Safety Recall S59 / NHTSA 16V-589 Chassis Fasteners – 2016 Chrysler 200

NHTSA Campaign Number: 16V589
Component(s): STEERING , STRUCTURE , SUSPENSION
Potential Number of Units Affected: 191

Manufacturer: Chrysler (FCA US LLC)

 

SUMMARY:

Chrysler (FCA US LLC) is recalling certain model year 2016 Chrysler 200 vehicles manufactured May 24, 2016, to May 25, 2016.

Multiple chassis fastener joints may not have been tightened to the proper torque specification.

 

CONSEQUENCE:

If the chassis fastener joints are improperly torqued they may loosen and fail or fall out, reducing steering and handling capability and increasing the risk of a crash.

 

REMEDY:

Chrysler has notified owners, and dealers will inspect the joints and tighten or replace the fasteners, as necessary, free of charge.

The recall began on September 2, 2016.

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

Chrysler’s number for this recall is S59.

 

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

 

August 2016

Dealer Service Instructions for:

 

Safety Recall S59 / NHTSA 16V-589 Chassis Fasteners

 

Models

2016

(UF)

Chrysler 200

 

NOTE: This recall applies only to the above vehicles built from May 24, 2016 through May 25, 2016 (MDH 052412 through 052516).

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

Specific front and/or rear chassis component fasteners on about 190 of the above vehicles were not tightened to the proper torque specification. Loose chassis component fasteners could alter the vehicle’s handling characteristics and cause a crash without warning.

 

Repair

Specific chassis components must have one-time use fasteners replaced and reusable fasteners tightened to the correct torque specification.

 

Parts Information

Required Fasteners All Vehicles:

Part Number	Description
06502696	Nut With Washer, Hex M10x1.25 (Qty. 2) (Front Lower Control Arm Ball Joint to Knuckle)
06510168AA	Bolt, 6 Lobe External Head, M10x1.5×65 (Qty. 2) (Front Lower Control Arm Ball Joint to Knuckle)
06510655AA	Nut, Hex Flange Nut, M14x1.5 (Qty. 2) (Outer Tie Rod Ball Stud to Knuckle)
06509898AA	Nut, Hex Flange Lock, M24x1.5 (Qty. 2) (Front Axle Halfshaft to Wheel Bearing)

 

Required Gaskets 3.6L Engine ONLY:

Part Number	Description
68110431AB	Gasket, Catalytic Converter (3.6L Engine ONLY) (Qty. 1) (Y-Pipe to Catalytic Converter)
52022294AA	Gasket, Crossunder Pipe (3.6L Engine ONLY) (Qty. 1) (Cross-Under Pipe to Catalytic Converter)
04880235AC	Gasket, Crossunder Pipe (3.6L Engine ONLY) (Qty. 1) (Cross-Under Pipe to Y-Pipe)

 

Due to the small number of involved vehicles, no parts will be distributed initially. Dealers should order the fasteners and gaskets if required for each vehicle at the time appointments are scheduled to assure that the part is available when the customer arrives.

NOTE: The below list of fasteners are to be replaced ONLY if the fastener is missing or damaged. Very few vehicles are expected to have any missing or damaged fasteners.

Part Number	Description
06511048AA	Bolt, Hex Flange Head, M14x1.50×90 (Qty. 1) (Torque Strut to Front Crossmember)
06104719AA	Nut, Hex Flange Lock, M14x1.5 (Qty. 1) (Torque Strut to Front Crossmember)
06511078AA	Bolt & Washer, Steering Gear (Qty. 2) (Steering Gear to Front Crossmember)
06104719AA	Nut, Hex Flange Lock, M14x1.5 (Qty. 2) (Steering Gear to Front Crossmember)
06511731AA	Bolt, Hex Head, M10x1.5×113 (Qty. 4) (Stabilizer Bar to Front Crossmember)
06104717AA	Nut, Hex Flange Lock, M10x1.5 (Qty. 2) (Stabilizer Bar to Front Crossmember)
06511384AA	Nut and Washer, Hex M10x1.25 (Qty. 2) (Stabilizer Bar Link to Front Suspension Strut)
06511018AA	Bolt, Hex Flange Head, M12x1.25×143 (Qty. 2) (Front Crossmember to Vehicle Body Upper Bolts)
06508844AA	Bolt and Washer, Hex Flange Head M14x1.50×95 (Qty. 4) (Front Crossmember to Vehicle Body Lower Bolts)
06511157AA	Bolt and Washer, Hex Head M14x2x85 (Qty. 2) (Rear Shock Absorber to Knuckle)
06104416AA	Bolt and Washer, Hex Head, M10x1.5×35 (Qty. 4) (Rear Shock Absorber Upper Mount to Vehicle Body)
06511572AA	Bolt and Washer, Hex Flange Head, M14x1.5×141.5 (Qty. 2) (Rear Crossmember to Vehicle Body)
06510867AA	Stud and Washer, M14x1.5×142/M10x1.5×36 (Qty. 2) (Rear Crossmember to Vehicle Body)
06502979	Nut and Washer, Hex, M10x1.5 (Qty. 2) (Crossmember Bracket to Rear Crossmember)

 

NOTE: The below list of fasteners are to be replaced ONLY if the fastener is missing or damaged. Very few vehicles are expected to have any missing or damaged fasteners.

Part Number	Description
06511061AA	Bolt and Washer, Hex Head M12x1.75×60 (Rear Suspension Link Trailing Arm to Vehicle Body)
06509954AA	Bolt, 6 Lobe, M12x1.25×78 (Qty. 2) (Front Suspension Strut to Knuckle)
06510103AA	Nut, Hex Flange Lock, M12x1.25 (Qty. 2) (Front Suspension Strut to Knuckle)

 

Parts Return

No parts return required for this campaign.

 

Special Tools

The following special tool is required to perform this repair:

10287

Tool, Front Hub Staking

 

Service Procedure

1. Lift and support the vehicle.
2. Remove and save all four wheels.
3. Remove and save the rear left side and rear right side wheelhouse fasteners and liners (Figure 1).

Figure 1 – Rear Wheelhouse Liner

 

NOTE: In steps 4 through 21, inspect the fasteners and replace any missing or damaged fasteners prior to tightening all fasteners to the proper torque specification.

 

4. Rear suspension link trailing arm to the vehicle body bolts on the left and right side, four bolts total. Tighten the bolts to 77 ft. lbs. (105 N·m) (Figure 2).

Figure 2 – Rear Suspension Link Trailing Arm

 

5. Rear shock absorber upper mount bolts on the left and right side of the vehicle, four bolts total. Tighten the bolts to  52 ft. lbs. (70 N·m) (Figure 3).

Figure 3 – Rear Shock Absorber Upper Mount

 

6. Use a jack stand to compress the rear suspension to normal curb ride height. Tighten the rear shock absorber-to-knuckle bolts on the left and right side of the vehicle, two bolts total, to 133 ft. lbs. (180 N·m) (Figure 4).

Figure 4 – Rear Shock Absorber

 

7. Remove and save the rear crossmember brackets and fasteners from the left and right side of the vehicle (Figure 5).

Figure 5 – Crossmember Brackets

 

8. Rear crossmember to the vehicle body bolts, four bolts total. Tighten the bolts to 111 ft. lbs. (150 N·m) (Figure 6).

Figure 6 – Rear Suspension Crossmember

 

9. Install the rear crossmember brackets and fasteners to the left and right side of the vehicle. Tighten  the bolts to 21 ft. lbs. (28 N·m) and tighten the nuts to 48 ft. lbs.  (65 N·m) (Figure 5).
10. Remove and save the underbody splash shield fasteners and splash shield (Figure 7).

Figure 7 – Underbody Splash Shield

 

11. For vehicles equipped with a 3.6L engine, perform the following steps:

a. Remove the rear flange nuts from the cross-under pipe (Figure 8).

b. Remove the cross-under pipe support bolt (Figure 8).

c. Remove the front flange nuts from the cross-under pipe (Figure 8).

d. Remove the cross-under pipe from the vehicle.

e. Loosen the muffler clamp from the Y-pipe (Figure 8).

f. Remove the Y-pipe support isolator bolts (Figure 8).

g. Remove the flange nuts from the Y-pipe (Figure 8).

h. Remove the Y-pipe from the vehicle.

i. Discard all three exhaust gaskets.

Figure 8 – Exhaust Cross-Under Pipe and Y-Pipe

 

12. Steering gear to the front crossmember fasteners on the left and right side of the steering gear. Hold the bolt while tightening the nut to 74 ft. lbs. (101 N·m) (Figure 9).

Figure 9 – Steering Gear

 

13. Stabilizer bar bracket to the front crossmember fasteners on the left and right side of the vehicle. Rear fasteners, hold the bolt while tightening the nut to 38 ft. lbs. (51.5 N·m). Front fasteners, nut is caged and does not need to be held. Tighten the bolt to 41 ft. lbs. (55 N·m) (Figure 10).

Figure 10 – Stabilizer Bar Bracket

 

14. Torque-strut to the front crossmember fastener. Hold the bolt while tightening the nut to 86 ft. lbs. (116 N·m) (Figure 11).

Figure 11 – Rear Torque-Strut

 

15. Front crossmember to the vehicle body upper bolts on the left and right side of the vehicle, two bolts total.  Tighten  the upper bolts to 89 ft. lbs. (120 N·m) (Figure 12).
16. Front crossmember to the vehicle body lower bolts on the left and right side of the vehicle, four bolts total. Tighten the lower bolts to 96 ft. lbs. (130 N·m) (Figure 12).

Figure 12 – Front Crossmember

 

17. Front lower control arm ball joint to knuckle fasteners on the left and right side of the vehicle. Remove and discard the bolt and nut. Install a NEW bolt and nut. Hold the bolt  while  tightening  the nut to 44 ft. lbs. + 48 degrees (60 N·m + 48 degrees) (Figure 13).

WARNING: Visually inspect that the lower control arm ball joint stud is fully inserted into knuckle before the pinch bolt is inserted into knuckle. Only the ball joint rubber boot should be visible below the knuckle; the ball joint stud should not be visible. Failure to fully and properly insert the ball joint stud into the knuckle could lead to wheel separation and loss of vehicle mobility and could  result  in  personal  injury  and/or  death (Figure 13).

Figure 13 – Lower Control Arm Ball Joint

 

18. Outer tie rod ball stud to knuckle; replace nut left and right side. Ensure ball stud does not rotate while tightening nut to 30 ft. lbs. + 90 degrees (40 N·m + 90 degrees) (Figure 14).

Figure 14 – Outer Tie Rod

 

19. Front suspension strut to the knuckle fasteners on the left and right side of the vehicle. Hold the bolt while tightening the nut to 81 ft. lbs. (110 N·m) (Figure 15).

Figure 15 – Front Suspension Strut

 

20. Front stabilizer bar link to the front suspension strut on the left and right side of the vehicle. Tighten the nut to 37 ft. lbs. (50 N·m) (Figure 16).

Figure 16 – Stabilizer Bar Link

 

21. Replace the front axle nut securing the halfshaft to the wheel bearing, left and right side. Tighten the nut to 178 ft. lbs. (200 N·m). Crimp the  nut in two places using Front Hub Staking Tool 10287 (Figure 17).

NOTE: The nut must be crimped in two places 180 degrees apart in direct line with the axle key slots  as shown in (Figure 17).

Figure 17 – Front Axle Nut

 

22. For vehicles equipped with a 3.6L engine, perform the following steps:

a. Use a new gasket between the catalytic converter and the Y-pipe. Install the Y-pipe between the catalytic converter and the resonator/muffler assembly.

b. Install the flange nuts securing the Y-pipe to the catalytic converter. Tighten the flange nuts to 18 ft. lbs. (25 N·m) (Figure 8).

c. Install the Y-pipe  support isolator bolts. Tighten the isolator bolts to 18 ft. lbs. (25 N·m) (Figure 8).

d. Tighten the muffler to Y-pipe clamp to 41 ft. lbs. (55 N·m) (Figure 8).

e. Use a new gasket between the catalytic converter and cross-under pipe. Also use a new gasket between the Y-pipe and cross-under pipe. Install the cross- under pipe between the catalytic converter and the Y-pipe.

f. Install the front cross-under pipe flange nuts. Tighten the flange nuts to 18 ft. lbs. (25 N·m) (Figure 8).

g. Install the cross-under pipe support bolt. Tighten the cross-under pipe support bolt to 17 ft. lbs. (23 N·m) (Figure 8).

h. Install the rear flange nuts to the cross-under pipe. Tighten the flange nuts to 18 ft. lbs. (25 N·m) (Figure 8).

23. Install the underbody splash shield and Tighten the fasteners to 53 in. lbs. (6 N·m) (Figure 7).
24. Install the left and right side rear wheelhouse liners and fasteners. Tighten the fasteners securely (Figure 1).
25. Install all four wheels. Tighten the wheel mounting lug bolts to 103 ft. lbs.  (140 N·m).
26. 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
Tighten Chassis Fasteners (3.6L Engine)	13-S5-91-82	2.1 hours
Tighten Chassis Fasteners (2.4L Engine)	13-S5-91-83	1.6 hours

 

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

 

CHASSIS FASTENERS

 

IMPORTANT SAFETY RECALL
S59 / NHTSA 16V-589

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 2016 model year Chrysler 200 vehicles. 

The problem is…	Specific  front  and/or  rear  chassis  component  fasteners  on  your  vehicle  were    not tightened to the proper torque specification. Loose chassis component fasteners could alter the vehicle’s handling characteristics and cause a crash without warning.
What your dealer will do…	FCA will repair your vehicle free of charge. To do this, your dealer will replace and/or tighten the chassis fasteners to the proper torque specifications. The work will take about 2½ hours 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.  Ask the dealer to hold the parts for your vehicle or to order them  before your 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.