Safety Recall S16 / NHTSA 16V-168 Left Front Brake Caliper – 2015-2016 Jeep Grand Cherokee & Dodge Durango

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NHTSA Campaign Number: 16V168
Component(s): SERVICE BRAKES, HYDRAULIC
Potential Number of Units Affected: 21,183

Manufacturer: Chrysler (FCA US LLC)

 

SUMMARY:

Chrysler (FCA US LLC) is recalling certain model year 2015-2016 Jeep Grand Cherokee and Dodge Durango vehicles manufactured December 9, 2015, to January 14, 2016.

In the affected vehicles, the left front brake caliper may crack due to being made from an incorrect material.

 

CONSEQUENCE:

A cracked brake caliper may lengthen the distance needed to stop the vehicle and increase the risk of a crash.

 

REMEDY:

Chrysler will notify owners, and dealers will inspect the front left brake caliper and depending on its casting date, replace it, free of charge.

The recall is expected to begin on May 12, 2016.

Owners may contact Chrysler customer service at 1-800-853-1403.

Chrysler’s number for this recall is S16.

 

NOTES:

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Vehicle has a Recall

 

 

Revised May 2016

Dealer Service Instructions for:

 

Safety Recall S16 / NHTSA 16V-168 Left Front Brake Caliper

NOTE:  The wheel lug nut torque specification has been updated.

 

Models

2015 – 2016 (WK) Jeep Grand Cherokee
(WD) Dodge Durango

 

NOTE:  This recall applies only to the above vehicles equipped with anti-lock 4-wheel disc brakes (sales code BR1, BR2, BR3, BR6, BR8 or BRY) built from December 09, 2015 through January 13, 2016 (MDH 120906 through 011320).

IMPORTANT:  Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall.

IMPORTANT:  Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery.  Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service.  Involved vehicles can be determined by using the VIP inquiry process.

 

Subject

The left front brake caliper housing on about 22,800 of the above vehicles may have been cast from an incorrect material.  Under extreme brake application, the left front brake caliper housing may rupture.  A ruptured left front disc brake caliper housing could increase the vehicle’s stopping distance and cause a crash.

 

Repair

The left front disc brake caliper housing must have the date code inspected.  Any brake calipers found with a specific date code must be replaced.

 

Alternate Transportation

Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that a left front brake caliper is required and the vehicle must be held overnight.

 

Parts Information

Part Number Description
CBBAS161AA Left Front Brake Caliper Package
Each package contains the following components:
Quantity Description
1
  • Caliper, Left Front Brake
2
  • Washer, Copper

 

Each dealer to whom vehicles in the recall were assigned will receive at least ONE (1) left front brake caliper. Additional left front brake calipers may be ordered as required.

Part Number Description
04318080AC Safety Recall S16 / NHTSA 16V-168 Left Front Brake Caliper - 2015-2016 Jeep Grand Cherokee & Dodge Durango | small light Fluid, DOT 3 Brake (MS.4574)

 

Parts Return

No parts return required for this campaign.

 

Special Tools

No special tools are required to perform this service procedure.

 

Service Procedure

A. Inspect Left Front Brake Caliper Date Code

  1. Lift the vehicle on an appropriate hoist.
  1. Remove and save the left front wheel/tire assembly.
  1. Using brake clean or equivalent, clean the caliper housing at the date code pad cast into the brake caliper housing (Figure 1).
  1. Read the date code cast into the brake caliper housing (Figure 1):
  • If the date code cast into the brake caliper housing is not 3405, continue with Step 5 of this procedure.
  1. Install the left front wheel/tire assembly. Tighten lug nuts to 100 ft. lbs. (136 N·m).
  1. Lower the vehicle from the hoist and return the vehicle to the customer.

Brake Caliper Date Code LocationFigure 1 – Brake Caliper Date Code Location

 

B.  Replace Left Front Brake Caliper 

  1. Drain small amount of brake fluid from the master cylinder brake reservoir with a clean suction gun (Figure 2).

CAUTION: Do not allow brake fluid to contact any painted surfaces.  Severe paint damage may occur.

  1. Lift the vehicle on an appropriate hoist.
  1. Push the brake caliper pistons into the brake caliper housing.

Fluid Removal with Suction GunFigure 2 – Fluid Removal with Suction Gun

 

  1. Remove the brake caliper tension clip by pressing rearward on the front of the clip while pulling the clip out from the brake caliper (Figure 3).

Brake Caliper Tension ClipFigure 3 – Brake Caliper Tension Clip

 

Brake Caliper Flex Hose Banjo Bolt and Slide Bolt Dust CoversFigure 4 – Brake Caliper Flex Hose Banjo Bolt and Slide Bolt Dust Covers

 

  1. Loosen, but do not remove, the brake flex hose banjo bolt (Figure 4).
  1. Remove and save the brake caliper slide bolt dust covers (Figure 4).
  1. Remove and save the brake caliper slide bolts (Figure 5).

Brake Caliper Slide BoltsFigure 5 – Brake Caliper Slide Bolts

 

  1. Remove the brake flex hose banjo bolt and copper washers. Save the banjo bolt and discard the original copper washers (Figure 6).
  1. Remove the original left brake caliper from the brake caliper adapter (Figure 7).

Banjo BoltFigure 6 – Banjo Bolt

 

Brake Caliper RemovalFigure 7 – Brake Caliper Removal

 

  1. Transfer the original inner brake pad from the original brake caliper to the new brake caliper.
  1. Position the new brake caliper onto the brake caliper adapter
  1. Install and tighten the brake caliper slide bolts to 41 ft. lbs. (55 N·m).

Tighten Brake Caliper Slide BoltsFigure 8 – Tighten Brake Caliper Slide Bolts

 

  1. Install the brake caliper slide bolt dust covers.
  1. Install brake flex hose to caliper using new copper washers and the original banjo bolt. Tighten the banjo bolt to 23 ft. lbs. (30 N·m).

CAUTION: Verify brake flex hose is not twisted or kinked before tightening banjo bolt.  

Banjo Bolt and Copper WashersFigure 9 – Banjo Bolt and Copper Washers

 

  1. Install the brake caliper tension clip (Figure 10).
  1. Use the following procedure to bleed the left front brake caliper:

a. Attach a clear plastic hose to the left front brake caliper bleeder screw and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose.

b. Have a helper pump the brake pedal three or four times and hold it in the down position.

Install Brake Caliper Tension ClipFigure 10 – Install Brake Caliper Tension Clip

 

c. With the pedal in the down position, open the bleeder screw on the left front brake caliper at least one full turn.

d. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake pedal.

e. Repeat the above steps until all trapped air is removed from the left front brake caliper (usually four or five times).

f. Monitor the fluid level in the master cylinder reservoir to make sure it does not run out of brake fluid.

CAUTION: Use only DOT3 brake fluid in the hydraulic brake system.

g. Check and adjust brake fluid level to the “FULL” mark on the reservoir.

h. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Bleed the brakes again as necessary.

  1. Install the left front wheel/tire assembly. Tighten lug nuts to 130 ft. lbs. (176 N·m).
  1. Lower the vehicle from the hoist.
  1. Verify that the brake fluid level is correct. Adjust the brake fluid level as required.
  1. Return the vehicle to the customer.

 

Completion Reporting and Reimbursement

Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab.   Claims submitted will be used by FCA to record recall service completions and provide dealer payments.

Use one of the following labor operation numbers and time allowances:

Labor Operation
Number
Time
Allowance
Inspect left front caliper date code 05-S1-61-81 0.2 hours
Inspect left front caliper date code and replace the left front brake caliper 05-S1-61-82 0.6 hours

 

Add the cost of the recall parts package plus applicable dealer allowance to your claim.

NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

 

Dealer Notification

To view this notification on DealerCONNECT, select “Global Recall System” on the Service tab, then click on the description of this notification.

 

Owner Notification and Service Scheduling

All involved vehicle owners known to FCA are being notified of the service requirement by first class mail.  They are requested to schedule appointments for this service with their dealers.  A generic copy of the owner letter is attached.

Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable.

 

Vehicle Lists, Global Recall System, VIP and Dealer Follow Up

All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed.

GRS provides involved dealers with an updated VIN list of their incomplete vehicles.  The owner’s name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission.

To use this system, click on the “Service” tab and then click on “Global Recall System.”  Your dealer’s VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence.

Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair.

Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states.  Use of this information is permitted for this recall only and is strictly prohibited from all other use.

 

Additional Information

If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager.

Customer Services / Field Operations

FCA US LLC

 

LEFT FRONT BRAKE CALIPER

 

IMPORTANT SAFETY RECALL
S16 / NHTSA 16V-168

 

This notice applies to your vehicle (VIN: xxxxxxxxxxxxxxxxx).               

 

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.

Dear: (Name)

FCA has decided that a defect, which relates to motor vehicle safety, exists in certain 2015 and 2016 model year Dodge Durango and Jeep® Grand Cherokee vehicles.

The problem is… The left front brake caliper housing on your vehicle may have been cast from an incorrect material.  Under extreme brake application, the left front brake caliper housing may rupture.  A ruptured left front disc brake caliper housing could increase the vehicle’s stopping distance and cause a crash.
What your dealer will do… FCA will repair your vehicle free of charge.  To do this, your dealer will inspect the left front caliper for a specific date code and replace the brake caliper if required.  The work will take about one hour to complete.  However, additional time may be necessary depending on service schedules.
What you must do to ensure your safety… Simply contact your Chrysler, Jeep, Dodge or RAM dealer right away to schedule a service appointment.  Please bring this letter with you to your dealer.
If you need help… If you have questions or concerns which your dealer is unable to resolve, please contact the

 

FCA Group Recall Assistance Center at either fcarecalls.com or 1-800-853-1403.

Please help us update our records by filling out the attached prepaid postcard if any of the conditions listed on the card apply to you or your vehicle.  If you have further questions go to fcarecalls.com.

If you have already experienced this specific condition and have paid to have it repaired, you may visit www.fcarecallreimbursement.com to submit your reimbursement request online or you can mail your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-8004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.  Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. If you’ve had previous repairs and/or reimbursement you may still need to have the recall repair performed on your vehicle.

 

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, 1200 New Jersey Ave., S.E., Washington, DC  20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to safercar.gov.

We’re sorry for any inconvenience, but we are sincerely concerned about your safety.  Thank you for your attention to this important matter.

Customer Services / Field Operations

FCA US LLC

 

Note to lessors receiving this recall: Federal regulation requires that you forward this recall notice to the lessee within 10 days.

 

 

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