-lbs. (10 N m).
34. Install splash shield at fuel tank sending unit and fuel filter.
35. Lower vehicle from hoist.
36. Install all tubes into dash panel rubber and plastic retainers. Be sure to position
each tube in the retainers as previously noted. If equipped, secure ABS wiring to tubes
with the provided tie straps at the previously noted locations.
Note: If necessary, verify proper tube position by comparing the vehicle to another PL
vehicle of the same tube configuration (de: ABS vs. NON-ABS).
37. Install the left rear and right rear brake tubes to the:
_ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles
or;
_ proportioning valves on the HCU on ABS equipped vehicles.Torque fittings to 145 in-lbs
(17 N m).
38. If the fuel supply tube was replaced, the engine compartment fuel hose to the fuel
rail must also be replaced. Install the provided SOHC (pn 4546923) or DOHC (pn
4546954) fuel hose from the fuel rail to the supply tube as appropriate.
Note for early built PL vehicles: The engine compartment end of the provided
fuel supply tube terminates at a different angle than the OEM tube. As a result, the
provided fuel supply hose will have a different shape than the OEM hose.
39. Install coolant overflow bottle.
40. Install air cleaner housing and air inlet duct.
41. Fill the master cylinder reservoir with clean brake fluid conforming to DOT
3specifications.
42. Remove the brake pedal fixture and install the brake lamp fuse into the PDC.
43. Bleed the rear brakes.
44. With the engine running and holding firm pressure on the brake pedal, inspect the
brake and fuel system to verify that no brake fluid or fuel leaks exist.
45. Road test vehicle to assure proper operation.
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.
Completion Reporting and Reimbursement (Continued)
Use one of the following labor operation numbers and time allowances:
Labor Operation Time Number Allowance
Inspect brake/fuel tubes and install clip 05705182 0.2 Hours
Replace one or all tubes and install clip -- vehicles without ABS 05705183 1.8
Hours
Replace one or all tubes and install clip -- vehicles with ABS 05705184 2.1 Hours
Add the cost of the recall parts package(s) plus applicable dealer allowance to your
claim.
Note: See the Warranty Administration Manual, Recall Claim Processing
Section 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
CIMS 482-00-85
800 Chrysler Drive East
Auburn Hills, Michigan 48326-2757
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.
Customer Services Field Operations
Chrysler Corporation
IMPORTANT
DEALER SERVICE INSTRUCTIONS
Safety Recall #705 -- Brake/Fuel Tube Corrosion
_ This service requirement applies only to 1995 model year Dodge/Plymouth Neon (PL)
vehicles built through:
_ September 6, 1994 (MDH 090610) at the Belvedere Assembly Plant ("D" in the
11th VIN position)
_ May 16, 1995 (MDH 051615) at the Toluca Assembly Plant ("T" in the 11th VIN
position)
_ The rubber isolator for the rear brake tubes, fuel vapor tube and fuel supply tube, may
cause the tubes to leak due to corrosion perforation. To correct this condition, the
rubber isolator must be removed and a clip installed to retain the four tubes to the cross
member Also, all four tubes must be inspected at the isolator location, and any tube found
with RED CORROSION must be replaced.
Note that only those tubes with RED CORROSION, as determined by the inspection in section
"A"require replacement. The brake tubes are the most susceptible to corrosion.
Very few fuel vapor tubes and even fewer fuel supply tubes are expected to require
replacement.
_ This notification will be implemented in phases. Owners of vehicles located in the
following salt belt states(Recall #7051) will be notified initially:
Connecticut Michigan Pennsylvania
Delaware Minnesota Rhode Island
Illinois Missouri Vermont
Indiana New Hampshire Virginia
Iowa New Jersey Washington, D.C.
Maine New York West Virginia
Maryland Ohio Wisconsin
Massachusetts
Owners of vehicles located in the remaining non-salt belt states (Recall #7052) will be
notified about one month later.
Parts Packages:
_ Each involved dealer, to whom vehicles in the recall were invoiced, will receive
enough Retainer Clip Packages to service 100% of those vehicles. In
addition, enough of the following tube packages will be distributed to service the
referenced percentage of those vehicles:
Salt Belt Non-Salt Belt
Description Recall #7051 Recall #7052
Left rear ABS brake tube 75% 10%
Right rear ABS brake tube 75% 10%
Left rear NON-ABS brake tube 75% 10%
Right rear NON-ABS brake tube 75% 10%
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