22E083 – Dim Amber Side Reflector – Mopar Headlamp Assemblies

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September 29, 2022 NHTSA CAMPAIGN NUMBER: 22E083000

Dim Amber Side Reflector/FMVSS 108

A dim reflector may reduce the visibility of the vehicle to other drivers, increasing the risk of a crash.

 

NHTSA Campaign Number: 22E083

Manufacturer Chrysler (FCA US, LLC)

Components EXTERIOR LIGHTING

Potential Number of Units Affected 16,604

 

Summary

Chrysler (FCA US LLC) is recalling certain Mopar Headlamp Assemblies with part numbers 05116288AC, 05116289AC, 68200084AB, and 68200085AB, sold as replacement parts. The amber side reflex reflector assembled into the headlamp may not reflect brightly enough. As such, these headlamps fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 108, “Lamps, Reflective Devices, and Associated Equipment.”

 

Remedy

Dealers will replace the headlamp assembly, free of charge. Owner notification letters were mailed February 16, 2023. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC’s number for this recall is ZA0.

 

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.

 


New Safety Recall Advanced Communication – ZA0

FCA US LLC (FCA US) has announced a safety recall on certain Mopar aftermarket headlamp assemblies 05116288AC, 05116289AC, 68200084AB, 68200085AB intended for use with 2008 through 2019 model year (JC) Dodge Journey vehicles.

 

REASON FOR THIS SAFETY RECALL

Some of the above headlamp assemblies manufactured and sold as aftermarket equipment may be equipped with a front amber side reflex reflector that may not meet the photometric requirements of Federal Motor Vehicle Safety Standard (FMVSS) 108 for lamps, reflective devices, and associated equipment. If the reflection of light from the reflector is below specification, the position and dimensions of the vehicle may not always be perceived by other drivers, which can cause a vehicle crash without prior warning.

The headlamp assemblies described above do not comply with FMVSS 108 S8.1.11 which requires amber side reflect reflectors to “conform to the photometry requirements of Table XVI-a when tested according to the procedure of S14.2.3 for the reflex reflector color as specified by this section.”

 

SERVICE ACTION

FCA US will conduct a voluntary safety recall on all affected headlamp assemblies. Remedy is under development and 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 4th Quarter of 2022.

 


February 2023

Dealer Service Instructions for:

Equipment Safety Recall ZA0
NHTSA 22E-083
Front Amber Side Reflex Reflector

 

Remedy Available

Mopar Headlamp Assembly 05116288AC
Mopar Headlamp Assembly 05116289AC
Mopar Headlamp Assembly 68200084AB
Mopar Headlamp Assembly 68200085AB

 

Intended for use with 2009 – 2019 model year (JC) Dodge Journey vehicles

 

Subject

Some of the above headlamp assemblies manufactured and sold as aftermarket equipment may be equipped with a front amber side reflex reflector that may not meet the photometric requirements of Federal Motor Vehicle Safety Standard (FMVSS) 108 for lamps, reflective devices, and associated equipment. If the reflection of light from the reflector is below specification, the position and dimensions of the vehicle may not always be perceived by other drivers, which can cause a vehicle crash without prior warning.

The headlamp assemblies described above do not comply with FMVSS 108 S8.1.11 which requires amber side reflect reflectors to “conform to the photometry requirements of Table XVI-a when tested according to the procedure of S14.2.3 for the reflex reflector color as specified by this section.”

 

Repair

If the Headlamp Assembly has not been installed, exchange it.

If the Headlamp Assembly has been installed, replace it using the following Service Procedure.

 

Parts Information

Without – Black Headlamp Bezels (Sales code -MFA)

Part Number Qty. Description
CSKJV221AB 1 Front Right Headlamp

Without – Black Headlamp Bezels (Sales code MFA)

 

Part Number Qty. Description
CSKJV222AB 1 Front Left Headlamp

Without – Black Headlamp Bezels (Sales code MFA)

 

With – Black Headlamp Bezels (Sales code MFA)

Part Number Qty. Description
CSKJV223AB 1 Front Right Headlamp – SAE Black

With – Black Headlamp Bezels (Sales code MFA)

 

Part Number Qty. Description
CSKJV224AB 1 Front Left Headlamp – SAE Black

With – Black Headlamp Bezels (Sales code MFA)

 

Parts Return

No parts return required for this campaign. Render the recalled headlamps unusable and discard.

 

Special Tools

No special tools are required to perform this service procedure.

 

Service Procedure

A. Headlamp Replacement

  1. Open the hood.

 

  1. Disconnect and isolate the negative battery cable terminal from the remote battery post (Figure 1).

 

  1. Remove the five push pins to release the grill from the air  duct and the radiator support (Figure 2).

 

  1. Tilt the grill forward slightly to reach behind the grill and release the six retaining tabs securing the grill to the fascia, then remove the grill. Center tab is for grill alignment only not a retaining tab (Figure 3).

 

  1. Raise and support the vehicle.

 

  1. Right side of the vehicle, remove three push pins securing the front fascia to the wheel house splash shield (Figure 4).

 

  1. Right side of the vehicle, remove the screw attaching the front fascia to the fender in the wheel house opening (Figure 4).

 

NOTE: Right side wheelhouse splash shield may be flexed out of the way to reach behind fascia. Left side wheelhouse splash shield must be removed due to battery tray not allowing splash shield to be flexed to reach behind fascia.

 

  1. Left side of the vehicle, remove the eight push pins securing the front lower splash shield then remove the front lower splash shield (Figure 5).

 

  1. Left side of the vehicle, remove the screw attaching the front fascia to the fender in the wheel house opening (Figure 5).

 

  1. Lower the vehicle.

 

  1. Right side of the vehicle, flex the wheelhouse splash shield out of the way enough to reach behind the fascia. Release the front fascia tabs from the retaining bracket to separate the fascia from the fender (Figure 6).

 

  1. Right side of the vehicle, slide the fascia out of the Front End Module (FEM) fascia alignment tab under the headlamp (Figure 6).

 

  1. Left side of the vehicle, reach behind the fascia. Release the front fascia tabs from the retaining bracket to separate the fascia from the fender (Figure 6).

 

  1. Right side of the vehicle, slide the fascia out of the FEM fascia alignment tab under the headlamp (Figure 6).

 

  1. Right and/or Left side of the vehicle as needed. Remove the three screws that secure the front lamp to the FEM (Figure 7).

 

  1. Right and/or Left side of the vehicle as needed. Pull the front lamp away from the FEM far enough to access and disconnect the lamp bulb wire harness connectors from the back of the lamp housing (Figure 8).

 

  1. Right and/or Left side of the vehicle as needed. Remove the front lamp from the   vehicle (Figure 8).

 

  1. Render the recalled headlamps unusable and discard.

 

  1. Right and/or Left side of the vehicle as needed. Position the NEW front lamp unit to the front of the vehicle.

 

  1. Right and/or Left side of the vehicle as needed. Connect the headlamp bulb wire harness connectors to the back of the lamp housing.

 

  1. Right and/or Left side of the vehicle as needed. Position the front lamp unit into the FEM.

 

  1. Right and/or Left side of the vehicle as needed. Install the three screws that secure the front lamp to the FEM. Tighten the screws to 6.5 N·m (58 In. lbs.) (Figure 7).

 

  1. Both right and left side of the vehicle. Slide the fascia into the FEM fascia alignment tab under the headlamp (Figure 6).

 

  1. Both right and left side of the vehicle. Insert and snap into place the fascia tabs at the retainer bracket (Figure 6).

 

  1. Raise and support the vehicle.

 

  1. Left side of the vehicle, install and tighten the screw attaching the front fascia to the fender in the front wheel house opening (Figure 5).

 

  1. Left side of the vehicle, install the front wheel house lower splash shield to the vehicle then install the eight push pins securing the splash shield (Figure 5).

 

  1. Right side of the vehicle, install and tighten the screw attaching the front fascia to the fender in the front wheel house opening (Figure 4).

 

  1. Right side of the vehicle, install the three push pins securing the front fascia to the front wheel house splash shield (Figure 4).

 

  1. Lower the vehicle.

 

  1. Position the grill to the fascia. The center tab is for grill alignment only not a retaining tab. Engage the six retaining tabs that secure the grill to the fascia (Figure 3).

 

  1. Install the five push pins to secure the grill to the air duct and the radiator support (Figure 2).

 

  1. Connect the negative battery cable terminal to the remote battery post. Tighten the nut to 28 N·m (18 ft. lbs.) (Figure 1).

 

  1. Proceed to Section B Headlamp Alignment.

 

B.  Headlamp Alignment

  1. If the vehicle is equipped with headlamp leveling, be certain that the headlamp leveling switch is in the 0 (zero) position.

 

  1. Verify proper tire inflation pressures.

 

  1. Verify that there is no load in the vehicle (cargo or passengers), except for the driver.

 

  1. The fuel tank should be FULL. Add 2.94 kilograms (6.5 pounds) of weight over the fuel tank for each estimated gallon of missing fuel.

 

Steps 5 – 12 will prepare a suitable headlamp alignment screen (Figure 9).

  1. Tape a line on a level floor 7.62 meters (25 feet) away (1) from and parallel to the flat wall that will be used as the lamp alignment screen. The level floor will be used as the horizontal zero reference (Figure 9).

 

  1. An adjacent wall or floor member that is perpendicular (2) to the alignment screen can be used as the vertical zero reference. If there is no adjacent wall or floor member that is perpendicular to the screen, tape a second line on the floor perpendicular to both the alignment screen and the first line, and outboard of either side of where the vehicle will be positioned. This will be used as the vertical zero reference (Figure 9).

 

  1. Position the vehicle so that the side of the vehicle is parallel to the vertical zero reference, and so that the front of the lamp lenses are in the vertical plane of the parallel line taped on the floor 7.62 meters (25 feet) away (1) from the screen (Figure 9).

 

  1. Rock the vehicle side-to-side three times to allow the suspension to stabilize.

 

  1. Jounce the front suspension three times by pushing downward on the front bumper and releasing.

 

  1. Measure the distance between the optical center of one of the headlamps and the floor (6) (horizontal zero reference). Transfer this measurement to the alignment screen with a piece of tape placed horizontally to the floor. This line will be used as the lamp horizontal reference (Figure 9).

 

  1. Measure the distance between the vertical zero reference and the optical center of the first headlamp being aimed. Transfer this measurement (7) to the alignment screen with a piece of tape placed vertically across the appropriate headlamp horizontal reference. This is the centerline reference for the first lamp (Figure 9).

 

  1. Measure the distance on center between the first and the second headlamp (8) being aimed. Transfer this measurement to the alignment screen with a second piece of tape placed vertically across the appropriate headlamp horizontal reference. This is the centerline reference for the second lamp (Figure 9).

 

NOTE: Due to the linear nature of the headlamp cutoff, a properly aimed low beam headlamp will project the top edge of the high intensity pattern on the alignment screen just below the horizontal line to 50 millimeters (2 inches) below the horizontal line for domestic market vehicles, or to 130 millimeters (5.12 inches) below the horizontal line for export market vehicles. No horizontal (right/left) adjustment is required for this headlamp beam pattern in domestic market vehicles. Export market vehicles have a second horizontal (right/left) adjustment screw provided on the outboard side of the headlamp unit rear housing. The high beam pattern will be correct when the low beams are properly aimed.

 

  1. Turn the headlamps ON and select the LOW beams.

 

  1. Rotate the vertical adjustment screw on each front lamp unit to adjust the beam height as required (Figure 10).

 

  1. Turn off the headlamps.

 

  1. Close the hood.

 

Owner Notification and Service Scheduling

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

 

RCRIT-22E083-0624

 


Chronology :

  • On December 18, 2018, the FCA US LLC (“FCA US”) Technical Safety and Regulatory Compliance (“TSRC”) organization opened an investigation as a result of an audit of a front amber side reflex reflector performed by Transport Canada.
  • From December 2018 through February 2019, meetings were conducted between FCA US TSRC, FCA US Engineering and the supplier to review the issue, confirm the test results and root cause, understand the suspect part delivery dates to identify the suspect period and scope of parts affected, and understand the supplier corrective actions implemented.
  • As of March 14, 2019, FCA US identified zero CAIRs, zero VOQs, and zero field reports related to this issue.
  • As of March 14, 2019, total warranty is 0.0 c/1000.
  • As of March 14, 2019, FCA US is not aware of any accidents or injuries potentially related to this issue.
  • On March 7, 2019 , FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected units.
  • On April 5, 2019, FCA US filed a petition for inconsequential treatment with NHTSA.
  • On September 12, 2022, FCA US received notice of NHTSA’s denial of FCA US’ petition with instruction to amend the Part 573 Defect Information Report related to recall 19E-025 (FCA US No. V24).
  • On September 19, 2022, FCA US filed the amended Part 573 Defect Information Report related to recall 19E-025 (FCA US No. V24).
  • On September 22, 2022, FCA US received a request from NHTSA to file a new Part 573 Defect Information Report rather than amend the prior report.
  • On September 29, 2022, FCA US filed a new Part 573 Defect Information Report as requested.

 


1 Affected Product

Equipment

BRAND PART NO. PRODUCTION DATES
MOPAR HEADLAMP ASSEMBLY

 


11 Associated Documents

Recall Acknowledgement

RCAK-22E083-2898.pdf 675.264KB

RCAK-22E083-2898

 


Noncompliance Notice 573 Report

RCLRPT-22E083-5715.PDF 217.906KB

RCLRPT-22E083-5715

 


Manufacturer Notices(to Dealers,etc) – FCA US LLC (FCA US) has announced a safety recall on certain Mopar aftermarket headlamp assemblies 05116288AC, 05116289AC, 68200084AB, 68200085AB intended for use with 2008 through 2019 model year (JC) Dodge Journey vehicles.

RCMN-22E083-8149.pdf 49.161KB

RCMN-22E083-8149

 


Recall 573 Report – 10/27/22

RCLRPT-22E083-4999.PDF 218.038KB

RCLRPT-22E083-4999

 


Manufacturer Notices(to Dealers,etc) – Owner Interim Combo Copy

RCMN-22E083-0728.pdf 182.66KB

RCMN-22E083-0728

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22E083-0047.pdf 149.295KB

RIONL-22E083-0047

 


Remedy Instructions and TSB

RCRIT-22E083-0624.pdf 1704.467KB

RCRIT-22E083-0624

 


ISSUED Owner Notification Letter(Part 577)

RCONL-22E083-4213.pdf 148.051KB

RCONL-22E083-4213

 


Recall Quarterly Report #1, 2023-1

RCLQRT-22E083-1692.PDF 211.137KB

RCLQRT-22E083-1692

 


Recall Quarterly Report #2, 2023-2

RCLQRT-22E083-1439.PDF 211.234KB

RCLQRT-22E083-1439

 


Recall Quarterly Report #3, 2023-3

RCLQRT-22E083-5759.PDF 211.454KB

RCLQRT-22E083-5759

 


Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22E083&docType=RCL

 


 

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