23E023 Frame Stud May Puncture Fuel Tank – Mopar Frame Assemblies

March 23, 2023 NHTSA CAMPAIGN NUMBER: 23E023000

Frame Stud May Puncture Fuel Tank

A fuel leak in the presence of an ignition source can increase the risk of a fire.

 

NHTSA Campaign Number: 23E023

Manufacturer Chrysler (FCA US, LLC)

Components STRUCTURE

Potential Number of Units Affected 165

 

Summary

Chrysler (FCA US, LLC) is recalling certain Mopar frame assemblies with part numbers 68495556AA, 68495556AB, 68438094AB, and 68438096AB. When installed in a vehicle, a stud on the frame assembly may puncture the fuel tank during a crash and result in a fuel leak.

 

Remedy

Dealers will inspect and, if necessary, remove the frame stud and apply paint, free of charge. Owner notification letters were mailed April 6, 2023. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC’s number for this recall is 29A.

 

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 – 29A

FCA US LLC (FCA US) has announced an equipment safety recall on certain MOPAR Frame Assemblies: 68495556AA, 68495556AB, 68438094AB, 68438096AB intended for use on 2018 through 2023 model year (JL) Jeep® Wrangler vehicles with short wheelbase (Body Style: JL72).

 

REASON FOR THIS SAFETY RECALL

Some of the above Jeep Wrangler frames may have been built with an unnecessary and unused frame stud. When installed in a vehicle, the frame stud may contact the fuel tank in a crash, which, in certain circumstances, can cause a fuel leak. A fuel leak in the presence of a competent ignition source may result in a fire, increasing the risk of occupant injury and/or injury to persons outside the vehicle.

 

SERVICE ACTION

FCA US will conduct a voluntary safety recall on all affected frames to inspect and, if necessary, remove the frame stud and apply paint. 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 2023.

 


March 2023

Dealer Service Instructions for:

Equipment Safety Recall 29A

NHTSA 23E-023

Frame Stud

 

Remedy Available

MOPAR Frame Assembly 68495556AA
MOPAR Frame Assembly 68495556AB
MOPAR Frame Assembly 68438094AB
MOPAR Frame Assembly 68438096AB

This recall applies only to the above short wheelbase frames (Body Style: JL72) intended for use on 2018-2023 (JL) Jeep Wrangler vehicles.

 

Subject

On about 160 of the above frames may have been built with an unnecessary and unused frame stud. When installed in a vehicle, the frame stud may contact the fuel tank in a crash, which, in certain circumstances, can cause a fuel leak. A fuel leak in the presence of a competent ignition source may result in a fire, increasing the risk of occupant injury and/or injury to persons outside the vehicle.

 

Repair

Inspect the frame and, if necessary, remove the frame stud then apply black paint to the removed stud area.

 

NOTE: Same remedy procedure applies to frames installed in vehicle or not.

 

Parts Information

NOTE: Paint is required ONLY for vehicles/frames that have stud removed: An equivalent black paint can be used if specified paint is not available.

Part Number Qty. Description
04443609AB As Required PAINT, Touch Up Spray Black (142g / 5oz)
(Each spray can will repair 25 vehicles)
OR
68626414AA

(Or equivalent black paint)

 

Parts Return

No parts return required for this campaign.

 

Special Tools

No special tools are required to perform frame stud removal service procedure.

 

Inspection Procedure (Off Vehicle)

A.  Frame Stud Inspection (Off Vehicle)

 

Visually look for a stud on the frame in the location shown in (Figure 1).

  • Frame Stud Located: Proceed to Section D. Frame Stud Removal for stud removal procedure and perform only Steps 1 – 3 then claim the “Off Vehicle” stud removal LOP.
  • Frame Stud Does NOT Exist: No further action required. Claim the “Off Vehicle” stud inspection LOP.

 

Inspection Procedure (On Vehicle)

B.  Frame Label Inspection

 

  1. Look for a label on the driver side frame rail just rearward of the door hinges.

 

  1. If the label looks like (Figure 2) and is readable not missing or covered over by an aftermarket coating material, then read the label as instructed in (Figure 2).

 

  1. If the label does NOT look like (Figure 2) or is unreadable, missing, or covered over by an aftermarket coating material, then proceed to Section C. Frame Stud Inspection.

 

  1. What were the first two characters on the label as instructed in (Figure 2).
    • First two characters were “TT” – No further action required. Claim the appropriate inspection LOP and return vehicle to customer.
    • First two characters were some other combination of characters – Proceed to Section C. Frame Stud Inspection.

 

C.  Frame Stud Inspection (On Vehicle)

 

  1. Raise and support the vehicle.

 

  1. Remove the fasteners, three bolts and one nut securing the front reinforcement crossmember then remove the crossmember from the vehicle (Figure 3).

 

  1. Release the fuel pipe retainer from the fuel tank front skid plate (Figure 4).

 

  1. Remove the fasteners, two bolts and three nuts securing the fuel tank front skid plate then remove the skid plate from the vehicle (Figure 5).

 

NOTE: Nut locations on skid plate are slotted so nuts do not need to be fully removed.

 

  1. Visually look for a stud on the frame in the location shown in (Figure 6).
    • Frame Stud Located: Proceed to Section D Frame Stud Removal for stud removal procedure. Do NOT continue with Inspection Procedure.
    • Frame Stud Does NOT Exist: Continue with Inspection Procedure to reassemble the vehicle. Section D is not required if no stud exists.

 

  1. Position the fuel tank front skid plate to the vehicle then install and tighten the fasteners, two bolts and three nuts (Figure 5).
    • Bolts: 75 N·m (55 ft. lbs.)
    • Nuts: 20 N·m (15 ft. lbs.)

 

  1. Install the fuel pipe retainer to the fuel tank front skid plate (Figure 4).

 

  1. Position the front reinforcement crossmember to the vehicle then install and tighten the three bolts and one nut (Figure 3).
    • Bolts crossmember to outer frame rails: 95 N·m (70 ft. lbs.)
    • Bolt crossmember center leg to crossmember: 75 N·m (55 ft. lbs.)
    • Nut: 20 N·m (15 ft. lbs.)

 

  1. Lower the vehicle and return to the customer or inventory.

 

  1. Claim the Inspection LOP.

 

D.  Frame Stud Removal

 

  1. Using a suitable chisel and hammer, cut the stud off as close to the frame as possible (Figure 7).

 

  1. After removing the frame stud (Figure 8).

 

  1. Obtain black spray paint specified in the Parts Section and a brush or cotton swab or suitable applicator. Spray a small amount of paint into a cup to dip the applicator or directly onto the applicator then apply the paint to the vehicle frame covering any bare exposed metal in the location of the removed frame stud (Figure 9).

 

  1. Position the fuel tank front skid plate to the vehicle then install and tighten the fasteners, two bolts and three nuts (Figure 5).
    • Bolts: 75 N·m (55 ft. lbs.)
    • Nuts: 20 N·m (15 ft. lbs.)

 

  1. Install the fuel pipe retainer to the fuel tank front skid plate (Figure 4).

 

  1. Position the front reinforcement crossmember to the vehicle then install and tighten the three bolts and one nut (Figure 3).
    • Bolts crossmember to outer frame rails: 95 N·m (70 ft. lbs.)
    • Bolt crossmember center leg to crossmember: 75 N·m (55 ft. lbs.)
    • Nut: 20 N·m (15 ft. lbs.)

 

  1. Lower the vehicle and return to the customer or inventory.

 

  1. Claim the stud removal LOP.

 


1 Affected Product

Equipment

BRAND PART NO. PRODUCTION DATES
MOPAR FRAME ASSEMBLY

 


6 Associated Documents

Defect Notice 573 Report

RCLRPT-23E023-8064.PDF 216.671KB

RCLRPT-23E023-8064

 


Miscellaneous Document – Chart re FCA US LLC Recall Part Number/Model Compatibility 29A Frame Assembly / Frame

RMISC-23E023-2381.pdf 109.477KB

RMISC-23E023-2381

 


Recall Acknowledgement

RCAK-23E023-1570.pdf 645.242KB

RCAK-23E023-1570

 


Remedy Instructions and TSB

RCRIT-23E023-6522.pdf 1126.423KB

RCRIT-23E023-6522

 


Manufacturer Notices(to Dealers,etc) – NSRAC re FCA US LLC (FCA US) has announced an equipment safety recall on certain MOPAR Frame Assemblies: 68495556AA, 68495556AB, 68438094AB, 68438096AB intended for use on 2018 through 2023 model year (JL) Jeep® Wrangler vehicles with short wheelbase (Body Style: JL72)

RCMN-23E023-8354.pdf 48.247KB

RCMN-23E023-8354

 


ISSUED Owner Notification Letter(Part 577)

RCONL-23E023-1872.pdf 148.136KB

RCONL-23E023-1872

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23E023&docType=RCL

 


 

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