Roof Rail Mounting: Rapid Response

[rickaren]

January 15 ,2009

TO: ALL DODGE DEALERS

FROM: GLOBAL SERVICE

SUBJECT: RAPID RESPONSE TRANSMITTAL/SERVICE Action# 08-099 REV.A
Roof Rack Mounting Stud Corrosion


THIS IS A REVISION TO RAPID RESPONSE TRANSMITTAL# 08-099 DATED
DECEMBER18, 2OO8 AND INCLUDES LABOR OPERATION CHANGES.THE
REVISIONS ARE HIGHLIGHTED WITH* *ASTERISKS**.
INVOLVED VEHICLES:

2007 (KA) Nitro

NOTE: This Service Action affects both sold and unsold vehicles.
NOTE: The VIN List is available on DealerCONNECT for all affected dealers.
The VIN List has been inserted in the Service Tab under Rapid Response Transmittals.

The dealers receiving the Rapid Response Transmittal Service Action are the
"Ship To" dealers and the VIN's listed are specific to their dealership. All
involved vehicles will be loaded into the VIP system.

NOTE: This should be a top priority and completed prior to sale to avoid suspect vehicles from being delivered to customers.

DISCUSSION:
A number of roof rack equipped vehicles were shipped that have roof rack
mounting studs that may prematurely corrode at their weld attachment to the roof panel. Dealers are required to inspect the studs for condition. lf the studs are found clean o r only lightly
corroded, they must be spot blasted to clean the area, treated with rust
neutralizer, then primed and sealed. lf significant corrosion (perforation) is found around the stud or if a stud is missing or separated, a replacement stud must be installed.

A specialized spot blaster will be sent to all dealers( no charge) to facilitate this repair.

NOTE: Before performing this repair, it is recommended to read through the
procedures to gain a full understanding of the steps and requirements.

PARTS REQUIRED:
1 CEL1H081 Roof Rack Stud Rust Repair Package
Each package contains the following components (enough for 1 vehicle):

Quantity Description

1 Abrasive Media (1 lb.b ag)
10 Mastic Patch
1 Primer (1 oz bottle)
1 Rust Neutralizer (1 oz bottle)
10 Plastic Stud Protector
1 Adhesion Promoter
4 Attachment tape
2 Application brush




PAGE 1 of 9



Form DMAIL-00R1 EV1 .01


If you have a NITRO this is a most important Recall (Rapid Response) that you should have performed! I was the first have this work done at my Dealer and they have another 59 to go! If you live in Canada or the Midwest like myself or maybe around saltwater, I suspect you have some Roof Rack Mounting Stud Corrosion. On my 07 Nitro with low miles (8,000) that has not spent much time out of the garage during Winter months it did have ONE mounting stud with corrosion that required treatment. This is not an easy or fast repair and pays four hours. Service Manager told me it took longer than that and that Chrysler will only supply the Dealerships with ONE of the specialized spot blaster tools, so only two at the most could be serviced and repaired daily! One positive note was I got them to install the new replacement style roof rail on the right side since they would only replace the left loose one last year, even tho it is recommended that both be replaced at the same time. If you are going to have this work performed it would only make sense to have them order new plastic roof rails if they are loose or cracked, since they must be removed anyway!

If you plan to keep your Nitro for a long time like myself, or even if you plan to sell or trade it in the future can you guess what a corroded mounted roof rail stud could do to the roof or headliner of your Nitro. Chrysler has stepped up to to protect your vehicle at considerable expense in these very uncertain times. Don't put this repair off!

I have the other 8 pages of this Transmittal that I may post since I think it is very informative but if you have questions please post here and I will respond.

[rickaren]

PARTS REQUIRED CONTINUED:

AR ' CEL1H082 Roof Stud Replacement Package

Each package contains the following components (enough for 1 stud):

Quantity Description

1 Carbide Cutter
1 Stud lnsert
1 Driver Nut
1 Spacer Nut

AR (1)CEL1H083 Roof Rail (Left Side)
AR (1)CEL1H084 Roof Rail (Right Side)

SPECIAL TOOLS/ EQUIPMENT REQUIRED:

1 400131 Spot Blaster
AR 08987 3M Adhesive Remover or Equivalent

NOTE: One spot blaster was mailed to each Chrysler/Jeep/Dodge dealer free of charge in December 2008. For warranty concerns on the tool or to purchase additional spot
blasters (at dealer expense) contact Wright Tool Company at 1-800-783-9826.

REPAIR PROCEDURE:

NOTE: The procedures are broken into several sections. Fully familiarize yourself before proceeding.

1. Remove the acorn nuts from the left and right side roof rack rails.

NOTE: The front acorn nut is located under a sliding panel in the roof rack rail.

2. Carefully lift and remove the right and left roof rack rails.

NOTE: The front edge of both roof rails are held to the roof panel with two-sided tape.

3. Inspect both plastic roof rails for cracks in the area shown( Fig 1). lf cracks are found, the rail(s)must be replaced during the re-assembly
process.

4. Using hot soapy water and a sponge, clean the right and left side roof rail troughs.

5. Wipe the roof rail troughs with a sponge and clean hot water.

NOTE: Use care when washing to prevent water from dripping through onto the headliner if roof perforation is found around the studs or if a stud is missing.

6. Dry the roof rail troughs with a soft towel.

7. Using compressed air, thoroughly dry the area around each of the roof
rail studs.





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