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November 24, 2021 NHTSA CAMPAIGN NUMBER: 21V925000
Side Curtain Air Bag May Deploy Improperly
An air bag that deploys improperly can increase the risk of injury in a crash.
NHTSA Campaign Number: 21V925
Manufacturer Chrysler (FCA US, LLC)
Components AIR BAGS
Potential Number of Units Affected 132
Summary
Chrysler (FCA US, LLC) is recalling certain 2021-2022 Ram 2500, Ram 3500, and 2021 Ram 1500 Classic pickup trucks. The side air bag inflatable curtain (SABIC) assemblies may have been manufactured with the incorrect amount of compressed gas, which can result in an improper air bag deployment.
Remedy
Dealers will replace the SABIC assemblies, free of charge. Owner notification letters were mailed January 17, 2022. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC’s number for this recall is Y99.
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.nhtsa.gov.
Check if your Vehicle has a Recall
New Safety Recall Advanced Communication – Y99
FCA US LLC (FCA US) has announced a safety recall on certain 2021 Model Year (DS) Ram 1500 Pickup, 2021 and 2022 Model Year (DJ) Ram 2500 Pickup and (D2) 3500 Pickup vehicles.
REASON FOR THIS SAFETY RECALL
Some of the above vehicles may have been built with a Side Air Bag Inflatable Curtain (SABIC) assembly containing an inflator with out of specification propellant gas mass. SABIC assemblies with low gas mass may result in non-deployment or low/slow deployment and high gas mass may result in aggressive deployment of the air bag, which may increase the risk of occupant injury in certain crashes.
SERVICE ACTION
FCA US will conduct a voluntary safety recall to replace the SABIC assembly. The remedy for this condition is not currently available. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 1st Quarter of 2022.
Revision 3 June 2022
Dealer Service Instructions for:
Safety Recall Y99 / NHTSA 21V-925 Side Air Bag Inflatable Curtain Inflator
Remedy Available
2021 | (DS) | Ram 1500 Pickup |
2021 – 2022 | (DJ) | Ram 2500 Pickup |
2021 – 2022 | (D2) | Ram 3500 Pickup |
NOTE: Some vehicles above may have been identified as not involved in this recall 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 Side Air Bag Inflatable Curtain (SABIC) on about 168 of the above vehicles may have been built with an inflator with out of specification propellant gas mass. SABIC assemblies with low gas mass may result in non-deployment or low/slow deployment and high gas mass may result in aggressive deployment of the air bag, which may increase the risk of occupant injury in certain crashes.
Repair
Identify the VIN below and the SABIC required to be replaced.
Parts Information
Part Number | Description |
CSSLY551AA | Right – Crew |
CSSLY552AA | Left – Crew |
CSSLY553AA | Right – Quad |
CSSLY554AA | Left – Quad |
CSSLY555AA | Right – Mega |
CSSLY556AA | Left – Mega |
CSSLY557AA | Right – Standard |
CSSLY558AA | Left – Standard |
Part Number | Required | Description |
06036773AA | 2 | Bolt |
06036690AA | 2 | Bolt, (Mega and Quad ONLY) |
Special Tools
The following special tools are required to perform this repair:
➢ NPN | wiTECH MicroPod II![]() |
➢ NPN | Laptop Computer |
➢ NPN | wiTECH Software |
➢ C-4755 | Trim Stick or equivalent |
Service Procedure
Follow the specific service procedure below for the vehicle being serviced:
A. Standard Cab – Page 6
B. Quad Cab – Page 17
C. Crew Cab – Page 33
D. Mega Cab – Page 47
Service Procedure [Continued] in PDF
Chronology :
- On November 8, 2021, FCA US LLC (“FCA US”) Quality was notified that, during a component test deployment of a SABIC at the supplier, the inflator did not fully inflate the cushion.
- On November 9, 2021, the FCA US Technical Safety and Regulatory Compliance (“TSRC”) organization opened an investigation and discovered that some SABIC assembly inflators with out of specification gas mass may have been built into some Ram 1500 Classic, Ram 2500, and Ram 3500 vehicles.
- On November 17, 2021, FCA US TSRC determined that the SABICs with suspect inflators were shipped to FCA US and built into vehicles from January 28, 2021, to November 8, 2021.
- As of November 18, 2021, FCA US has identified zero customer assistance records, zero warranty claims, and zero field reports potentially relating to this issue for all markets.
- As of November 18, 2021, FCA US is not aware of any accidents or injuries potentially relating to this issue for all markets.
- On November 18, 2021, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles.
5 Affected Products
Vehicles
MAKE | MODEL | YEAR |
RAM | 1500 | 2021 |
RAM | 2500 | 2021-2022 |
RAM | 3500 | 2021-2022 |
24 Associated Documents
ISSUED Owner Notification Letter(Part 577)
RCONL-21V925-7992.pdf 516.673KB
Manufacturer Notices(to Dealers,etc) – FCA US LLC (FCA US) has announced a safety recall on certain 2021 through 2022 Model Year (DS) Ram 1500 Pickup, (DJ) Ram 2500 Pickup, (D2) Ram 3500 Pickup and (DX) Ram Truck (Mexico) vehicles.
RCMN-21V925-6427.pdf 100.718KB
Manufacturer Notices(to Dealers,etc) – NSRAC re New Safety Recall Advanced Communication Y99 FCA US LLC (FCA US) has announced a safety recall on certain 2021 Model Year (DS) Ram 1500 Pickup, 2021 and 2022 Model Year (DJ) Ram 2500 Pickup and (D2) 3500 Pickup vehicles
Defect Notice 573 Report
RCLRPT-21V925-7013.PDF 216.951KB
Recall Acknowledgement
RCAK-21V925-3961.pdf 645.214KB
Manufacturer Notices(to Dealers,etc) – NSRAC re New Safety Recall Advanced Communication Y99 FCA US LLC (FCA US) has announced a safety recall on certain 2021 Model Year (DS) Ram 1500 Pickup, 2021 and 2022 Model Year (DJ) Ram 2500 Pickup and (D2) 3500 Pickup vehicles.
RCMN-21V925-2969.pdf 100.004KB
Remedy Instructions and TSB
RCRIT-21V925-4842.pdf 2792.81KB
Remedy Instructions and TSB
RCRIT-21V925-9505.pdf 4297.332KB
Recall 573 Report
RCLRPT-21V925-7832.PDF 216.961KB
Manufacturer Notices(to Dealers,etc) – NSRAC re FCA US LLC (FCA US) has announced a safety recall on certain 2021 through 2022 Model Year (DS) Ram 1500 Pickup, (DJ) Ram 2500 Pickup, (D2) Ram 3500 Pickup and (DX) Ram Truck (Mexico) vehicles.
Remedy Instructions and TSB
RCRIT-21V925-7510.pdf 2357.458KB
Remedy Instructions and TSB
RCRIT-21V925-9450.pdf 3842.376KB
ISSUED Owner Notification Letter(Part 577)
RCONL-21V925-9727.pdf 517.231KB
Remedy Instructions and TSB
RCRIT-21V925-5543.pdf 2357.873KB
Recall Quarterly Report #1, 2022-1
RCLQRT-21V925-0852.PDF 211.152KB
Remedy Instructions and TSB
RCRIT-21V925-5752.pdf 2349.501KB
Manufacturer Notices(to Dealers,etc) – Safety Recall Z07 / NHTSA 21V-925 Side Air Bag Inflatable Curtain Inflator
RCMN-21V925-6848.pdf 1788.082KB
ISSUED Renotification Notice
Miscellaneous Document – Safety Recall Email
RMISC-21V925-2478.pdf 254.18KB
Miscellaneous Document – Safety Recall Email
RMISC-21V925-2219.pdf 253.136KB
Recall Quarterly Report #2, 2022-2
RCLQRT-21V925-6924.PDF 211.25KB
ISSUED Renotification Notice
RCRN-21V925-6273.pdf 142.599KB
ISSUED Renotification Notice
RCRN-21V925-1465.pdf 142.608KB
Recall Quarterly Report #3, 2022-3
RCLQRT-21V925-2546.PDF 211.335KB
Latest Recalls Documents
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V925&docType=RCL
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Last update on 2024-06-13 / Affiliate links / Images from Amazon Product Advertising API
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SEOCONTENT-START
View as web uag~ IMPORTANT SAFETY RECALL INFORMATION Issued in Accordance With Federal Law N**H**T*S A www.nhtsa.gov URGENT SAFETY RECALL NOTICE Your 2021 RAM 3500 TRADESMAN CREW CAB 4X4 is under recall for SABIC Inflator. To schedule your recall repair contact your dealership or the FCA US Recall Team at 1-800-853-1403 .. Recall notice issued to: Vehicle information: VIN 2021 RAM 3500 TRADESMAN CREW CAB 4X4 Recall information: Y99/NHTSA 21 V-925 Visit recalls.mop_ar.com for more information or call the FCA US Recall Team at 1-800-853-1403. Details of the Recall Your vehicle may have been built with a Side Air Bag Inflatable Curtain (SABIC) assembly containing an inflator with out of specification propellant gas mass. SABIC assemblies with low gas mass may result in non-deployment or low/slow deployment and high gas mass may result in aggressive deployment of the air bag which may increase the risk of occupant injury in certain crashes. FCA US will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the Side Air Bag Inflatable Curtain (SABIC) assembly. The estimated repair time is about 3 hours. In addition, your dealer will require your vehicle for proper check-in, preparation, and check-out during your visit, which may require more time. Your time is important to us, so we recommend that you schedule a service appointment to minimize your inconvenience. How do I schedule my FREE repair? ♦ Simply contact your Chrysler, Jeep®, Dodge or RAM dealer right away to schedule a service appointment. We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you for your attention to this important matter. Customer Assistance/Field Operations FCA US LLC Team 1-800-853-1403. recalls.moP.ar.com
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View as web uag~ IMPORTANT SAFETY RECALL INFORMATION Issued in Accordance With Federal Law N**H**T*S A www.nhtsa.gov URGENT SAFETY RECALL NOTICE Your 2022 RAM 2500 TRADESMAN CREW CAB 4X4 is under recall for SABIC Inflator. To schedule your recall repair contact your dealership or the FCA US Recall Team at 1-800-853-1403 .. Recall notice issued to: Vehicle information: VIN 2022 RAM 2500 TRADESMAN CREW CAB 4X4 Recall information: Z07 /NHTSA 21 V-925 Visit recalls.mop_ar.com for more information or call the FCA US Recall Team at 1-800-853-1403. Details of the Recall Your vehicle may have been built with a Side Air Bag Inflatable Curtain (SABIC) assembly containing an inflator with out of specification propellant gas mass. SABIC assemblies with low gas mass may result in non-deployment or low/slow deployment and high gas mass may result in aggressive deployment of the air bag which may increase the risk of occupant injury in certain crashes. FCA US will repair your vehicle free of charge (parts and labor). To do this, your dealer will inspect and if necessary, replace one or both SABI C’s as needed. The estimated repair time is 3 hours. In addition, your dealer will require your vehicle for proper check-in, preparation, and check-out during your visit, which may require more time. Your time is important to us, so we recommend that you schedule a service appointment to minimize your inconvenience. How do I schedule my FREE repair? ♦ Simply contact your Chrysler, Jeep®, Dodge or RAM dealer right away to schedule a service appointment. We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you for your attention to this important matter. Customer Assistance/Field Operations FCA US LLC Team 1-800-853-1403. recalls.moP.ar.com
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Schedule your FREE repair today! URGENT SAFETY RECALL SIDE AIR BAG INFLATABLE CURTAIN INFLATOR — Y99/21V-925 [MY Make Model] AA111111 Dear CUSTOMER NAME: Please bring your vehicle and this card to your scheduled appointment. We apologize for any inconvenience and do appreciate your attention to this urgent matter. Safety recall campaign Y99/21V-925 is open on your [MY Make Model]. ATENCIÓN! La unidad descrita en esta carta tiene un llamado a revisión pendiente por realizer. Para protegerlo a usted y a su familia, es urgente que se comunique con el grupo FCA US al teléfono 1-800-853-1403 con el fin de programar una cita y se reparada su unidad sin costo para usted. 0001617/#103532/Y99-FST Call 1-800-853-1403 Visit recalls.mopar.com to locate your closest dealer Download the Mopar Owner’s Companion App at either the App or Google Play Stores LOGO VEHICLE PICTURE
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Schedule your FREE repair today! URGENT SAFETY RECALL SIDE AIR BAG INFLATABLE CURTAIN INFLATOR — Y99/21V-925 [MY Make Model] AA111111 Dear CUSTOMER NAME: Please bring your vehicle and this card to your scheduled appointment. We apologize for any inconvenience and do appreciate your attention to this urgent matter. Safety recall campaign Y99/21V-925 is open on your [MY Make Model]. ATENCIÓN! La unidad descrita en esta carta tiene un llamado a revisión pendiente por realizer. Para protegerlo a usted y a su familia, es urgente que se comunique con el grupo FCA US al teléfono 1-800-853-1403 con el fin de programar una cita y se reparada su unidad sin costo para usted. 0000008/#104026/Y99-FSP Call 1-800-853-1403 Visit recalls.mopar.com to locate your closest dealer Download the Mopar Owner’s Companion App at either the App or Google Play Stores LOGO VEHICLE PICTURE
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Schedule your FREE repair today! URGENT SAFETY RECALL SIDE AIR BAG INFLATABLE CURTAIN — Z07/21V-925 [MY Make Model] AA111111 Dear CUSTOMER NAME: Please bring your vehicle and this card to your scheduled appointment. We apologize for any inconvenience and do appreciate your attention to this urgent matter. Safety recall campaign Z07/21V-925 is open on your [MY Make Model]. ATENCIÓN! La unidad descrita en esta carta tiene un llamado a revisión pendiente por realizer. Para protegerlo a usted y a su familia, es urgente que se comunique con el grupo FCA US al teléfono 1-800-853-1403 con el fin de programar una cita y se reparada su unidad sin costo para usted. 0000004/#104026/Z07-FSP Call 1-800-853-1403 Visit recalls.mopar.com to locate your closest dealer Download the Mopar Owner’s Companion App at either the App or Google Play Stores LOGO VEHICLE PICTURE
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© Copyright 2022, FCA US LLC, All Rights Reserved (kka) Revision 3 June 2022 Dealer Service Instructions for: Safety Recall Y99 / NHTSA 21V-925 Side Air Bag Inflatable Curtain Inflator NOTE: Revised service procedure and LOP time allowance. 2021 (DS) Ram 1500 Pickup 2021 – 2022 (DJ) Ram 2500 Pickup 2021 – 2022 (D2) Ram 3500 Pickup NOTE: Some vehicles above may have been identified as not involved in this recall and therefore have been excluded from this recall. The Side Air Bag Inflatable Curtain (SABIC) on about 168 of the above vehicles may have been built with an inflator with out of specification propellant gas mass. SABIC assemblies with low gas mass may result in non-deployment or low/slow deployment and high gas mass may result in aggressive deployment of the air bag, which may increase the risk of occupant injury in certain crashes. Remedy Available 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 Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 2 Identify the VIN below and the SABIC required to be replaced. VIN Last 8 Part Number VIN Last 8 Part Number CSSLY551AA CSSLY552AA CSSLY551AA CSSLY552AA CSSLY552AA CSSLY552AA CSSLY551AA CSSLY552AA CSSLY551AA CSSLY552AA CSSLY551AA CSSLY552AA CSSLY552AA CSSLY552AA CSSLY551AA CSSLY551AA CSSLY551AA CSSLY551AA CSSLY552AA CSSLY552AA CSSLY551AA CSSLY551AA CSSLY551AA CSSLY552AA CSSLY551AA CSSLY552AA CSSLY552AA CSSLY552AA CSSLY552AA CSSLY552AA CSSLY551AA CSSLY552AA CSSLY552AA CSSLY552AA CSSLY552AA CSSLY557AA CSSLY551AA CSSLY552AA CSSLY551AA CSSLY552AA CSSLY555AA CSSLY551AA CSSLY551AA CSSLY551AA CSSLY551AA CSSLY551AA CSSLY555AA CSSLY552AA CSSLY552AA CSSLY551AA CSSLY552AA CSSLY551AA CSSLY558AA CSSLY551AA CSSLY552AA CSSLY551AA CSSLY551AA CSSLY551AA CSSLY552AA CSSLY551AA CSSLY552AA CSSLY551AA CSSLY552AA CSSLY551AA CSSLY555AA CSSLY552AA CSSLY552AA CSSLY552AA CSSLY551AA CSSLY552AA CSSLY552AA CSSLY551AA CSSLY552AA CSSLY554AA CSSLY558AA CSSLY554AA CSSLY551AA CSSLY553AA CSSLY551AA CSSLY554AA CSSLY556AA CSSLY553AA CSSLY552AA CSSLY551AA Repair Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 3 VIN Last 8 Part Number VIN Last 8 Part Number CSSLY553AA CSSLY552AA CSSLY553AA CSSLY551AA CSSLY554AA CSSLY552AA CSSLY553AA CSSLY552AA CSSLY554AA CSSLY552AA CSSLY553AA CSSLY551AA CSSLY553AA CSSLY552AA CSSLY554AA CSSLY551AA CSSLY553AA CSSLY551AA CSSLY553AA CSSLY551AA CSSLY554AA CSSLY552AA CSSLY553AA CSSLY552AA CSSLY553AA CSSLY551AA CSSLY553AA CSSLY551AA CSSLY553AA CSSLY551AA CSSLY553AA CSSLY552AA CSSLY553AA CSSLY552AA CSSLY553AA CSSLY551AA CSSLY553AA CSSLY552AA CSSLY553AA CSSLY552AA CSSLY553AA CSSLY552AA CSSLY554AA CSSLY551AA CSSLY551AA CSSLY551AA CSSLY553AA CSSLY551AA CSSLY553AA CSSLY552AA CSSLY551AA CSSLY552AA CSSLY553AA CSSLY552AA CSSLY553AA CSSLY552AA CSSLY551AA CSSLY551AA CSSLY554AA CSSLY552AA CSSLY553AA CSSLY551AA CSSLY554AA CSSLY552AA CSSLY552AA CSSLY551AA CSSLY551AA CSSLY551AA CSSLY552AA CSSLY557AA CSSLY551AA CSSLY552AA CSSLY551AA CSSLY551AA CSSLY552AA CSSLY552AA CSSLY551AA CSSLY551AA CSSLY558AA CSSLY551AA CSSLY552AA CSSLY551AA CSSLY551AA CSSLY552AA Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 4 Part Number Description CSSLY551AA Right – Crew CSSLY552AA Left – Crew CSSLY553AA Right – Quad CSSLY554AA Left – Quad CSSLY555AA Right – Mega CSSLY556AA Left – Mega CSSLY557AA Right – Standard CSSLY558AA Left – Standard Part Number Required Description 06036773AA 2 Bolt 06036690AA 2 Bolt, (Mega and Quad ONLY) No parts return required for this campaign. Dispose of all non-deployed air bags in a manner consistent with state, provincial, local and federal regulations. Provided packaging is not authorized for the transport of the recalled SABIC module. Parts will need to be either deployed on-site or transported in alternative approved containers. The following special tools are required to perform this repair: ➢ NPN wiTECH MicroPod II ➢ NPN Laptop Computer ➢ NPN wiTECH Software ➢ C-4755 Trim Stick or equivalent Parts Information Parts Return Special Tools Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 5 Follow the specific service procedure below for the vehicle being serviced: A. Standard Cab – Page 6 B. Quad Cab – Page 17 C. Crew Cab – Page 33 D. Mega Cab – Page 47 Service Procedure Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 6 A. Standard Cab 1. Using a small flat-bladed tool, carefully open the two fastener covers (3) located in the A-pillar trim panel (2) (Figure 1). 2. Remove the two bolts (4) that secure the A-pillar trim panel to the A-pillar (1) and remove the trim panel (Figure 1). 3. Push in the buttons on front seat headrest sleeves then pull the headrest up and remove (Figure 2). 4. Fold the seats forward. Service Procedure [Continued] Figure 1 – A-Pillar Figure 2 – Front Seat Head Rest Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 7 5. Release the upper retaining clips of the B-pillar lower trim panel to allow for removal of the B-pillar upper trim panel (Figure 3). 6. Separate the seatbelt turning loop cover then remove the turning loop bolt (Figure 4). Service Procedure [Continued] Figure 3 – B-Pillar Lower Trim Panel Figure 4 – Seat Belt Turning Loop B-PILLAR LOWER TRIM PANEL COVER BOLT Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 8 7. Using a trim stick or equivalent, release the B-pillar airbag applique then remove the screw that secures the upper trim panel (Figure 5). 8. Release the retaining clips and remove the B-pillar upper trim panel (1) (Figure 6). 9. Recline seat backs rearward to allow for room to lower the headliner. Service Procedure [Continued] Figure 5 – B-Pillar Upper Trim Panel Fastener Figure 6 – B-Pillar Upper Trim Panel APPLIQUE SCREW Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 9 10. Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable. Wait two minutes for the system capacitor to discharge before further service. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the side curtain airbag, or becoming entrapped between the side curtain airbag cushion and the headliner. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged side curtain airbag (also known as Side Air Bag Inflatable Curtain/SABIC). If the airbag is ineffective or damaged, but not deployed, review local ordinances regarding recommended procedures for handling and disposal of Non-Deployed Supplemental Restraints. NOTE: If a side curtain airbag is being removed, but has not been deployed, the headliner does not need to be removed from the passenger compartment. Lowering the headliner and resting it on the seat backs will allow enough clearance to remove the side curtain airbag from the vehicle. Service Procedure [Continued] Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 10 CAUTION: Hands should be clean or clean cloth gloves used when handling the visors and headliner to avoid marks or damage. 11. Separate the visor from the support (1) then remove the screw and remove the visor support (Figure 7). 12. Remove the visor screws (2) then remove the visor (Figure 7). Using a small flat bladed tool or equivalent, release the retaining tabs (1) and separate the visor from the headliner (Figure 8). 13. Disconnect the visor electrical connector if equipped. NOTE: In some cases, the wire harness for the visor vanity mirror may be glued to the top side of the headliner and may be a little difficult to release. 14. Using a small flat bladed tool, open the coat hook screw cover (2) then remove the screw and coat hook (Figure 9). Service Procedure [Continued] Figure 7 – Visors Figure 9 – Coat Hook Figure 8 – Visors Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 11 15. As necessary, release the headliner wiring harness clips (3) from the A-pillar to allow enough wiring harness slack for lowering the headliner (Figure 10). 16. Release the door seals from the door openings to allow for lowering of the headliner. 17. Carefully lower the headliner allowing it to rest on the seat backs and instrument panel (Figure 11). CAUTION: Disconnect any wiring harness electrical connectors as necessary to allow enough wiring harness slack for lowering headliner. It will not be necessary to remove the headliner from the vehicle. 18. Obtain the appropriate replacement SABIC(s) for the vehicle based on its VIN. Service Procedure [Continued] Figure 10 – Headliner Harness Figure 11 – Headliner HEADLINER Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 12 19. The body wire harness connector is secured by integral latches to the connector receptacle on the inflator. Pinch both latches firmly, then pull the connector straight out from the airbag inflator to disconnect it from the connector receptacle (Figure 12). 20. Remove the four bolts that secure the side curtain airbag to the inner roof rail and A-pillar (Figure 12). 21. Disengage the one plastic push-in retainer that secures the side curtain airbag tether to the inner A-pillar (Figure 12). 22. Slide the inflator rearward far enough to disengage the T-tab at the front of the inflator bracket from the keyed T-slot in the inner roof rail over the front door opening (Figure 13). 23. Remove the SABIC from the vehicle as a unit and DISCARD following local ordinances and recommended procedures for handling and disposal of non-deployed supplemental restraints. Provided packaging is not authorized for the transport of the recalled SABIC Module. Parts will need to be either deployed on-site or transported in alternative approved containers. Service Procedure [Continued] Figure 12 – SABIC BOLT BOLT BOLT BOLT CONNECTOR RETAINER INFLATOR SABIC Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 13 24. Check to be certain that the two spring nuts are properly installed in the inner roof rail and that they are in good condition. 25. Position the NEW SABIC into the vehicle as a unit (Figure 12). 26. Insert the T-tab at the front of the inflator bracket into the keyed T-slot in the inner roof rail over the front door opening and slide the inflator forward to engage it (Figure 13). 27. Ensure the tether is not twisted then engage the one plastic push-in retainer that secures the side curtain airbag front tether to the assist handle bracket on the inner A-pillar (Figure 12). 28. Working from rear to front, install and tighten the four bolts that secure the side curtain airbag to the inner roof rail and A-pillar. Tighten the bolts to 7 N·m (62 in. lbs.) (Figure 12). 29. Connect the body wire harness connector for the side curtain airbag to the connector receptacle of the inflator. Be certain that each connector is fully engaged in its receptacle by listening carefully for a distinct, audible click as the connector latches snap into place (Figure 12). Service Procedure [Continued] Figure 13 – SABIC Inflator T-Tab and Inner Roof Rail T-Slot T-SLOT T-TAB SABIC Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 14 CAUTION: Hands should be clean or clean cloth gloves used when handling the headliner to avoid damage to the headliner. 30. Raise the headliner into proper vehicle position and connect any electrical connectors previously disconnected from the headliner. CAUTION: Be certain to avoid any wiring or drain tube interference. 31. Position the coat hooks (5) onto the headliner and install the screws tightening securely into the mounting clips then close the screw cap fully (Figure 9). 32. Position the visor supports (1) onto the headliner and install the screws into the mounting clips (Figure 7). 33. If equipped with illuminated vanity mirror, connect the wire harness connector. 34. Position the visor to the headliner and install the screws (2) that secure the visor to the roof panel. Tighten the screws to 6 N·m (53 in. lbs.) (Figure 7). 35. Reattach any headliner wiring harness clips (3) removed from the A-pillar to allow slack while lowering headliner (Figure 10). WARNING: Do not connect the negative battery cable at this time. The Supplemental Restraint System (SRS) Verification Test procedure should be performed following service of any SRS component. NOTE: The following procedure should be performed using a diagnostic scan tool to verify proper Supplemental Restraint System (SRS) operation following the service or replacement of any SRS component. Refer to the appropriate diagnostic procedures. 36. During the following test, the negative cable remains disconnected and isolated from the battery, as it was during the Supplemental Restraint System (SRS) component removal and installation procedures. Service Procedure [Continued] Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 15 37. Be certain that the diagnostic scan tool contains the latest version of the proper diagnostic software. Connect the scan tool to the 16-way Data Link Connector (DLC). The DLC is located on the driver side lower edge of the instrument panel, near the steering column opening cover and outboard of the steering column. 38. Transition the status of the ignition switch (also known as the Keyless Ignition Node/KIN or IGnition Node Module/IGNM) to ON and exit the vehicle with the scan tool. 39. Check to be certain that nobody is in the vehicle, then connect the negative cable to the battery. 40. Using the scan tool, read and record the active (current) Diagnostic Trouble Code (DTC) data. 41. Next, use the scan tool to read and record any stored (historical) DTC data. 42. If any SRS related DTC is found in the previous two steps, refer to the appropriate diagnostic information. 43. Use the scan tool to erase the stored DTC data. If any problems remain, the stored DTC data will not erase. Refer to the appropriate diagnostic information to diagnose any stored DTC that will not erase. If the stored DTC information is successfully erased, continue to the next step. 44. Transition the status of the ignition switch to OFF for about 15 seconds, and then back to ON. Observe the airbag indicator in the instrument cluster. It should light from four to six seconds, and then go out. This indicates that the SRS is functioning normally and that the repairs are complete. If the airbag indicator fails to light, or lights and stays ON, there is still an active SRS fault or malfunction. Refer to the appropriate diagnostic information to diagnose the problem. 45. Raise the seat backs and position the seats forward. 46. Install the B-pillar upper trim panel (1) and engage the retaining clips fully (Figure 6). Service Procedure [Continued] Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 16 47. Install and tighten the screw that secures the B-pillar upper trim panel then install the airbag applique cover (Figure 5). 48. Remove and DISCARD the bolt retainer and the bolt from the seat belt turning loop, save the spacer washer for reuse (Figure 14). 49. Using a NEW bolt and reusing the spacer washer, install the turning loop then tighten the bolt to 40 N·m (30 ft. lbs.) (Figure 4). 50. Install the turning loop cover (Figure 4). 51. Position the B-pillar lower trim panel and engage the retaining clips fully (Figure 3). NOTE: Ensure that all B-pillar fasteners are installed/engaged properly. 52. Install the front seat headrests (Figure 2). 53. Position the locating tab of the A-pillar trim panel (2) into the slot located in the top of the instrument panel (Figure 1). 54. Install the A-pillar trim panel onto the A-pillar (1) and install the two bolts (4). Tighten the bolts to 5 N·m (44 in. lbs.) (Figure 1). 55. Close the two fastener covers (3) located in the A-pillar trim panel (Figure 1). 56. Install the door seals around the door openings. 57. Return the vehicle to the customer or inventory. Service Procedure [Continued] Figure 14 – Headliner RETAINER BOLT SPACER WASHER Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 17 B. Quad Cab 1. Using a small flat-bladed tool, carefully open the two fastener covers (3) located in the A-pillar trim panel (2) (Figure 15). 2. Remove the two bolts (4) that secure the A-pillar trim panel to the A-pillar (1) and remove the trim panel (Figure 15). 3. Push in the buttons on front seat headrest sleeves then pull the headrest up and remove (Figure 16). 4. Position the front seats to the full forward position with the seat backs fully forward. Service Procedure [Continued] Figure 15 – A-Pillar Figure 16 – Head Rest Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 18 5. Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable. Wait two minutes for the system capacitor to discharge before further service. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the side curtain airbag, or becoming entrapped between the side curtain airbag cushion and the headliner. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged side curtain airbag (also known as Side Air Bag Inflatable Curtain/SABIC). If the airbag is ineffective or damaged, but not deployed, review local ordinances regarding recommended procedures for handling and disposal of Non-Deployed Supplemental Restraints. NOTE: If a side curtain airbag is being removed, but has not been deployed, the headliner does not need to be removed from the passenger compartment. Lowering the headliner and resting it on the seat backs will allow enough clearance to remove the side curtain airbag from the vehicle. Service Procedure [Continued] Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 19 6. Release the front and rear door sill scuff plates on either side of the B-pillar lower trim panel to allow for removal of the B-pillar lower trim panel (Figure 17). 7. Release the retaining clips and remove the B-pillar lower trim panel to allow for removal of the B-pillar upper trim panel (Figure 18). Service Procedure [Continued] Front Door Sill Rear Door Sill Figure 17 – Door Sill Scuff Plates Figure 18 – B-Pillar Lower Trim Panel SCUFF PLATE SCUFF PLATE Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 20 8. On the B-pillar, separate the seatbelt turning loop cover then remove the turning loop bolt (Figure 19). 9. On the B-pillar, use a small flat-bladed tool to carefully open the two fastener covers (2) located on the grab handle (Figure 20). 10. Remove the two bolts (3) that secure the grab handle to the B-pillar (Figure 20). 11. Using a trim stick C-4755 or equivalent, release the retaining clips that secure the B-pillar upper trim panel (1) then position the trim panel out of the way. It is not necessary to remove the seat belt from the trim panel (Figure 20). Service Procedure [Continued] Figure 19 – Seat Belt Turning Loop Figure 20 – B-Pillar Upper Trim Panel COVER BOLT Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 21 12. Using a small flat bladed tool, open the coat hook screw cover (2) then remove the screw and coat hook (Figure 21). 13. On the C-pillar, lift the seat belt turning loop cover then remove the turning loop bolt (Figure 22). Service Procedure [Continued] Figure 22 – Seat Belt Turning Loop COVER BOLT Figure 21 – Coat Hook Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 22 NOTE: Do not drop the screw inside the C-pillar, a magnetic screw driver may be helpful. 14. Using a trim stick or equivalent, release the C-pillar airbag applique then remove the screw that secures the upper trim panel (Figure 23). 15. Release the retaining clips and tilt the top of the C-pillar upper trim panel inward (Figure 24). Service Procedure [Continued] Figure 24 – C-Pillar Upper Trim Panel C-PILLAR TRIM Figure 23 – C-Pillar Upper Trim Panel SCREW APPLIQUE Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 23 CAUTION: Hands should be clean or clean cloth gloves used when handling the visors and headliner to avoid marks or damage. 16. If equipped with DVD monitor, remove the screws (2) and separate the monitor (1) from the roof (Figure 25). 17. If equipped with DVD monitor, disconnect the electrical connectors (1) (Figure 26). Service Procedure [Continued] Figure 25 – Rear Seat DVD Monitor Figure 26 – DVD Monitor Electrical Connectors Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 24 18. Separate the visor from the support (1) then remove the screw and remove the visor support (Figure 27). 19. Remove the visor screws (2) then remove the visor (Figure 27). Using a small flat bladed tool or equivalent, release the retaining tabs (1) and separate the visor from the headliner (Figure 28). 20. Disconnect the visor electrical connector if equipped. NOTE: In some cases, the wire harness for the visor vanity mirror may be glued to the top side of the headliner and may be a little difficult to release. 21. As necessary, release the headliner wiring harness clips (3) from the A-pillar to allow enough wiring harness slack for lowering the headliner (Figure 29). Service Procedure [Continued] Figure 27 – Visors Figure 28 – Visors Figure 29 – Headliner Harness Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 25 22. Release the door seals from the door openings to allow for lowering of the headliner. 23. Tilt the rear view mirror up to allow clearance for lowering the headliner (Figure 30). 24. Carefully tilt the front of the headliner (2) down to clear the rear view mirror then slide the headliner forward to clear the C-pillar trim while disconnecting any wiring harness electrical connectors (1) as necessary to allow enough wiring harness slack to lower the headliner (Figure 31). 25. lower the headliner (2) allowing it to rest on the seat backs and instrument panel (Figure 31). NOTE: It will not be necessary to remove the headliner from the vehicle. 26. Obtain the appropriate replacement SABIC(s) for the vehicle based on its VIN. Service Procedure [Continued] Figure 30 – Headliner Harness Figure 31 – Headliner Harness MIRROR HEADLINER Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 26 27. The body wire harness connector (5) is secured by integral latches to the connector receptacle on the inflator (4). Pinch both latches firmly, then pull the connector straight out from the airbag inflator to disconnect it from the connector receptacle (Figure 32). 28. Remove the six bolts (8) that secure the side curtain airbag (6) to the inner roof rail and A-pillar (Figure 32). 29. Disengage the plastic push-in retainer (9) that secures the side curtain airbag tether to the inner A-pillar (1) and the plastic push-in retainer (7) that secures the side curtain airbag to the inner roof rail (Figure 32). 30. Slide the inflator rearward far enough to disengage the T-tab at the front of the inflator bracket from the keyed T-slot in the inner roof rail over the rear door opening (Figure 33). 31. Remove the SABIC (6) from the vehicle as a unit and DISCARD following local ordinances and recommended procedures for handling and disposal of Non-Deployed Supplemental Restraints (Figure 32). Provided packaging is not authorized for the transport of the recalled SABIC Module. Parts will need to be either deployed on-site or transported in alternative approved containers. Service Procedure [Continued] Figure 32 – SABIC Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 27 32. Check to be certain that the spring nuts are properly installed in the inner roof rail and that they are in good condition. 33. Position the NEW SABIC (6) into the vehicle as a unit (Figure 32). 34. Insert the T-tab at the front of the inflator bracket into the keyed T-slot in the inner roof rail over the rear door opening and slide the inflator forward to engage it (Figure 33). 35. Engage the plastic push-in retainer (7) that secures the side curtain airbag to the inner roof rail and ensure the tether is not twisted then engage the plastic push-in retainer (9) that secures the side curtain airbag front tether to the assist handle bracket on the inner A-pillar (1) (Figure 32). 36. Working from rear to front, install and tighten the seven bolts (8) that secure the side curtain airbag (6) to the inner roof rail and A-pillar. Tighten the bolts to 7 N·m (62 in. lbs.) (Figure 32). 37. Connect the body wire harness connector (5) for the side curtain airbag to the connector receptacle of the inflator (4). Be certain that each connector is fully engaged in its receptacle by listening carefully for a distinct, audible click as the connector latches snap into place (Figure 32). Service Procedure [Continued] Figure 33 – SABIC Inflator T-Tab and Inner Roof Rail T-Slot T-SLOT T-TAB SABIC Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 28 CAUTION: Hands should be clean or clean cloth gloves used when handling the headliner to avoid damage to the headliner. 38. Raise the headliner into proper vehicle position and connect any electrical connectors previously disconnected from the headliner (Figure 31). CAUTION: Be certain to avoid any wiring or drain tube interference. 39. Tilt the rear view mirror down to support the headliner (Figure 30). 40. Reattach any headliner wiring harness clips (3) removed from the A-pillar to allow slack while lowering headliner (Figure 29). 41. Position the visor supports (1) onto the headliner and install the screws into the mounting clips (Figure 27). 42. If equipped with illuminated vanity mirror, connect the wire harness connector. 43. Position the visor to the headliner and install the screws (2) that secure the visor to the roof panel. Tighten the screws to 6 N·m (53 in. lbs.) (Figure 27). 44. If equipped with DVD monitor, connect the DVD monitor electrical connectors (1) (Figure 26). Position the DVD monitor to the roof then install and tighten the screws (2) (Figure 25). Service Procedure [Continued] Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 29 45. Position the upper trim to the C-pillar then engage the retaining clips (Figure 24). 46. Install and tighten the screw that secures the C-pillar upper trim panel. Then install the airbag applique (Figure 23). 47. Remove and DISCARD the bolt retainer and bolt from the seat belt turning loop, save the spacer washer for reuse (Figure 34). 48. Using a NEW bolt and reusing the spacer, install the turning loop then tighten the bolt to 40 N·m (30 ft. lbs.) (Figure 22). 49. Install the seat belt turning loop cover (Figure 22). 50. Position the coat hooks (5) onto the headliner and install the screws tightening securely into the mounting clips then close the screw cap fully (Figure 21). Service Procedure [Continued] Figure 34 – Turning Loop Bolt RETAINER BOLT SPACER Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 30 51. Install the B-pillar upper trim panel (1) and engage the retaining clips fully (Figure 20). 52. Install the grab handle bolts (3) and tighten to 5 N·m (44 in. lbs.). Close the fastener covers (2) (Figure 20). 53. Remove and DISCARD the bolt retainer and bolt from the seat belt turning loop, save the spacer washer for reuse (Figure 35). 54. Using a NEW bolt and reusing the spacer washer, install the turning loop then tighten the bolt to 40 N·m (30 ft. lbs.) (Figure 19). 55. Install the seat belt turning loop cover (Figure 19). 56. Position the B-pillar lower trim panel and engage the retaining clips fully (Figure 18). 57. Position the front and rear door sill scuff plates and engage the retainers (Figure 17). Service Procedure [Continued] Figure 35 – Turning Loop Bolt RETAINER BOLT SPACER WASHER Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 31 WARNING: Do not connect the negative battery cable at this time. The Supplemental Restraint System (SRS) Verification Test procedure should be performed following service of any SRS component. NOTE: The following procedure should be performed using a diagnostic scan tool to verify proper Supplemental Restraint System (SRS) operation following the service or replacement of any SRS component. Refer to the appropriate diagnostic procedures. 58. During the following test, the negative cable remains disconnected and isolated from the battery, as it was during the Supplemental Restraint System (SRS) component removal and installation procedures. 59. Be certain that the diagnostic scan tool contains the latest version of the proper diagnostic software. Connect the scan tool to the 16-way Data Link Connector (DLC). The DLC is located on the driver side lower edge of the instrument panel, near the steering column opening cover and outboard of the steering column. 60. Transition the status of the ignition switch (also known as the Keyless Ignition Node/KIN or IGnition Node Module/IGNM) to ON and exit the vehicle with the scan tool. 61. Check to be certain that nobody is in the vehicle, then connect the negative cable to the battery. Service Procedure [Continued] Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 32 62. Using the scan tool, read and record the active (current) Diagnostic Trouble Code (DTC) data. 63. Next, use the scan tool to read and record any stored (historical) DTC data. 64. If any SRS related DTC is found in the previous two steps, refer to the appropriate diagnostic information. 65. Use the scan tool to erase the stored DTC data. If any problems remain, the stored DTC data will not erase. Refer to the appropriate diagnostic information to diagnose any stored DTC that will not erase. If the stored DTC information is successfully erased, continue to the next step. 66. Transition the status of the ignition switch to OFF for about 15 seconds, and then back to ON. Observe the airbag indicator in the instrument cluster. It should light from four to six seconds, and then go out. This indicates that the SRS is functioning normally and that the repairs are complete. If the airbag indicator fails to light, or lights and stays ON, there is still an active SRS fault or malfunction. Refer to the appropriate diagnostic information to diagnose the problem. 67. Install the front seat headrests (Figure 16). 68. Position the locating tab of the A-pillar trim panel (2) into the slot located in the top of the instrument panel (Figure 15). 69. Install the A-pillar trim panel onto the A-pillar (1) and install the two bolts (4). Tighten the bolts to 5 N·m (44 in. lbs.) (Figure 15). 70. Close the two fastener covers (3) located in the A-pillar trim panel (Figure 15). 71. Install the door seals around the door openings. 72. Return the vehicle to the customer or inventory. Service Procedure [Continued] Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 33 C. Crew Cab 1. Using a small flat-bladed tool, carefully open the two fastener covers (3) located in the A-pillar trim panel (2) (Figure 36). 2. Remove the two bolts (4) that secure the A-pillar trim panel to the A-pillar (1) and remove the trim panel (Figure 36). 3. Push in the buttons on front seat headrest sleeves then pull the headrest up and remove (Figure 37). 4. Position the front seats to the full forward position with the seat backs fully forward. Service Procedure [Continued] Figure 36 – A-Pillar Figure 37 – Head Rest Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 34 5. Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable. Wait two minutes for the system capacitor to discharge before further service. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the side curtain airbag, or becoming entrapped between the side curtain airbag cushion and the headliner. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged side curtain airbag (also known as Side Air Bag Inflatable Curtain/SABIC). If the airbag is ineffective or damaged, but not deployed, review local ordinances regarding recommended procedures for handling and disposal of Non-Deployed Supplemental Restraints. NOTE: If a side curtain airbag is being removed, but has not been deployed, the headliner does not need to be removed from the passenger compartment. Lowering the headliner and resting it on the seat backs will allow enough clearance to remove the side curtain airbag from the vehicle. Service Procedure [Continued] Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 35 6. Release the front and rear door sill scuff plates on either side of the B-pillar lower trim panel to allow for removal of the B-pillar lower trim panel (Figure 38). 7. Release the retaining clips and remove the B-pillar lower trim panel to allow for removal of the B-pillar upper trim panel (Figure 39). Service Procedure [Continued] Front Door Sill Rear Door Sill Figure 38 – Door Sill Scuff Plates Figure 39 – B-Pillar Lower Trim Panel SCUFF PLATE SCUFF PLATE Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 36 8. On the B-pillar, separate the seatbelt turning loop cover then remove the turning loop bolt (Figure 40). 9. On the B-pillar, use a small flat-bladed tool to carefully open the two fastener covers (2) located on the grab handle (Figure 41). 10. Remove the two bolts (3) that secure the grab handle to the B-pillar (Figure 41). 11. Using a trim stick C-4755 or equivalent, release the retaining clips that secure the B-pillar upper trim panel (1) then position the trim panel out of the way. It is not necessary to remove the seat belt from the trim panel (Figure 41). Service Procedure [Continued] Figure 40 – Seat Belt Turning Loop Figure 41 – B-Pillar Upper Trim Panel COVER BOLT Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 37 12. Using a small flat bladed tool, open the coat hook screw cover (2) then remove the screw and coat hook (Figure 42). NOTE: Do not drop the screw inside the C-pillar, a magnetic screw driver may be helpful. 13. Using a trim stick or equivalent, release the C-pillar airbag applique then remove the screw that secures the upper trim panel (Figure 43). 14. Release the retaining clips and tilt the top of the C-pillar upper trim panel inward (Figure 44). Service Procedure [Continued] Figure 43 – C-Pillar Upper Trim Panel Figure 44 – C-Pillar Trim Panels APPLIQUE SCREW C-PILLAR UPPER TRIM PANEL Figure 42 – Coat Hook Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 38 15. If equipped with DVD monitor, remove the screws (2) and separate the monitor (1) from the roof (Figure 45). 16. If equipped with DVD monitor, disconnect the electrical connectors (1) (Figure 46). Service Procedure [Continued] Figure 45 – Rear Seat DVD Monitor Figure 46 – DVD Monitor Electrical Connectors Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 39 17. Separate the visor from the support (1) then remove the screw and remove the visor support (Figure 47). 18. Remove the visor screws (2) then remove the visor (Figure 47). Using a small flat bladed tool or equivalent, release the retaining tabs (1) and separate the visor from the headliner (Figure 48). 19. Disconnect the visor electrical connector if equipped. NOTE: In some cases, the wire harness for the visor vanity mirror may be glued to the top side of the headliner and may be a little difficult to release. 20. As necessary, release the headliner wiring harness clips (3) from the A-pillar to allow enough wiring harness slack for lowering the headliner (Figure 49). Service Procedure [Continued] Figure 47 – Visors Figure 49 – Headliner Harness Figure 48 – Visors Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 40 21. Release the door seals from the door openings to allow for lowering of the headliner. 22. Tilt the rear view mirror up to allow clearance for lowering the headliner (Figure 50). 23. Carefully tilt the front of the headliner (2) down to clear the rear view mirror then slide the headliner forward to clear the C-pillar trim while disconnecting any wiring harness electrical connectors (1) as necessary to allow enough wiring harness slack to lower the headliner (Figure 51). 24. lower the headliner (2) allowing it to rest on the seat backs and instrument panel (Figure 51). NOTE: It will not be necessary to remove the headliner from the vehicle. 25. Obtain the appropriate replacement SABIC(s) for the vehicle based on its VIN. Service Procedure [Continued] Figure 50 – Rearview Mirror Figure 51 – Headliner Harness MIRROR HEADLINER Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 41 26. The body wire harness connector (5) is secured by integral latches to the connector receptacle on the inflator (4). Pinch both latches firmly, then pull the connector straight out from the airbag inflator to disconnect it from the connector receptacle (Figure 52). 27. Remove the six bolts (8) that secure the side curtain airbag (6) to the inner roof rail and A-pillar (Figure 52). 28. Disengage the plastic push-in retainer (9) that secures the side curtain airbag tether to the inner A-pillar (1) and the plastic push-in retainer (7) that secures the side curtain airbag to the inner roof rail (Figure 52). 29. Slide the inflator rearward far enough to disengage the T-tab at the front of the inflator bracket from the keyed T-slot in the inner roof rail over the rear door opening (Figure 53). 30. Remove the SABIC (6) from the vehicle as a unit and DISCARD following local ordinances and recommended procedures for handling and disposal of Non-Deployed Supplemental Restraints (Figure 52). Provided packaging is not authorized for the transport of the recalled SABIC Module. Parts will need to be either deployed on-site or transported in alternative approved containers. Service Procedure [Continued] Figure 52 – SABIC Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 42 31. Check to be certain that the spring nuts are properly installed in the inner roof rail and that they are in good condition. 32. Position the NEW SABIC (6) into the vehicle as a unit (Figure 52). 33. Insert the T-tab at the front of the inflator bracket into the keyed T-slot in the inner roof rail over the rear door opening and slide the inflator forward to engage it (Figure 53). 34. Engage the plastic push-in retainer (7) that secures the side curtain airbag to the inner roof rail and ensure the tether is not twisted then engage the plastic push-in retainer (9) that secures the side curtain airbag front tether to the assist handle bracket on the inner A-pillar (1) (Figure 52). 35. Working from rear to front, install and tighten the seven bolts (8) that secure the side curtain airbag (6) to the inner roof rail and A-pillar. Tighten the bolts to 7 N·m (62 in. lbs.) (Figure 52). 36. Connect the body wire harness connector (5) for the side curtain airbag to the connector receptacle of the inflator (4). Be certain that each connector is fully engaged in its receptacle by listening carefully for a distinct, audible click as the connector latches snap into place (Figure 52). Service Procedure [Continued] Figure 53 – SABIC Inflator T-Tab and Inner Roof Rail T-Slot T-SLOT T-TAB SABIC Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 43 CAUTION: Hands should be clean or clean cloth gloves used when handling the headliner to avoid damage to the headliner. 37. Raise the headliner into proper vehicle position and connect any electrical connectors previously disconnected from the headliner (Figure 51). CAUTION: Be certain to avoid any wiring or drain tube interference. 38. Tilt the rear view mirror down to allow it to support the headliner (Figure 50). 39. Reattach any headliner wiring harness clips (3) removed from the A-pillar to allow slack while lowering headliner (Figure 49). 40. Position the visor supports (1) onto the headliner and install the screws into the mounting clips (Figure 47). 41. If equipped with illuminated vanity mirror, connect the wire harness connector. 42. Position the visor to the headliner and install the screws (2) that secure the visor to the roof panel. Tighten the screws to 6 N·m (53 in. lbs.) (Figure 47). 43. If equipped with DVD monitor, connect the DVD monitor electrical connectors (1) (Figure 46). Position the DVD monitor to the roof then install and tighten the screws (2) (Figure 45). 44. Position the upper trim panel to the C-pillar then engage the retaining clips (Figure 44). 45. Install and tighten the screw that secures the C-pillar upper trim panel. Then install the airbag applique (Figure 43). 46. Position the coat hooks (5) onto the headliner and install the screws tightening securely into the mounting clips then close the screw cap fully (Figure 42). Service Procedure [Continued] Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 44 47. Install the B-pillar upper trim panel (1) and engage the retaining clips fully (Figure 41). 48. Install the grab handle bolts (3) and tighten to 5 N·m (44 in. lbs.). Close the fastener covers (2) (Figure 41). 49. Remove and DISCARD the bolt retainer and the bolt from the seat belt turning loop, save the spacer washer for reuse (Figure 54). 50. Using a NEW bolt and reusing the spacer washer, install the turning loop then tighten the bolt to 40 N·m (30 ft. lbs.) (Figure 40). 51. Install the seat belt turning loop cover (Figure 40). 52. Position the B-pillar lower trim panel and engage the retaining clips fully (Figure 39). 53. Position the front and rear door sill scuff plates and engage the retainers (Figure 38). Service Procedure [Continued] Figure 54 – Turning Loop Bolt RETAINER BOLT SPACER WASHER Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 45 WARNING: Do not connect the negative battery cable at this time. The Supplemental Restraint System (SRS) Verification Test procedure should be performed following service of any SRS component. NOTE: The following procedure should be performed using a diagnostic scan tool to verify proper Supplemental Restraint System (SRS) operation following the service or replacement of any SRS component. Refer to the appropriate diagnostic procedures. 54. During the following test, the negative cable remains disconnected and isolated from the battery, as it was during the Supplemental Restraint System (SRS) component removal and installation procedures. 55. Be certain that the diagnostic scan tool contains the latest version of the proper diagnostic software. Connect the scan tool to the 16-way Data Link Connector (DLC). The DLC is located on the driver side lower edge of the instrument panel, near the steering column opening cover and outboard of the steering column. 56. Transition the status of the ignition switch (also known as the Keyless Ignition Node/KIN or IGnition Node Module/IGNM) to ON and exit the vehicle with the scan tool. 57. Check to be certain that nobody is in the vehicle, then connect the negative cable to the battery. Service Procedure [Continued] Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 46 58. Using the scan tool, read and record the active (current) Diagnostic Trouble Code (DTC) data. 59. Next, use the scan tool to read and record any stored (historical) DTC data. 60. If any SRS related DTC is found in the previous two steps, refer to the appropriate diagnostic information. 61. Use the scan tool to erase the stored DTC data. If any problems remain, the stored DTC data will not erase. Refer to the appropriate diagnostic information to diagnose any stored DTC that will not erase. If the stored DTC information is successfully erased, continue to the next step. 62. Transition the status of the ignition switch to OFF for about 15 seconds, and then back to ON. Observe the airbag indicator in the instrument cluster. It should light from four to six seconds, and then go out. This indicates that the SRS is functioning normally and that the repairs are complete. If the airbag indicator fails to light, or lights and stays ON, there is still an active SRS fault or malfunction. Refer to the appropriate diagnostic information to diagnose the problem. 63. Install the front seat headrests (Figure 37). 64. Position the locating tab of the A-pillar trim panel (2) into the slot located in the top of the instrument panel (Figure 36). 65. Install the A-pillar trim panel onto the A-pillar (1) and install the two bolts (4). Tighten the bolts to 5 N·m (44 in. lbs.) (Figure 36). 66. Close the two fastener covers (3) located in the A-pillar trim panel (Figure 36). 67. Install the door seals around the door openings. 68. Return the vehicle to the customer or inventory. Service Procedure [Continued] Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 47 D. Mega Cab 1. Using a small flat-bladed tool, carefully open the two fastener covers (3) located in the A-pillar trim panel (2) (Figure 55). 2. Remove the two bolts (4) that secure the A-pillar trim panel to the A-pillar (1) and remove the trim panel (Figure 55). 3. Push in the buttons on front seat headrest sleeves then pull the headrest up and remove (Figure 56). 4. Fold the seats forward. Service Procedure [Continued] Figure 55 – A-Pillar Figure 56 – Head Rest Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 48 5. Release the front and rear door sill scuff plates on either side of the B-pillar lower trim panel to allow for removal of the B-pillar lower trim panel (Figure 57). 6. Release the retaining clips and remove the B-pillar lower trim panel to allow for removal of the B-pillar upper trim panel (Figure 58). Service Procedure [Continued] Front Door Sill Rear Door Sill Figure 57 – Door Sill Scuff Plates Figure 58 – B-Pillar Lower Trim Panel SCUFF PLATE SCUFF PLATE Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 49 7. On the B-pillar, separate the seatbelt turning loop cover then remove the turning loop bolt (Figure 59). 8. On the B-pillar, use a small flat-bladed tool to carefully open the two fastener covers (2) located on the grab handle (Figure 60). 9. Remove the two bolts (3) that secure the grab handle to the B-pillar (Figure 60). 10. Using a trim stick C-4755 or equivalent, release the retaining clips that secure the B-pillar upper trim panel (1) then position the trim panel out of the way. It is not necessary to remove the seat belt from the trim panel (Figure 60). Service Procedure [Continued] Figure 59 – Seat Belt Turning Loop Figure 60 – B-Pillar Upper Trim Panel COVER BOLT Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 50 11. Fold the rear seat backs down. 12. Release the upper retaining clips of the lower C-pillar trim panel to allow for removal of the upper C-pillar trim panel (Figure 61). 13. On the C-pillar, lift the seat belt turning loop cover then remove the turning loop bolt (Figure 62). Service Procedure [Continued] Figure 61 – C-Pillar Lower Trim Panel Figure 62 – Seat Belt Turning Loop COVER BOLT LOWER TRIM PANEL Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 51 14. Using a trim stick or equivalent, release the B-pillar airbag applique then remove the screw that secures the upper trim panel (Figure 63). 15. Release the retaining clips and remove the C-pillar upper trim panel (1) (Figure 64). 16. Recline the front seat backs to allow for room to lower the headliner. Service Procedure [Continued] Figure 63 – C-Pillar Upper Trim Panel Fasteners Figure 64 – C-Pillar Upper Trim Panel APPLIQUE SCREW APPLIQUE SCREW Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 52 17. Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable. Wait two minutes for the system capacitor to discharge before further service. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the side curtain airbag, or becoming entrapped between the side curtain airbag cushion and the headliner. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged side curtain airbag (also known as Side Air Bag Inflatable Curtain/SABIC). If the airbag is ineffective or damaged, but not deployed, review local ordinances regarding recommended procedures for handling and disposal of Non-Deployed Supplemental Restraints. NOTE: If a side curtain airbag is being removed, but has not been deployed, the headliner does not need to be removed from the passenger compartment. Lowering the headliner and resting it on the seat backs will allow enough clearance to remove the side curtain airbag from the vehicle. Service Procedure [Continued] Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 53 CAUTION: Hands should be clean or clean cloth gloves used when handling the visors and headliner to avoid marks or damage. 18. If equipped with DVD monitor, remove the screws (2) and separate the monitor (1) from the roof (Figure 65). 19. If equipped with DVD monitor, disconnect the electrical connectors (1) (Figure 66). Service Procedure [Continued] Figure 65 – Rear Seat DVD Monitor Figure 66 – DVD Monitor Electrical Connectors Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 54 20. Separate the visor from the support (1) then remove the screw and remove the visor support (Figure 67). 21. Remove the visor screws (2) then remove the visor (Figure 78). Using a small flat bladed tool or equivalent, release the retaining tabs (1) and separate the visor from the headliner (Figure 68). 22. Disconnect the visor electrical connector if equipped. NOTE: In some cases, the wire harness for the visor vanity mirror may be glued to the top side of the headliner and may be a little difficult to release. 23. Using a small flat bladed tool, open the coat hook screw cover (2) then remove the screw and coat hook (Figure 69). Service Procedure [Continued] Figure 67 – Visors Figure 69 – Coat Hook Figure 68 – Visors Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 55 24. As necessary, release the headliner wiring harness clips (3) from the A-pillar to allow enough wiring harness slack for lowering the headliner (Figure 70). 25. Release the door seals from the door openings to allow for lowering of the headliner. 26. Carefully lower the headliner (2) allowing it to rest on the seat backs and instrument panel (Figure 71). CAUTION: Disconnect any wiring harness electrical connectors (1) as necessary to allow enough wiring harness slack while lowering headliner. It will not be necessary to remove the headliner from the vehicle (Figure 71). 27. Obtain the appropriate replacement SABIC(s) for the vehicle based on its VIN. Service Procedure [Continued] Figure 70 – Headliner Harness Figure 71 – Headliner Harness Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 56 28. The body wire harness connector (5) is secured by integral latches to the connector receptacle on the inflator (4). Pinch both latches firmly, then pull the connector straight out from the airbag inflator to disconnect it from the connector receptacle (Figure 72). 29. Remove the seven bolts (8) that secure the side curtain airbag (6) to the inner roof rail and A-pillar (Figure 72). 30. Disengage the plastic push-in retainer (9) that secures the side curtain airbag tether to the inner A-pillar (1) and the plastic push-in retainer (7) that secures the side curtain airbag to the inner roof rail (Figure 72). 31. Slide the inflator rearward far enough to disengage the T-tab at the front of the inflator bracket from the keyed T-slot in the inner roof rail over the rear door opening (Figure 73). 32. Remove the SABIC (6) from the vehicle as a unit and DISCARD following local ordinances and recommended procedures for handling and disposal of Non-Deployed Supplemental Restraints (Figure 72). Provided packaging is not authorized for the transport of the recalled SABIC Module. Parts will need to be either deployed on-site or transported in alternative approved containers. Service Procedure [Continued] Figure 72 – SABIC Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 57 33. Check to be certain that the spring nuts are properly installed in the inner roof rail and that they are in good condition. 34. Position the NEW SABIC (6) into the vehicle as a unit (Figure 72). 35. Insert the T-tab at the front of the inflator bracket into the keyed T-slot in the inner roof rail over the rear door opening and slide the inflator forward to engage it (Figure 73). 36. Engage the plastic push-in retainer (7) that secures the side curtain airbag to the inner roof rail and ensure the tether is not twisted then engage the plastic push-in retainer (9) that secures the side curtain airbag front tether to the assist handle bracket on the inner A-pillar (1) (Figure 72). 37. Working from rear to front, install and tighten the seven bolts (8) that secure the side curtain airbag (6) to the inner roof rail and A-pillar. Tighten the bolts to 7 N·m (62 in. lbs.) (Figure 72). 38. Connect the body wire harness connector (5) for the side curtain airbag to the connector receptacle of the inflator (4). Be certain that each connector is fully engaged in its receptacle by listening carefully for a distinct, audible click as the connector latches snap into place (Figure 72). Service Procedure [Continued] Figure 73 – SABIC Inflator T-Tab and Inner Roof Rail T-Slot T-SLOT T-TAB SABIC Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 58 CAUTION: Hands should be clean or clean cloth gloves used when handling the headliner to avoid damage to the headliner. 39. Raise the headliner into proper vehicle position and connect any electrical connectors previously disconnected from the headliner (Figure 71). CAUTION: Be certain to avoid any wiring or drain tube interference. 40. Position the coat hooks (5) onto the headliner and install the screws tightening securely into the mounting clips then close the screw cap fully (Figure 69). 41. Position the visor supports (1) onto the headliner and install the screws into the mounting clips (Figure 67). 42. If equipped with illuminated vanity mirror, connect the wire harness connector. 43. Position the visor to the headliner and install the screws (2) that secure the visor to the roof panel. Tighten the screws to 6 N·m (53 in. lbs.) (Figure 67). 44. Reattach any headliner wiring harness clips (3) removed from the A-pillar to allow slack while lowering headliner (Figure 70). 45. If equipped with DVD monitor, connect the DVD monitor electrical connectors (1) (Figure 66). Position the DVD monitor to the roof then install and tighten the screws (2) (Figure 65). WARNING: Do not connect the negative battery cable at this time. The Supplemental Restraint System (SRS) Verification Test procedure should be performed following service of any SRS component. NOTE: The following procedure should be performed using a diagnostic scan tool to verify proper Supplemental Restraint System (SRS) operation following the service or replacement of any SRS component. Refer to the appropriate diagnostic procedures. Service Procedure [Continued] Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 59 46. During the following test, the negative cable remains disconnected and isolated from the battery, as it was during the Supplemental Restraint System (SRS) component removal and installation procedures. 47. Be certain that the diagnostic scan tool contains the latest version of the proper diagnostic software. Connect the scan tool to the 16-way Data Link Connector (DLC). The DLC is located on the driver side lower edge of the instrument panel, near the steering column opening cover and outboard of the steering column. 48. Transition the status of the ignition switch (also known as the Keyless Ignition Node/KIN or IGnition Node Module/IGNM) to ON and exit the vehicle with the scan tool. 49. Check to be certain that nobody is in the vehicle, then connect the negative cable to the battery. 50. Using the scan tool, read and record the active (current) Diagnostic Trouble Code (DTC) data. 51. Next, use the scan tool to read and record any stored (historical) DTC data. 52. If any SRS related DTC is found in the previous two steps, refer to the appropriate diagnostic information. 53. Use the scan tool to erase the stored DTC data. If any problems remain, the stored DTC data will not erase. Refer to the appropriate diagnostic information to diagnose any stored DTC that will not erase. If the stored DTC information is successfully erased, continue to the next step. 54. Transition the status of the ignition switch to OFF for about 15 seconds, and then back to ON. Observe the airbag indicator in the instrument cluster. It should light from four to six seconds, and then go out. This indicates that the SRS is functioning normally and that the repairs are complete. If the airbag indicator fails to light, or lights and stays ON, there is still an active SRS fault or malfunction. Refer to the appropriate diagnostic information to diagnose the problem. Service Procedure [Continued] Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 60 55. Raise the front seat backs and position the seats forward. 56. Install the C-pillar upper trim panel (1) and engage the retaining clips fully (Figure 64). 57. Install and tighten the screws that secure the C-pillar upper trim panel then install the airbag applique covers (Figure 63). 58. Remove and DISCARD the bolt retainer and the bolt from the seat belt turning loop, save the spacer for reuse (Figure 74). 59. Using a NEW bolt and reusing the spacer washer, install the turning loop then tighten the bolt to 40 N·m (30 ft. lbs.) (Figure 62). 60. Install the seat belt turning loop cover (Figure 62). 61. Position the lower C-pillar trim panel and engage the retaining clips fully (Figure 61). NOTE: Ensure that all C-pillar fasteners are installed/engaged properly. 62. Install the B-pillar upper trim panel (1) and engage the retaining clips fully (Figure 60). 63. Install the grab handle bolts and tighten to 5 N·m (44 in. lbs.). Close the fastener covers (2) (Figure 60). Service Procedure [Continued] Figure 74 – Turning Loop Bolt RETAINER BOLT SPACER Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 61 64. Remove and DISCARD the bolt retainer and the bolt from the seat belt turning loop, save the spacer washer for reuse (Figure 75). 65. Using a NEW bolt and reusing the spacer washer, install the turning loop then tighten the bolt to 40 N·m (30 ft. lbs.) (Figure 59). 66. Install the seat belt turning loop cover (Figure 59). 67. Position the B-pillar lower trim panel and engage the retaining clips fully (Figure 58). 68. Position the front and rear door sill scuff plates and engage the retainers (Figure 57). 69. Install the front seat headrests (Figure 56). 70. Position the locating tab of the A-pillar trim panel (2) into the slot located in the top of the instrument panel (Figure 55). 71. Install the A-pillar trim panel onto the A-pillar (1) and install the two bolts (4). Tighten the bolts to 5 N·m (44 in. lbs.) (Figure 55). 72. Close the two fastener covers (3) located in the A-pillar trim panel (Figure 55). 73. Install the door seals around the door openings. 74. Return the vehicle to the customer or inventory. Service Procedure [Continued] Figure 75 – Turning Loop Bolt RETAINER BOLT SPACER WASHER Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 62 Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims paid will be used by FCA to record recall service completions and provide dealer payments. Use the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace One SABIC (Standard Cab) 23-Y9-91-82 1.4 hours Replace One SABIC (Crew/Quad Cab) 23-Y9-91-83 1.7 hours Replace One SABIC (Mega Cab) 23-Y9-91-84 2.2 hours Floor Plan Reimbursement 95-95-95-97 Calculate See Below Floor Plan Reimbursement represents the vehicle’s average daily allowance (see table below) multiplied by the number of days the vehicle was in dealer inventory and not available for sale. This reimbursement is limited to the number of days from the date of the stop sale to the date that the remedy was made available. Note: If the vehicle was received by your dealership (KZX date) AFTER the stop sale date, you will use the KZX date instead of the stop sale date. For this Recall, the stop sale was initiated on 12/02/2021 and the remedy was made available on 01/13/2022, therefore, the number of days cannot exceed 42 days. Vehicle Average Daily Allowance 2021 (DS) Ram 1500 Pickup 2021 – 2022 (DJ) Ram 2500 Pickup 2021 – 2022 (D2) Ram 3500 Pickup NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Completion Reporting and Reimbursement Safety Recall Y99 – Side Air Bag Inflatable Curtain Inflator Page 63 To view this notification on DealerCONNECT, select “Global Recall System” on the Service tab, then click on the description of this notification. 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. 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. 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 Dealer Notification Owner Notification and Service Scheduling Vehicle Lists, Global Recall System, VIP and Dealer Follow Up Additional Information This notice applies to your vehicle, Y99/NHTSA 21V-925 YOUR SCHEDULING OPTIONS 1. RECOMMENDED OPTION Call your authorized Chrysler / Dodge / Jeep® / RAM Dealership 2. Call the FCA Recall Assistance Center at 1-800-853-1403. An agent can confirm part availability and help schedule an appointment 3. Visit recalls.mopar.com, scan the QR code below, or download the Mopar Owner’s Companion App. Get access to recall notifications, locate your nearest dealer, and more through this website or Mopar Owner’s Companion App. You will be asked to provide your Vehicle Identification Number (VIN) to protect and verify your identity. The last eight characters of your VIN are provided above. DEALERSHIP INSTRUCTIONS Please reference Safety Recall Y99. IMPORTANT SAFETY RECALL Side Air Bag Inflatable Curtain Inflator Dear [Name], This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. FCA US has decided that a defect, which relates to motor vehicle safety, exists in certain [2021 (DS) Ram 1500 Pickup and 2021 – 2022 (DJ) Ram 2500 Pickup, (D2) Ram 3500 Pickup] vehicles. It is extremely important to take steps now to repair your vehicle to ensure the safety of you and your passengers. WHY DOES MY VEHICLE NEED REPAIRS? Your vehicle [1] may have been built with a Side Air Bag Inflatable Curtain (SABIC) assembly containing an inflator with out of specification propellant gas mass. SABIC assemblies with low gas mass may result in non-deployment or low/slow deployment and high gas mass may result in aggressive deployment of the air bag which may increase the risk of occupant injury in certain crashes. HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE? FCA US will repair your vehicle [2] free of charge (parts and labor). To do this, your dealer will replace the Side Air Bag Inflatable Curtain (SABIC) assembly. The estimated repair time is about 3 hours. In addition, your dealer will require your vehicle for proper check-in, preparation, and check-out during your visit, which may require more time. Your time is important to us, so we recommend that you schedule a service appointment to minimize your inconvenience. Please bring this letter with you to your dealership. TO SCHEDULE YOUR FREE REPAIR, CALL YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED? 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. [3] Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. If you have had previous repairs performed and/or already received reimbursement, you may still need to have the recall repair performed. We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you for your attention to this important matter. Customer Assistance/Field Operations FCA US LLC [Model Year and Model] VIN XXXXXXXXXXXXXXXXX LOGO VEHICLE PICTURE QR Code [1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information. [2] 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. [3] You can also mail in 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. Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days. Mr. Mrs. Customer 1234 Main Street Hometown, MI 48371
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This notice applies to your vehicle, Z07/NHTSA 21V-925 YOUR SCHEDULING OPTIONS 1. RECOMMENDED OPTION Call your authorized Chrysler / Dodge / Jeep® / RAM Dealership 2. Call the FCA Recall Assistance Center at 1-800-853-1403. An agent can confirm part availability and help schedule an appointment 3. Visit recalls.mopar.com, scan the QR code below, or download the Mopar Owner’s Companion App. Get access to recall notifications, locate your nearest dealer, and more through this website or Mopar Owner’s Companion App. You will be asked to provide your Vehicle Identification Number (VIN) to protect and verify your identity. The last eight characters of your VIN are provided above. DEALERSHIP INSTRUCTIONS Please reference Safety Recall Z07. IMPORTANT SAFETY RECALL Side Air Bag Inflatable Curtain Dear [Name], This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. FCA US has decided that a defect, which relates to motor vehicle safety, exists in certain [2021-2022 (DS) Ram 1500 Pickup, (DJ) Ram 2500 Pickup, (D2) Ram 3500 Pickup] vehicles. It is extremely important to take steps now to repair your vehicle to ensure the safety of you and your passengers. WHY DOES MY VEHICLE NEED REPAIRS? Your vehicle [1] may have been built with a Side Air Bag Inflatable Curtain (SABIC) assembly containing an inflator with out of specification propellant gas mass. SABIC assemblies with low gas mass may result in non-deployment or low/slow deployment and high gas mass may result in aggressive deployment of the air bag which may increase the risk of occupant injury in certain crashes. HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE? FCA US will repair your vehicle [2] free of charge (parts and labor). To do this, your dealer will inspect and if necessary, replace one or both SABIC’s as needed. The estimated repair time is 3 hours. In addition, your dealer will require your vehicle for proper check-in, preparation, and check-out during your visit, which may require more time. Your time is important to us, so we recommend that you schedule a service appointment to minimize your inconvenience. Please bring this letter with you to your dealership. TO SCHEDULE YOUR FREE REPAIR, CALL YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED? 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. [3] Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. If you have had previous repairs performed and/or already received reimbursement, you may still need to have the recall repair performed. We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you for your attention to this important matter. Customer Assistance/Field Operations FCA US LLC [Model Year and Model] VIN XXXXXXXXXXXXXXXXX LOGO VEHICLE PICTURE QR Code [1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information. [2] 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. [3] You can also mail in 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. Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days. Mr. Mrs. Customer 1234 Main Street Hometown, MI 48371
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This notice applies to your vehicle, Y99/NHTSA 21V-925 YOUR SCHEDULING OPTIONS 1. RECOMMENDED OPTION Call your authorized Chrysler / Dodge / Jeep® / RAM Dealership 2. Call the FCA Recall Assistance Center at 1-800-853-1403. An agent can confirm part availability and help schedule an appointment 3. Visit recalls.mopar.com, scan the QR code below, or download the Mopar Owner’s Companion App. Get access to recall notifications, locate your nearest dealer, and more through this website or Mopar Owner’s Companion App. You will be asked to provide your Vehicle Identification Number (VIN) to protect and verify your identity. The last eight characters of your VIN are provided above. DEALERSHIP INSTRUCTIONS Please reference Safety Recall Y99. IMPORTANT SAFETY RECALL Side Air Bag Inflatable Curtain Inflator Dear [Name], This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. FCA US has decided that a defect, which relates to motor vehicle safety, exists in certain [2021 (DS) Ram 1500 Pickup and 2021 – 2022 (DJ) Ram 2500 Pickup, (D2) Ram 3500 Pickup] vehicles. It is extremely important to take steps now to repair your vehicle to ensure the safety of you and your passengers. WHY DOES MY VEHICLE NEED REPAIRS? Your vehicle [1] may have been built with a Side Air Bag Inflatable Curtain (SABIC) assembly containing an inflator with out of specification propellant gas mass. SABIC assemblies with low gas mass may result in non-deployment or low/slow deployment and high gas mass may result in aggressive deployment of the air bag which may increase the risk of occupant injury in certain crashes. HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE? FCA US will repair your vehicle [2] free of charge (parts and labor). To do this, your dealer will replace the Side Air Bag Inflatable Curtain (SABIC) assembly. The estimated repair time is about 3 hours. In addition, your dealer will require your vehicle for proper check-in, preparation, and check-out during your visit, which may require more time. Your time is important to us, so we recommend that you schedule a service appointment to minimize your inconvenience. Please bring this letter with you to your dealership. TO SCHEDULE YOUR FREE REPAIR, CALL YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED? 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. [3] Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. If you have had previous repairs performed and/or already received reimbursement, you may still need to have the recall repair performed. We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you for your attention to this important matter. Customer Assistance/Field Operations FCA US LLC [Model Year and Model] VIN XXXXXXXXXXXXXXXXX LOGO VEHICLE PICTURE QR Code [1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information. [2] 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. [3] You can also mail in 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. Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days. Mr. Mrs. Customer 1234 Main Street Hometown, MI 48371
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01/12/2022 New Safety Recall Advanced Communication – Z07 FCA US LLC (FCA US) has announced a safety recall on certain 2021 through 2022 Model Year (DS) Ram 1500 Pickup, (DJ) Ram 2500 Pickup, (D2) Ram 3500 Pickup and (DX) Ram Truck (Mexico) vehicles. REASON FOR THIS SAFETY RECALL Some of the above vehicles may have been built with a Side Air Bag Inflatable Curtain (SABIC) assembly containing an inflator with out of specification propellant gas mass. SABIC assemblies with low gas mass may result in non-deployment or low/slow deployment and high gas mass may result in aggressive deployment of the air bag which may increase the risk of occupant injury in certain crashes. SERVICE ACTION FCA US will conduct a voluntary safety recall to inspect and replace the SABIC as needed. The remedy for this condition is not currently available. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 1st Quarter of 2022. We ask that you please take the time to ensure that your personnel are aware of this communication and are prepared to execute a customer friendly process for inquiries regarding involved vehicles. Customer Services Field Operations FCA US LLC
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11/25/2021 New Safety Recall Advanced Communication – Y99 FCA US LLC (FCA US) has announced a safety recall on certain 2021 Model Year (DS) Ram 1500 Pickup, 2021 and 2022 Model Year (DJ) Ram 2500 Pickup and (D2) 3500 Pickup vehicles. REASON FOR THIS SAFETY RECALL Some of the above vehicles may have been built with a Side Air Bag Inflatable Curtain (SABIC) assembly containing an inflator with out of specification propellant gas mass. SABIC assemblies with low gas mass may result in non-deployment or low/slow deployment and high gas mass may result in aggressive deployment of the air bag which may increase the risk of occupant injury in certain crashes. SERVICE ACTION FCA US will conduct a voluntary safety recall to replace the SABIC assembly. The remedy for this condition is not currently available. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 1st Quarter of 2022. We ask that you please take the time to ensure that your personnel are aware of this communication and are prepared to execute a customer friendly process for inquiries regarding involved vehicles. Customer Services Field Operations FCA US LLC
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01/14/2022 New Safety Recall Advanced Communication – Z07 FCA US LLC (FCA US) has announced a safety recall on certain 2021 through 2022 Model Year (DS) Ram 1500 Pickup, (DJ) Ram 2500 Pickup, (D2) Ram 3500 Pickup and (DX) Ram Truck (Mexico) vehicles. VINs identified as being involved in this campaign are currently live and searchable. Stop sale is in effect for the above-identified vehicles. Vehicles impacted by a stop sale are eligible for reimbursement allowance through the Recall Floorplan Reimbursement Policy (RFPRP), which can be requested upon recall claim submission. REASON FOR THIS SAFETY RECALL Some of the above vehicles may have been built with a Side Air Bag Inflatable Curtain (SABIC) assembly containing an inflator with out of specification propellant gas mass. SABIC assemblies with low gas mass may result in non-deployment or low/slow deployment and high gas mass may result in aggressive deployment of the air bag which may increase the risk of occupant injury in certain crashes. SERVICE ACTION FCA US will conduct a voluntary safety recall to inspect and replace the SABIC as needed. The remedy for this condition is not currently available. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 1st Quarter of 2022. We ask that you please take the time to ensure that your personnel are aware of this communication and are prepared to execute a customer friendly process for inquiries regarding involved vehicles. Customer Services Field Operations FCA US LLC 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. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Involved vehicles can be determined by using the VIP inquiry process.
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12/02/2021 New Safety Recall Advanced Communication – Y99 FCA US LLC (FCA US) has announced a safety recall on certain 2021 Model Year (DS) Ram 1500 Pickup, 2021 and 2022 Model Year (DJ) Ram 2500 Pickup and (D2) 3500 Pickup vehicles. VINs identified as being involved in this campaign are currently live and searchable. Stop sale is in effect for the above-identified vehicles. Vehicles impacted by a stop sale are eligible for reimbursement allowance through the Recall Floorplan Reimbursement Policy (RFPRP), which can be requested upon recall claim submission. REASON FOR THIS SAFETY RECALL Some of the above vehicles may have been built with a Side Air Bag Inflatable Curtain (SABIC) assembly containing an inflator with out of specification propellant gas mass. SABIC assemblies with low gas mass may result in non-deployment or low/slow deployment and high gas mass may result in aggressive deployment of the air bag, which may increase the risk of occupant injury in certain crashes. SERVICE ACTION FCA US will conduct a voluntary safety recall to replace the SABIC assembly. The remedy for this condition is not currently available. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 1st Quarter of 2022. We ask that you please take the time to ensure that your personnel are aware of this communication and are prepared to execute a customer friendly process for inquiries regarding involved vehicles. Customer Services Field Operations FCA US LLC 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. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Involved vehicles can be determined by using the VIP inquiry process.
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-925 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Chrysler (FCA US, LLC) Submission Date : JAN 11, 2022 NHTSA Recall No. : 21V-925 Manufacturer Recall No. : Y99, Z07 Manufacturer Information : Manufacturer Name : Chrysler (FCA US, LLC) Address : 800 Chrysler Drive CIMS 482-00-91 Auburn Hills MI 48326-2757 Company phone : 1-800-853-1403 Population : Number of potentially involved : 376 Estimated percentage with defect : 38 % Vehicle Information : Vehicle 1 : 2021-2021 Ram 1500 Classic Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR Descriptive Information : Some 2021 MY Ram 1500 Classic vehicles may have been built with a side air bag inflatable curtain (“SABIC”) assembly containing an inflator with out of specification propellant gas mass (“gas mass”). The suspect period began on February 1, 2021, when SABIC assemblies with out of specification gas mass were first introduced into vehicle production, and ended on December 18, 2021, when SABIC assemblies with out of specification gas mass were no longer used in vehicle production. The vehicle population was determined through supplier’s inflator traceability records and vehicle production records. Similar vehicles not included in this recall were built with SABIC assembly inflators with proper gas mass. The total affected vehicles for this model is 77. Production Dates : FEB 01, 2021 – DEC 18, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 21V-925 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2021-2022 Ram 2500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR Descriptive Information : Some 2021-2022 MY Ram 2500 vehicles may have been built with a SABIC assembly containing an inflator with out of specification gas mass. The suspect period began on January 28, 2021, when SABIC assemblies with out of specification gas mass were first introduced into vehicle production, and ended on November 29, 2021, when SABIC assemblies with out of specification gas mass were no longer used in vehicle production. The vehicle population was determined through supplier’s inflator traceability records and vehicle production records. Similar vehicles not included in this recall were built with SABIC assembly inflators with proper gas mass. The total affected vehicles for this model is 217. Production Dates : JAN 28, 2021 – NOV 29, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2021-2022 Ram 3500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR Descriptive Information : Some 2021-2022 MY Ram 3500 vehicles may have been built with a SABIC assembly containing an inflator with out of specification gas mass. The suspect period began on January 28, 2021, when SABIC assemblies with out of specification gas mass were first introduced into vehicle production, and ended on November 29, 2021, when SABIC assemblies with out of specification gas mass were no longer used in vehicle production. The vehicle population was determined through supplier’s inflator traceability records and vehicle production records. Similar vehicles not included in this recall were built with SABIC assembly inflators with proper gas mass. The total affected vehicles for this model is 82. Production Dates : JAN 28, 2021 – NOV 29, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 21V-925 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Defect : Description of the Defect : SABIC assemblies with low gas mass may result in non-deployment or low/ slow deployment and high gas mass may result in aggressive deployment of the air bag. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Non-deployment, low/slow deployment or aggressive deployment of the SABIC may increase the risk of occupant injury in certain crashes. Description of the Cause : NR Identification of Any Warning that can Occur : None Involved Components : Component Name 1 : Side Airbag Inflatable Curtain Component Description : Right – Crew Component Part Number : 68161578AJ Component Name 2 : Side Airbag Inflatable Curtain Component Description : Left – Crew Component Part Number : 68161579AJ Component Name 3 : Side Airbag Inflatable Curtain Component Description : Right – Quad Component Part Number : 68161580AK Component Name 4 : Side Airbag Inflatable Curtain Component Description : Left – Quad Component Part Number : 68161581AK Part 573 Safety Recall Report 21V-925 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 5 : Side Airbag Inflatable Curtain Component Description : Right – Standard Component Part Number : 68184326AI Component Name 6 : Side Airbag Inflatable Curtain Component Description : Left – Standard Component Part Number : 68184327AI Component Name 7 : Side Airbag Inflatable Curtain Component Description : Right – Mega Component Part Number : 68444248AA Component Name 8 : Side Airbag Inflatable Curtain Component Description : Left – Mega Component Part Number : 68444249AA Supplier Identification : Component Manufacturer Name : Joyson Safety Systems Address : 2025 Harmon Road Auburn Hills Michigan 48326 Country : United States Chronology : • On November 8, 2021, FCA US LLC (“FCA US”) Quality was notified that, during a component test deployment of a SABIC at the supplier, the inflator did not fully inflate the cushion. • On November 9, 2021, the FCA US Technical Safety and Regulatory Compliance (“TSRC”) organization opened an investigation and discovered that some SABIC assembly inflators with out of specification gas mass may have been built into some Ram 1500 Classic, Ram 2500, and Ram 3500 vehicles. • On November 17, 2021, FCA US TSRC determined that the SABICs with suspect inflators were shipped to FCA Part 573 Safety Recall Report 21V-925 Page 5 The information contained in this report was submitted pursuant to 49 CFR §573 US and built into vehicles from January 28, 2021, to November 8, 2021. • As of November 18, 2021, FCA US has identified zero customer assistance records, zero warranty claims, and zero field reports potentially relating to this issue for all markets. • As of November 18, 2021, FCA US is not aware of any accidents or injuries potentially relating to this issue for all markets. • On November 18, 2021, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles. Description of Remedy : Description of Remedy Program : FCA US will conduct a voluntary safety recall on all affected vehicles. For vehicles in Recall ID Y99, FCA US will replace the suspect SABIC. For vehicles in Recall ID Z07, FCA US will inspect and replace the SABIC as needed. FCA US has a longstanding policy and practice of reimbursing owners who have incurred the cost of repairing a problem that subsequently becomes the subject of a field action. To ensure consistency, FCA US, as part of the owner letter, will request that customers send the original receipt and/or other adequate proof of payment to the company for confirmation of the expense. How Remedy Component Differs from Recalled Component : The remedy component will be a SABIC built with an inflator verified to have the proper gas mass. Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : **01/11/2022: For the added population (Z07), FCA US will notify dealers and begin notifying owners on or about 02/25/2022. **11/24/2021: FCA US will notify dealers and begin notifying owners on or about 01/13/2022. Planned Dealer Notification Date : JAN 13, 2022 – JAN 13, 2022 Planned Owner Notification Date : JAN 13, 2022 – JAN 13, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-925 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Chrysler (FCA US, LLC) Submission Date : NOV 24, 2021 NHTSA Recall No. : 21V-925 Manufacturer Recall No. : Y99 Manufacturer Information : Manufacturer Name : Chrysler (FCA US, LLC) Address : 800 Chrysler Drive CIMS 482-00-91 Auburn Hills MI 48326-2757 Company phone : 1-800-853-1403 Population : Number of potentially involved : 132 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2022 Ram 2500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR Descriptive Information : Some 2021-2022 MY Ram 2500 vehicles may have been built with a SABIC assembly containing an inflator with out of specification gas mass. The suspect period began on January 28, 2021, when SABIC assemblies with out of specification gas mass were first introduced into vehicle production, and ended on November 4, 2021, when SABIC assemblies with out of specification gas mass were no longer used in vehicle production. The vehicle population was determined through supplier’s inflator traceability records and vehicle production records. Similar vehicles not included in this recall were built with SABIC assembly inflators with proper gas mass. The total affected vehicles for this model is 71. Production Dates : JAN 28, 2021 – NOV 04, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 21V-925 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2021-2021 Ram 1500 Classic Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR Descriptive Information : Some 2021 MY Ram 1500 Classic vehicles may have been built with a side air bag inflatable curtain (“SABIC”) assembly containing an inflator with out of specification propellant gas mass (“gas mass”). The suspect period began on February 1, 2021, when SABIC assemblies with out of specification gas mass were first introduced into vehicle production, and ended on November 8, 2021, when SABIC assemblies with out of specification gas mass were no longer used in vehicle production. The vehicle population was determined through supplier’s inflator traceability records and vehicle production records. Similar vehicles not included in this recall were built with SABIC assembly inflators with proper gas mass. The total affected vehicles for this model is 33. Production Dates : FEB 01, 2021 – NOV 08, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2021-2022 Ram 3500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR Descriptive Information : Some 2021-2022 MY Ram 3500 vehicles may have been built with a SABIC assembly containing an inflator with out of specification gas mass. The suspect period began on January 28, 2021, when SABIC assemblies with out of specification gas mass were first introduced into vehicle production, and ended on November 5, 2021, when SABIC assemblies with out of specification gas mass were no longer used in vehicle production. The vehicle population was determined through supplier’s inflator traceability records and vehicle production records. Similar vehicles not included in this recall were built with SABIC assembly inflators with proper gas mass. The total affected vehicles for this model is 28. Production Dates : JAN 28, 2021 – NOV 05, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 21V-925 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Defect : Description of the Defect : SABIC assemblies with low gas mass may result in non-deployment or low/ slow deployment and high gas mass may result in aggressive deployment of the air bag. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Non-deployment, low/slow deployment or aggressive deployment of the SABIC may increase the risk of occupant injury in certain crashes. Description of the Cause : NR Identification of Any Warning that can Occur : None Involved Components : Component Name 1 : Side Airbag Inflatable Curtain Component Description : Right – Crew Component Part Number : 68161578AJ Component Name 2 : Side Airbag Inflatable Curtain Component Description : Left – Crew Component Part Number : 68161579AJ Component Name 3 : Side Airbag Inflatable Curtain Component Description : Right – Quad Component Part Number : 68161580AK Component Name 4 : Side Airbag Inflatable Curtain Component Description : Left – Quad Component Part Number : 68161581AK Part 573 Safety Recall Report 21V-925 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 5 : Side Airbag Inflatable Curtain Component Description : Right – Standard Component Part Number : 68184326AI Component Name 6 : Side Airbag Inflatable Curtain Component Description : Left – Standard Component Part Number : 68184327AI Component Name 7 : Side Airbag Inflatable Curtain Component Description : Right – Mega Component Part Number : 68444248AA Component Name 8 : Side Airbag Inflatable Curtain Component Description : Left – Mega Component Part Number : 68444249AA Supplier Identification : Component Manufacturer Name : Joyson Safety Systems Address : 2025 Harmon Road Auburn Hills Michigan 48326 Country : United States Chronology : • On November 8, 2021, FCA US LLC (“FCA US”) Quality was notified that, during a component test deployment of a SABIC at the supplier, the inflator did not fully inflate the cushion. • On November 9, 2021, the FCA US Technical Safety and Regulatory Compliance (“TSRC”) organization opened an investigation and discovered that some SABIC assembly inflators with out of specification gas mass may have been built into some Ram 1500 Classic, Ram 2500, and Ram 3500 vehicles. • On November 17, 2021, FCA US TSRC determined that the SABICs with suspect inflators were shipped to FCA Part 573 Safety Recall Report 21V-925 Page 5 The information contained in this report was submitted pursuant to 49 CFR §573 US and built into vehicles from January 28, 2021, to November 8, 2021. • As of November 18, 2021, FCA US has identified zero customer assistance records, zero warranty claims, and zero field reports potentially relating to this issue for all markets. • As of November 18, 2021, FCA US is not aware of any accidents or injuries potentially relating to this issue for all markets. • On November 18, 2021, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles. Description of Remedy : Description of Remedy Program : FCA US will conduct a voluntary safety recall on all affected vehicles to replace the SABIC assembly. FCA US has a longstanding policy and practice of reimbursing owners who have incurred the cost of repairing a problem that subsequently becomes the subject of a field action. To ensure consistency, FCA US, as part of the owner letter, will request that customers send the original receipt and/or other adequate proof of payment to the company for confirmation of the expense. How Remedy Component Differs from Recalled Component : The remedy component will be a SABIC built with an inflator verified to have the proper gas mass. Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : **11/24/2021: FCA US will notify dealers and begin notifying owners on or about 01/13/2022. Planned Dealer Notification Date : JAN 13, 2022 – JAN 13, 2022 Planned Owner Notification Date : JAN 13, 2022 – JAN 13, 2022 * NR – Not Reported
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