Safety Recall P80 / NHTSA 14V-795 Clutch Interlock Switch

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NHTSA Campaign Number: 14V795
Manufacturer Chrysler Group LLC
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 54,164

Clutch Ignition Interlock Switch

Broken springs can result in a no-start condition, or cause unintended movement when the ignition is cranked, increasing the risk of a vehicle crash.

Summary

Chrysler Group LLC (Chrysler) is recalling certain model year 2006-2007 Dodge Ram 1500, 2500, 3500, Dakota, and 2006 Mitsubishi Raider vehicles manufactured July 1, 2005, to July 31, 2006 with manual transmissions.

The return springs in the clutch ignition interlock switch may break.

Remedy

Chrysler will notify owners, and dealers will replace the clutch ignition interlock switch, free of charge.

The recall began on March 27, 2015.

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

Chrysler’s number for this recall is P80.

Notes

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

Check if your Vehicle has a Recall

Revised April 2015

Dealer Service Instructions for:

Safety Recall P80 / NHTSA 14V-795 Clutch Interlock Switch

NOTE: The parts section of this recall has been updated. It now includes a part number for the clutch interlock switch cover.

Models

2006 – 2007	(DR)	Dodge RAM Truck (1500 series)
	(DH)	Dodge RAM Truck (2500/3500 series)
	(D1)	Dodge RAM Truck (3500 series)
	(ND)	Dodge Dakota

NOTE: This recall applies only to the above vehicles equipped with a manual transmission (sales code DEG or DEC or DEJ or DDT) built through July 31, 2006 (MDH 073123).

IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service.Involved vehicles can be determined by using the VIP inquiry process.

Subject

The clutch interlock switch on about 54,000 of the above vehicles may contain a return spring that fatigues. A fatigued clutch interlock switch return spring could allow the driver to engage the engine starter motor without the clutch pedal being depressed. Engaging the engine starter motor with the transmission in gear and the clutch engaged, could result in unintended vehicle movement and cause a crash without warning.

Repair

The clutch interlock switch must be replaced on all involved vehicles.

Parts Information

Part Number	Description
CBGZP801AA	Switch, Clutch Interlock

Each dealer to whom vehicles in the recall were assigned will receive enough clutch interlock switches to service about 15% of those vehicles.

Part Number	Description
05015960AA	Cover, Clutch Interlock Switch

NOTE: The clutch interlock switch cover is only required if the original cover breaks during the repair. Very few covers are expected to break.

Parts Return

No parts return required for this campaign.

Special Tools

No special tools are required to perform this service procedure.

Service Procedure

Move the driver seat to the full rearward position.

Disconnect the negative battery cable.

Remove and save the driver floor mat.

Locate the green clutch pedal position switch connector under the instrument panel near the clutch pedal.

Unlock the red electrical connector lock on the green clutch pedal position switch electrical connector by sliding it rearward (Figure 1).

NOTE: Use a small screwdriver to unlock the red electrical connector lock. The lock may be difficult to unlock.

Depress the green clutch pedal position switch electrical connector retainer tab and disconnect the clutch pedal position switch electrical connector (Figure 1).

Figure 1 – Clutch Pedal Position Switch Electrical Connector

Figure 2 – Clutch Pedal Position Switch Retaining Clip

(Clutch Master Cylinder Removed for Photographic Purposes Only)

Use the following procedure to remove the white clutch pedal position switch retaining clip:

a. Squeeze the two clutch retaining arms of the pedal position switch retaining clip together (Figure 2).

b. Slide the clutch pedal position switch retaining clip rearward (towards the clutch pedal).

c. Remove and save the clutch pedal position switch retaining clip.

NOTE: The clutch pedal position switch retaining clip will be reused.

Figure 3 – Clutch Pedal Position Switch Removal

(Clutch Master Cylinder Removed for Photographic Purposes Only)

Pull the switch towards the clutch pedal slightly. Then pull the back of the clutch pedal position switch outward, away from the clutch actuation rod (Figure 3).

Remove and discard the clutch pedal position switch.

Figure 4 – Clutch Pedal Position Switch Installation

(Clutch Master Cylinder Removed for Photographic Purposes Only)

Use the following procedure to install the new clutch pedal position switch:

a. Place the new switch against the clutch rod at an angle (Figure 4).

NOTE: Be sure that the spring loaded plunger inside the switch is on the chrome section of the clutch actuation rod.

b. Slide the clutch pedal position switch up the clutch actuation rod slightly to compress the plunger return springs.

Figure 5 – Clutch Pedal Position Switch Installation

(Clutch Master Cylinder Removed for Photographic Purposes Only)

c. Place the back of the clutch pedal position switch against the rod. Then push the back of the switch against the clutch actuation rod until an auditable click is heard (Figure 5).

CAUTION: Failure to install the switch as described or forcing the switch onto the rod will crack the switch.

Install the original white plastic clutch pedal position switch retaining clip (Figure 2).

Connect the clutch pedal position switch green electrical connector to the green body wire harness electrical connector (Figure 1).

Engage the clutch pedal position switch red connector lock (Figure 1).

Connect the negative battery cable.

Use the following procedure to check clutch position switch operation:

a. Place the gear shift in the “Neutral” position.

b. Apply the service brake.

c. Turn the ignition key to the “Start” position. The engine should not crank.

d. Depress the clutch pedal.

e. With the clutch pedal depressed, turn the ignition key to the “Start” position. The engine should crank.

NOTE: If the engine cranks with the clutch engaged (clutch pedal released), the repair was not done correctly.

Install the driver side floor mat.

Return the vehicle to the customer.

Completion Reporting and Reimbursement

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

Use the following labor operation number and time allowance:

	Labor Operation Number	Time Allowance
Replace clutch interlock switch	08-P8-01-82	0.2 hours

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

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

Dealer Notification

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

Owner Notification and Service Scheduling

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

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

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

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

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

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

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

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

Additional Information

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

Customer Services / Field Operations

FCA US LLC

CLUTCH INTERLOCK SWITCH

__________________________

IMPORTANT SAFETY RECALL
P80 / NHTSA 14V-795

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

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

Dear: (Name)

FCA US LLC has decided that a defect, which relates to motor vehicle safety, exists in certain 2006 and 2007 model year Dodge Dakota and Dodge RAM trucks equipped with a manual transmission.

*The problem is…*	The clutch interlock switch on your truck may contain a return spring that fatigues. A fatigued clutch interlock switch return spring could allow the driver to engage the engine starter motor without the clutch pedal being depressed. Engaging the engine starter motor with the transmission in gear and the clutch engaged could result in unintended vehicle movement and cause a crash without warning
*What your dealer will do…*	FCA will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the clutch interlock switch. The work will take about one hour to complete. However, additional time may be necessary depending on service schedules.
*What you must do to ensure your safety…*	Simply contact your Chrysler, Jeep, Dodge or RAM dealer right away to schedule a service appointment. Ask the dealer to hold the part for your vehicle or to order it before your appointment. Please bring this letter with you to your dealer.
*If you need help…*	If you have questions or concerns which your dealer is unable to resolve, please contact the FCA Group Recall Assistance Center at either recalls.mopar.com or

1-800-853-1403.

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

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

If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to https://www.safercar.gov.

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

Customer Services / Field Operations

FCA US LLC

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

https://static.nhtsa.gov/odi/rcl/2014/RCRIT-14V795-9207.pdf