This Bulletin Supersedes Service Bulletin 19-008-05, Dated October 26, 2005, Which Should Be Removed from Your Files

NUMBER: 19-008-05 REV. A

GROUP: Steering

DATE: November 2, 2005

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.

THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-008-05, DATED OCTOBER 26, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A NEW PARTS TABLE AND CAUTION.

SUBJECT: Revised Power Steering System Bleeding Procedures

MODELS:

2004 - 2006 (CS) Pacifica 2002 - 2006 (DR/DH/D1) Ram Pickup 2004 - 2006 (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - 2006 (KJ) Liberty 2005 - 2006 (LX/LE) 300/Charger/Magnum 2005 - 2006 (ND) Dakota 2000 - 2005 (PL) Neon/SRT4 2001 - 2006 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK/XH) Commander

NOTE: This bulletin does NOT apply to DR SRT10 vehicles. 19-008-05 REV. A -2-

PARTS REQUIRED:

Qty. Part No. Description **AR 05166226AA Power Steering Fluid, ATF+4 (MS 9602) For use in: CS, DR, DH, D1, HB, JR, KJ, LX, LE, ND, PL, PT, RG, RS vehicles** **AR 05142893AA Power Steering Fluid, Hydraulic System (MS 10838) For use in: WK, WH, XK, KH vehicles**

SPECIAL TOOLS/EQUIPMENT REQUIRED:

9688 Adapter, P/S Cap C-4207-A Vacuum Pump, Hand (or equivalent)

POWER STEERING SYSTEM BLEEDING PROCEDURE: WARNING:The fluid level should be checked with engine off to prevent injury from moving components.

CAUTION: **MOPAR® Power Steering Fluid +4 or ATF+4 (MS-9602) is to be used in the power steering system of CS, DR, DH, D1, HB, JR, KJ, LX, LE, ND, PL, PT, RG, and RS vehicles. Mopar Hydraulic Power Steering Fluid (MS 10838) is to be used in the power steering system of WK, WH, XH, and XK vehicles. No other power steering or automatic transmission fluid is to be used in these systems. Damage may result to the power steering pump and system if the incorrect fluid is used. Do not overfill the power steering reservoir.**

CAUTION: If the air is not purged from the power steering system correctly, pump failure could result.

NOTE: If the power steering reservoir cap does not have a dipstick, there will be a sight window on the side of the reservoir for checking fluid level.

NOTE: Be sure the vacuum tool used in the following procedure is clean and free of any fluids. 1. Wipe the filler cap clean with a clean rag and fill the power steering reservoir to the proper level. The dipstick should indicate COLD when the fluid is at normal ambient temperature. 2. Tightly insert Miller Special Tool, 9688 - P/S Cap Adapter, onto the pump reservoir (Fig. 1). -3- 19-008-05 REV. A

Fig. 1 VACUUM PUMP

1 - HAND VACUUM PUMP C-4207-A 2 - CLEAR HOSE FROM ADAPTER TO RESERVOIR 3 - SPECIAL TOOL - 9688 4 - VACUUM PUMP RESERVOIR

CAUTION: Failure to properly connect the vacuum pump reservoir may allow power steering fluid to be sucked into the vacuum pump.

CAUTION: Do not run the engine while vacuum is applied to the power steering system.

NOTE: When performing Step #3, make sure the minimum vacuum level is maintained during the entire time period. 3. Using a hand vacuum pump, Miller Special Tool C-4207-A, with the vacuum reservoir attached, apply 68-85 kPa (20-25 in. Hg) of vacuum to the power steering system for a minimum of 3 minutes. 4. Slowly release the vacuum, remove the special tools and add fluid to the proper level if necessary. 5. Repeat Step #1 through Step #4 until the fluid level no longer drops. 6. Start the engine and cycle the steering wheel from lock to lock three times. NOTE: Do not hold the steering wheel on stops. 7. Stop the engine and check for leaks at all connections. Check for any signs of air in the reservoir and check reservoir level. If air is present repeat the procedure if necessary. POLICY: Information Only.

June 2004 Dealer Service Instructions for: Customer Satisfaction Notification D27 Tire and Loading Information Label

Models

2005 (LX) Chrysler 300 NOTE: This recall only applies to certain vehicles equipped with P215/65R17 tires (Sales Code TWH) that were built through April 15, 2004 (MDH 0415XX). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification.

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

Subject

The tire and loading information label on about 750 of the above vehicles incorrectly states that the vehicle is equipped with a full size spare tire. Since a full size spare tire is not an available option on the listed model, all involved vehicles are equipped with a compact spare tire (T135/90D17).

Repair

Tire and loading information overlay labels will be mailed to all owners known to DaimlerChrysler for the owners to install (or for installation by their dealer if preferred).

Parts Information

Each dealer, to whom vehicles in the recall were invoiced, will receive enough Tire and Loading Information Overlay Labels, P/N CEA0D270, (included with the vehicle list) to service 100% of unsold vehicles. Tire and loading information overlay labels are being mailed to all owners known to DaimlerChrysler. If an owner’s label is lost, dealers may order additional labels if necessary.

Service Procedure

1. Open the driver’s door and locate the Tire and Loading Information Label on the driver’s door opening B-Pillar (Figure 1).

2. Clean the existing label by wiping it with a household cleaner to remove any dirt, oil residue or grease.

3. Remove the overlay label from its paper backing and carefully install it on the tire and loading information label covering the original spare tire information (Figure 1). Firmly press and smooth the label to the surface of the existing label to ensure good adhesion.

Figure 1 Customer Satisfaction Notification D27 Page 3 Tire and Loading Information Label

Completion Reporting and Reimbursement

Labor Operation Time Number Allowance Install Tire and Loading Information Overlay Label 23-D2-71-82 0.2 hours

Add the cost of the label, if necessary, plus applicable dealer allowance to your claim.

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

Parts Return

Not applicable.

Dealer Notification and Vehicle List

All dealers will receive a copy of this dealer notification letter by DMAIL and by mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this notification in the near future.

Customer Satisfaction Notification D27 Page 4 Tire and Loading Information Label

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. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer notification letter. 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 should 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.

Owner Notification and Service Scheduling

All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to install the labels themselves or schedule an appointment 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.

Customer Satisfaction Notification D27 Page 5 Tire and Loading Information Label

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 DaimlerChrysler Corporation

CUSTOMER SATISFACTION NOTIFICATION – SPARE TIRE INFORMATION

Dear: (Name) DaimlerChrysler has determined that incorrect spare tire information was listed on the Tire and Loading Information Label installed on some 2005 model year Chrysler 300 vehicles. The problem is... The tire and loading information label on your Chrysler 300 (VIN: xxxxxxxxxxxxxxxxx) incorrectly states that your vehicle is equipped with a full size spare tire. Since a full size spare tire is not an available option, your vehicle is equipped with a compact spare tire. What you must ¾ We ask that you apply the enclosed label overlay as described on the do... reverse side of this letter. ¾ If preferred, you may contact your dealer to schedule a service appointment for installation of the label overlay. The service will be provided free of charge and should only take a few minutes to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. Remember to bring this letter and the enclosed label overlay with you to your dealer. If you need If you have questions or concerns which your dealer is unable to resolve, help... please contact DaimlerChrysler at 1-800-853-1403. Please help us update our records, using the enclosed prepaid post card, if any of the conditions listed apply to you and/or your vehicle. Be sure to check the appropriate box(s), print the last eight (8) characters of the VIN (VVVVVVVV) and the notification code (D27), and list any additional information requested. We're sorry for any inconvenience, but we believe that this information will help to ensure your continuing satisfaction with your vehicle. Thank you for your attention to this important matter. Customer Services Field Operations DaimlerChrysler Corporation D27

(Over)

Installation Instructions for the Tire and Loading Information Label Overlay 1. Open the driver’s door and locate the Tire and Loading Information Label on the driver’s door opening B-Pillar (Figure 1).

2. Clean the existing label by wiping it with a household cleaner to remove any dirt, oil residue or grease.

Figure 2

July 2004 Dealer Service Instructions for: Safety Recall D21 Rear Floorpan Reinforcement Spot Welds

Models

2005 (LX) Chrysler 300 and Dodge Magnum NOTE: This recall applies only to the certain vehicles built from May 14, 2004 through May 16, 2004 (MDH 051420 through 051609). IMPORTANT: Most of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall.

IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and 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

A spot welding operation for the rear floorpan reinforcement on 21 of the above vehicles may not have been performed. This could cause the rear seat belt anchors and the child seat anchors to separate in certain crash conditions, which can increase the risk of injury to rear seat passengers.

Repair

All involved vehicles must be inspected for the presence of rear floorpan reinforcement spot welds. Vehicles that have missing welds must have structural rivets installed.

Alternate Transportation

Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that riveting is required and the vehicle must be held overnight.

Parts Information

Due to the small number of involved vehicles expected to require rivet installation, no parts will be distributed initially. Rivets and mastic patches should be ordered only after inspection determines that repair is required. Very few vehicles are expected to require rivet installation.

Part Number Quantity Description 06034573 18 Structural Rivet 02654684 18 Mastic Patch

Special Tool

A special air/hydraulic power set riveter tool is required for the installation of the structural rivets. ALL Chrysler and Dodge dealers previously received ONE (1) W-AK175ACH Power Set Riveter, free of charge, through Pentastar Service Equipment (PSE) in December 1998.

Additional power riveters may be ordered through Pentastar Service Equipment (PSE) at dealer cost by calling 1-800-223-5623 or faxing 1-800-734-4334. Additional power riveters are NOT reimbursable by DaimlerChrysler.

Safety Recall D21 – Rear Floorpan Reinforcement Spot Welds Page 3

Service Procedure

A. Inspect Rear Floorpan Reinforcement Spot Welds: 1. Open the trunk. REAR FLOORPAN 2. Lift the rear of the trunk floor REINFORCEMENT cover and then pull the floor cover rearward.

3. Open the rear driver side door. 4. Fold the rear seat back forward to expose the cargo/trunk area. 5. Remove the seat back carpet push pin retainer on each side of the vehicle and then pull the carpet back. 6. Pull the floor silencer pad forward to expose the rear Figure 1 floorpan reinforcement (Figure 1).

7. Inspect the floorpan reinforcement for the presence of the two spot welds shown in Figure 2.

Figure 2 – Driver’s Side Shown Safety Recall D21 – Rear Floorpan Reinforcement Spot Welds Page 4

Service Procedure (Continued)

8. If spot welds are present, no further action is necessary. Continue with Step 9.

If spot welds are missing, continue with Section B – Install Structural Rivets.

9. Return the floor silencer pad to its original position.

10. Return the seat back carpet to its original position and install the push pins.

11. Return the seat back to its upright position. 12. Close the door. 13. Return the trunk floor cover to its original position. 14. Close the trunk lid. 15. Return the vehicle to the customer. Safety Recall D21 – Rear Floorpan Reinforcement Spot Welds Page 5

Service Procedure (Continued)

B. Install Structural Rivets: NOTE: Only vehicles with missing spot welds, as determined by the inspection in Section A, require repair. Very few vehicles are expected to require rivet installation. 1. Return the seat back to its upright position.

2. Release the two (2) rear seat cushion clips and remove the rear seat cushion from the vehicle. 3. Remove six (6) rear seat back nuts and then remove the seat back from vehicle. 4. Roll the floor silencer pad forward.

5. Disconnect the guides for the wiring harness and battery cable from the floor pan and set the cable and wiring aside.

6. Make full size copies of the five (5) templates on pages 7 – 11. Cut out the templates and place them on the vehicle as shown in Figure 3.

Figure 3 Safety Recall D21 – Rear Floorpan Reinforcement Spot Welds Page 6

Service Procedure (Continued)

7. Mark the 18 locations shown in Figure 3 on the rear floorpan reinforcement with a center punch, permanent marker or paint pen.

8. Using a 9/32” (7 mm) bit, drill a hole through the reinforcement and the floorpan at each location. Ensure that the center line of each hole is no less than 3/8” (10 mm) from the nearest edge.

9. Vacuum any metal shavings from the vehicle.

10. Using the W-AK175ACH Power Set Riveter, install a structural rivet (Mopar P/N 06034573) at each location. 11. Install an interior mastic patch (Mopar P/N 02654684) over each structural rivet. 12. Install the guides for the wiring harness and battery cable into their original locations.

13. Return the floor silencer pad to its original position. 14. Install the rear seat back. Tighten the six (6) seat back nuts to 35 ft-lbs (47 N·m). 15. Install the rear seat cushion. 16. Close the door. 17. Return the trunk floor cover to its original position. 18. Close the trunk lid. Safety Recall D21 – Rear Floorpan Reinforcement Spot Welds Page 7

Safety Recall D21 – Rear Floorpan Reinforcement Spot Welds Page 8

Safety Recall D21 – Rear Floorpan Reinforcement Spot Welds Page 9

Safety Recall D21 – Rear Floorpan Reinforcement Spot Welds Page 10

Safety Recall D21 – Rear Floorpan Reinforcement Spot Welds Page 11

Safety Recall D21 – Rear Floorpan Reinforcement Spot Welds Page 12

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 DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Inspect rear floorpan reinforcement 23-D2-11-81 0.2 hours spot welds Inspect rear floorpan reinforcement 23-D2-11-82 1.0 hours spot welds and install rivets Add the cost of the parts plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

Parts Return

Not applicable.

Dealer Notification and Vehicle List

All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future.

Safety Recall D21 – Rear Floorpan Reinforcement Spot Welds Page 13

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. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. 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.

Owner Notification and Service Scheduling

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 DaimlerChrysler Corporation

SAFETY RECALL – REAR FLOORPAN REINFORCEMENT SPOT WELDS Dear: (Name) This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has decided that a defect, which relates to motor vehicle safety, exists in a small number of 2005 model year Chrysler 300 and Dodge Magnum vehicles. The problem is... A spot welding operation for the rear floorpan reinforcement on your vehicle (VIN: xxxxxxxxxxxxxxxxx) may not have been performed. This could cause the rear seat belt anchors and/or the child seat anchors to separate in certain crash conditions, which can increase the risk of injury to rear seat passengers. What your dealer DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do will do... this, your dealer will inspect the rear floorpan reinforcement for missing welds and install structural rivets if necessary. The inspection will take only a few minutes while the rivet installation will require about an hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must Simply contact your dealer right away to schedule a service appointment. Ask the do to ensure your dealer to hold the parts for your vehicle or to order them before your appointment. safety... Remember to bring this letter with you to your dealer. If you need If you have questions or concerns which your dealer is unable to resolve, please help... contact DaimlerChrysler at 1-800-853-1403. Please help us update our records, by filling out the enclosed prepaid postcard, if any of the conditions listed on the card apply to you or your vehicle. Be sure to print the last eight (8) characters of the VIN (VVVVVVVV) and notification code D21 on the postcard. If you have already experienced this condition and have paid to have it repaired, you may send your original receipts and/or other adequate proof of payment to the following address for reimbursement: DaimlerChrysler, P.O. Box 610207, Port Huron, MI 48061-0207, Attention: Reimbursement. 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, 400 Seventh Street, S.W., Washington, DC 20590, or call the toll-free Auto Safety Hotline at 1-888-327-4236. 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 DaimlerChrysler Corporation D21 Note to lessors receiving this recall: Federal regulation requires that you forward this recall notice to the lessee within 10 days.

July 2004 Dealer Service Instructions for: Safety Recall DD2828 Battery Cable Bulkhead Stud Fasteners

Models

2005 (LX) Chrysler 300 and Dodge Magnum NOTE: This recall applies only to the above vehicles built through April 20, 2004 (MDH 042013). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall.

Subject

The battery cable fasteners at the bulkhead stud on about 20,000 of the above vehicles may not have been properly tightened. A loose fastener can cause an instrument panel fire.

Repair

The battery cable fasteners at the bulkhead stud must be tightened to the proper specification.

Parts Information

No parts are required to perform this service procedure.

Service Procedure

A. Tighten Battery Cable Bulkhead Stud Fasteners: 1. Open the trunk lid. 2. Remove the battery access panel. 3. Disconnect the negative battery cable.

NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Open the front passenger door. 5. Remove the front passenger side floor mat. A-PILLAR 6. Remove the front door sill trim/kick SILL panel (Figure 1). TRIM/KICK PANEL 7. Remove the carpet push pin and then pull back the passenger side carpet and padding. 8. Pull up the kick-up panel silencer pad to expose the battery cable bulkhead stud. Figure 1 9. Inspect the battery cable bulkhead stud for signs of arcing and/or cross- threading (Figure 2). If the bulkhead stud is damaged, continue with Section B – Replace Battery Cable Bulkhead Stud. Safety Recall D28 – Battery Cable Bulkhead Stud Fasteners Page 3

Service Procedure (Continued)

10. Tighten the battery cable-to- bulkhead stud fastener to 80 in-lbs (9 N·m) (Figure 2).

11. Return the kick-up panel silencer pad to its original position.

12. Install the carpet and padding and install the carpet push pin. 13. Install the front door sill trim/kick BULKHEAD STUD panel (Figure 1). ASSEMBLY 14. Install the passenger side floor mat. 15. Close the front passenger door. BATTERY 16. Raise the vehicle on an appropriate CABLE hoist. Figure 2 17. Remove the six (6) passenger side underbody splash shield push pins WHEEL WELL (Figure 3). SPLASH SHIELD 18. Remove the underbody splash shield (Figure 3). PUSH PINS 19. Inspect the battery cable bulkhead stud for signs of arcing and/or cross- threading (Figure 4). If the bulkhead stud is damaged, continue with Section B – Replace Battery UNDERBODY Cable Bulkhead Stud. SPLASH SHIELD

Figure 3 Safety Recall D28 – Battery Cable Bulkhead Stud Fasteners Page 4

Service Procedure (Continued)

20. Tighten the battery cable-to- bulkhead stud fastener to 80 in-lbs (9 N·m) (Figure 4). BULKHEAD STUD 21. Install the underbody splash shield ASSEMBLY (Figure 3).

22. Install the underbody splash shield push pins (Figure 3). 23. Lower the vehicle. 24. Connect the negative battery cable. FRONT BATTERY 25. Install the battery access cover. CABLE Figure 4 26. Close the trunk lid. 27. Continue with Section C – Express Window and/or ESP Calibration.

B. Replace Battery Cable Bulkhead Stud: NOTE: Only damaged battery cable bulkhead stud assemblies require replacement. Very few vehicles are expected to require bulkhead stud replacement. 1. If the damaged bulkhead cable stud was found during the interior portion of the service procedure:

a. Raise the vehicle on an appropriate hoist. b. Remove the six (6) passenger side underbody splash shield push pins (Figure 3). c. Remove the underbody splash shield (Figure 3).

2. Disconnect the battery cable from the bulkhead cable stud (Figure 4).

3. Lower the vehicle. Safety Recall D28 – Battery Cable Bulkhead Stud Fasteners Page 5

Service Procedure (Continued)

4. If the damaged bulkhead cable stud was found during the exterior/underbody portion of the service procedure: a. Remove the front passenger side floor mat.

b. Remove the front door sill trim/kick panel (Figure 1).

c. Remove the carpet push pin and then pull back the passenger side carpet and padding.

d. Pull up the kick-up panel silencer pad to expose the battery cable bulkhead stud. 5. Disconnect the battery cable from the bulkhead stud (Figure 2). 6. Remove the retaining nut for the bulkhead stud assembly and then remove and discard the bulkhead stud assembly (Figure 2). 7. Install a new bulkhead stud assembly (P/N 05059113AC).

8. Install the bulkhead stud assembly retaining nut (Figure 2), tighten the nut to 80 in-lbs (9 N·m). 9. Install the battery cable onto the bulkhead stud (Figure 2). Install a new battery cable nut (P/N 06101809) and tighten to 80 in-lbs (9 N·m). 10. Return the kick-up panel silencer pad to its original position. 11. Install the carpet and padding and install the carpet push pin. 12. Install the front door sill trim/kick panel (Figure 1).

13. Install the passenger side floor mat.

14. Close the front passenger door. 15. Raise the vehicle on an appropriate hoist.

16. Install the battery cable onto the bulkhead stud (Figure 4). Install a new battery cable nut (P/N 06101809) and tighten to 80 in-lbs (9 N·m). Safety Recall D28 – Battery Cable Bulkhead Stud Fasteners Page 6

Service Procedure (Continued)

17. Install the underbody splash shield (Figure 3).

18. Install the underbody splash shield push pins (Figure 3).

19. Lower the vehicle.

20. Connect the negative battery cable.

21. Install the battery access cover.

22. Close the trunk lid.

23. Continue with Section C – Express Window and/or ESP Calibration.

C. Express Window and/or ESP Calibration. 1. For vehicles equipped with Express Windows (Sales Code JP3), calibrate the windows as follows:

NOTE: Vehicles equipped with Express Windows will have BOTH front window switches labeled “AUTO”. a. Turn the ignition key to the “RUN” position. b. Move the driver’s window upward until the window stalls in the full up position. Allow the window motor to stall for at least two (2) seconds before releasing the switch. c. Move the driver’s window downward until the window stalls in the full down position. Allow the window motor to stall for at least two (2) seconds before releasing the switch. d. Move the driver’s window upward until the window stalls in the full up position. Allow the window motor to stall for at least two (2) seconds before releasing the switch.

e. Repeat Steps b. – d. for the passenger side window.

f. Verify that the windows learned the calibration by operating the express up and express down features on the windows. Safety Recall D28 – Battery Cable Bulkhead Stud Fasteners Page 7

Service Procedure (Continued)

2. For vehicles equipped with the Electronic Stability Program (ESP) (Sales Code BNB), calibrate the Steering Angle Sensor as follows:

NOTE: Vehicles equipped with ESP will have an ESP ON/OFF switch present in the instrument panel center stack. a. Start the engine and let it idle.

b. Turn the steering wheel to the right until the wheel is locked at the full right position. c. Turn the steering wheel to the left until the wheel is locked at the full left position. d. Turn the steering wheel until the wheels are centered. 3. Cycle the ignition switch to the “OFF” position and then back to the “RUN” position.

4. Use the StarSCAN to clear any DTC’s from all modules. Safety Recall D28 – Battery Cable Bulkhead Stud Fasteners Page 8

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 DaimlerChrysler to record recall service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Tighten battery cable bulkhead stud fasteners 08-D2-81-82 0.3 hours Replace battery cable bulkhead stud 08-D2-81-83 0.4 hours and tighten battery cable fasteners Add the cost of the parts, if necessary, plus applicable dealer allowance to your claim. NOTE: Labor Operation times include express window and ESP calibration, if necessary. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

Parts Return

Not required.

Dealer Notification and Vehicle List

Safety Recall D28 – Battery Cable Bulkhead Stud Fasteners Page 9

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. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. 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.

Owner Notification and Service Scheduling

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 DaimlerChrysler Corporation

SAFETY RECALL – BATTERY CABLE BULKHEAD STUD FASTENERS Dear: (Name) This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has decided that a defect, which relates to motor vehicle safety, exists in some 2005 model year Chrysler 300 and Dodge Magnum vehicles. The problem is... The battery cable fasteners at the bulkhead stud on your vehicle (VIN: xxxxxxxxxxxxxxxxx) may not have been properly tightened. A loose fastener can cause an instrument panel fire. What your dealer DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do will do... this, your dealer will tighten the bulkhead stud battery cable fasteners to the proper specification. The work will take less than ½ hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must Simply contact your dealer right away to schedule a service appointment. do to ensure your Remember to bring this letter with you to your dealer. safety... If you need If you have questions or concerns which your dealer is unable to resolve, please help... contact DaimlerChrysler at 1-800-853-1403. Please help us update our records, by filling out the enclosed prepaid postcard, if any of the conditions listed on the card apply to you or your vehicle. Be sure to print the last eight (8) characters of the VIN (VVVVVVVV) and notification code D28 on the postcard. If you have already experienced this condition and have paid to have it repaired, you may send your original receipts and/or other adequate proof of payment to the following address for reimbursement: DaimlerChrysler, P.O. Box 610207, Port Huron, MI 48061-0207, Attention: Reimbursement. 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, 400 Seventh Street, S.W., Washington, DC 20590, or call the toll-free Auto Safety Hotline at 1-888-327-4236. 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 DaimlerChrysler Corporation D28 Note to lessors receiving this recall: Federal regulation requires that you forward this recall notice to the lessee within 10 days.

July 2004 Dealer Service Instructions for: Safety Recall DD3030 Shoulder Belt AdjustAdjusterer Turning Loop Bolts

Models

2005 (LX) Chrysler 300 and Dodge Magnum NOTE: This recall applies only to the above vehicles built through May 20, 2004 (MDH 052012).

IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall.

Subject

The front shoulder belt adjuster turning loop bolts on about 12,000 of the above vehicles may not have been properly tightened. This could cause shoulder belt separation in certain crash conditions, which can increase the risk of injury to front seat occupants.

Repair

The shoulder belt adjuster turning loop bolts must be tightened to the proper specification.

Parts Information

No parts are required to perform this service procedure.

Service Procedure

1. Using a trim stick placed between UPPER the turning loop cover and the B-PILLAR release button, pry the top of the driver’s side turning loop bolt cover open and then remove the cover (Figure 1).

COVER 2. Tighten the turning loop bolt to TURNING 30 ft-lbs (40 N·m). LOOP BOLT TURNING 3. Install the turning loop bolt cover LOOP by aligning catches on the bottom of the cover with the turning loop bracket and then snapping the cover over the top of the bracket. Ensure that the cover is fully Figure 1 – Passenger Side Shown installed.

NOTE: There should be no gap between the turning loop cover and the turning loop. Pinch the turning loop and cover with your finger and thumb to fully seat the cover. NOTE: If the turning loop cover was damaged during removal, replace it with a new cover (P/N 5HF07BD1AC).

4. Repeat Steps 1-3 for the passenger side turning loop bolt. Safety Recall D30 – Shoulder Belt Adjuster Turning Loop Bolts Page 3

Completion Reporting and Reimbursement

Parts Return

Not applicable.

Dealer Notification and Vehicle List

Safety Recall D30 – Shoulder Belt Adjuster Turning Loop Bolts Page 4

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

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.

Owner Notification and Service Scheduling

All involved vehicle owners known to DaimlerChrysler 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. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair.

Safety Recall D30 – Shoulder Belt Adjuster Turning Loop Bolts Page 5

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 DaimlerChrysler Corporation

SAFETY RECALL – SHOULDER BELT ADJUSTER TURNING LOOP BOLTS Dear: (Name) This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has decided that a defect, which relates to motor vehicle safety, exists in some 2005 model year Chrysler 300 and Dodge Magnum vehicles. The problem is... The front shoulder belt adjuster turning loop bolts on your vehicle (VIN: xxxxxxxxxxxxxxxxx) may not have been properly tightened. This could cause shoulder belt separation in certain crash conditions, which can increase the risk of injury to front seat occupants. What your dealer DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do will do... this, your dealer will tighten the shoulder belt adjuster turning loop bolts to the proper specification. The work will take less than ½ hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must Simply contact your dealer right away to schedule a service appointment. do to ensure your Remember to bring this letter with you to your dealer. safety... If you need If you have questions or concerns which your dealer is unable to resolve, please help... contact DaimlerChrysler at 1-800-853-1403. Please help us update our records, by filling out the enclosed prepaid postcard, if any of the conditions listed on the card apply to you or your vehicle. Be sure to print the last eight (8) characters of the VIN (VVVVVVVV) and notification code D30 on the postcard. If you have already experienced this condition and have paid to have it repaired, you may send your original receipts and/or other adequate proof of payment to the following address for reimbursement: DaimlerChrysler, P.O. Box 610207, Port Huron, MI 48061-0207, Attention: Reimbursement. 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, 400 Seventh Street, S.W., Washington, DC 20590, or call the toll-free Auto Safety Hotline at 1-888-327-4236. 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 DaimlerChrysler Corporation D30 Note to lessors receiving this recall: Federal regulation requires that you forward this recall notice to the lessee within 10 days.

July 2004 Dealer Service Instructions for: Customer Satisfaction Notification D29 Reprogram PCM – Electronic Throttle Control

Models

2005 (LX) Chrysler 300 and Dodge Magnum NOTE: This notification applies only to the above vehicles equipped with a 2.7L engine (Sales Code EER) built through May 11, 2004 (MDH 051115).

Subject

The Powertrain Control Module (PCM) software on about 3,500 of the above vehicles may cause an intermittent loss of throttle control. If this occurs, the vehicle’s engine speed will be held at a relatively low level.

Repair

The PCM must be reprogrammed (flashed) with updated software.

Parts Information

Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed.

Part Number Description 04275086AB Label, Authorized Modifications

Special Tools

The following existing special tools may be required to perform this repair:

CH9401* StarSCAN Tool

CH9404* StarSCAN Vehicle Cable

CH9409* StarSCAN Documentation Kit

CH9410* StarSCAN Ethernet Cable 12 ft.

CH9412* StarSCAN Software Update Device Kit

NPN TechCONNECT PC

NPN StarSCAN Software Update CD

* Part of CH9400 kit.

Customer Satisfaction Notification D29 Page 3 Reprogram PCM – Electronic Throttle Control

Service Procedure

A. Program the PCM

There are two methods which can be used to retrieve the flash file required to program the PCM. The flash file can be accessed using the internet (accessed through the DealerCONNECT portal) or by using the StarSCAN Software Update Compact Disc (CD). Either method is acceptable to complete this notification.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

Method I. Program the PCM Using the DealerCONNECT Internet System to Retrieve the Flash File:

NOTE: The DealerCONNECT System, StarSCAN Tool (CH9401), StarSCAN Vehicle Cable (CH9404) and StarSCAN Ethernet Cable (CH9410) are required to use this programming method.

CAUTION: The StarSCAN must be at version 4.06 or higher before this procedure can be performed.

NOTE: The StarSCAN diagnostic scan tool fully supports DealerCONNECT Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN for your dealership’s network. For instructions on setting up your StarSCAN for the dealer’s network; refer to the StarSCAN Quick Start Networking Guide available on the www.dcctools.com website under the “download center” link.

1. Use the following procedure to determine the PCM part number: a. Connect the StarSCAN to the vehicle data link connector located under the steering column.

b. Power ON the StarSCAN.

c. From the StarSCAN Home Screen, select “ECU View”.

d. From the StarSCAN ECU View Screen, select “PCM/NGC Engine”.

e. Record the PCM part number shown on the StarSCAN screen.

IMPORTANT: The PCM part number recorded will be used to select the correct software. Be sure to record the part number exactly as it is shown.

f. If the last two digits of the PCM part number are “AL” or higher, the module is up to date. No further action is required. If the last two digits of the PCM part number are “AK” or lower continue with Step 2 of this procedure. Customer Satisfaction Notification D29 Page 4 Reprogram PCM – Electronic Throttle Control

Service Procedure (Continued)

2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer’s network drop.

3. Download the flash file from the internet to the StarSCAN. Starting at the StarSCAN “Home” screen: a. Select “Flash Download”.

b. On the flash update text box, select “Enter Information Manually”.

c. Press the “Next” button.

d. Select “By Part Number” and then press next.

e. Press the “Show Keyboard” button and then enter the PCM part number recorded in Step 1e of this procedure.

f. Press next and then follow the screen instructions.

g. Select the file shown on the screen.

h. Press the “Download to Scan Tool” button on the StarSCAN.

4. Install a battery charger and verify that the charging rate provides approximately 13.5 volts.

5. Press the “Show Shortcuts” key and then press the “Home” key to return to the “Home” screen.

6. Download the file from StarSCAN to the vehicle. Starting at the StarSCAN “Home” screen:

a. Select “ECU View”.

b. Browse the list of controllers using the scroll arrows. Highlight “PCM/NGC III.”

c. Select “More Options”.

d. Select “ECU Flash”.

e. Highlight the calibration shown on the screen.

f. Select “Update Controller”.

g. Follow the on-screen instructions and perform prompts as required.

h. When update is completed, select “OK”. Customer Satisfaction Notification D29 Page 5 Reprogram PCM – Electronic Throttle Control

Service Procedure (Continued)

7. Check all modules for Diagnostic Trouble Codes (DTC’s).

NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, FCM, CCN, WCM, etc.) within the vehicle, if so equipped. Some DTC’s may cause the MIL to illuminate. Check all modules using “ECU View” from the ”Home” screen, record the DTC’s, and erase these DTC’s prior to returning the vehicle to the customer. Erase any DTC’s in the PCM only after all other modules have had their DTC’s erased.

8. Continue with Section “B”- Install the Authorized Modifications Label.

Method II. Program the PCM Using StarSCAN Update CD:

NOTE: The software update CD being used must be at level 4.07 or higher.

1. Use the following procedure to determine the PCM part number:

a. Connect the StarSCAN to the vehicle data link connector located under the steering column.

b. Power ON the StarSCAN.

c. From the StarSCAN Home Screen, select “ECU View”.

d. From the StarSCAN ECU View Screen, select “PCM/NGC Engine”.

e. Record the PCM part number shown on the StarSCAN screen.

IMPORTANT: The PCM part number recorded will be used to select the correct software. Be sure to record the part number exactly as it is shown.

Customer Satisfaction Notification D29 Page 6 Reprogram PCM – Electronic Throttle Control

Service Procedure (Continued)

2. Insert the USB key into the USB port on the TechCONNECT PC (Figure 1).

3. Press the button located below the CD/DVD ROM drive to open the drive. Insert the StarSCAN Software Update CD into the TechCONNECT PC and press the button again to close the ROM drive. The StarSCAN Software Update CD will start automatically.

4. Select “Controller Flash”. Figure 1 5. Select “Enter Part Number”.

6. Enter PCM part number recorded in Step 1e of this procedure and then press next.

7. Select the update shown on the screen and press next.

8. Follow the on-screen instructions. Select “Next” after each step. Select “Finish” after completing the last step.

9. With the StarSCAN powered OFF, connect the USB Key and adapter to the StarSCAN USB port (Figure 2).

10. Install a battery charger and verify that the charging rate provides approximately 13.5 volts.

11. Connect the StarSCAN to the data link connector located below the Figure 2 steering column. Customer Satisfaction Notification D29 Page 7 Reprogram PCM – Electronic Throttle Control

Service Procedure (Continued)

12. Turn the ignition key to the “RUN” position.

13. Power ON the StarSCAN.

14. Download the file from the USB key to the StarSCAN. Starting at the StarSCAN “Home” screen:

a. Select “Flash Download”.

b. Select “Use USB Device”.

c. Follow the on-screen instructions. Select “Next” after each step. Select “Finish” after completing the last step.

d. At the “Flash File List” screen, highlight the PCM calibration.

e. Select “Download to Scantool”.

f. When download is complete, select “Close”.

15. Return to the “Home” screen.

16. Select “Show Shortcuts”.

17. Select “Home”.

18. Down load the file from the StarSCAN to the vehicle. Starting at the StarSCAN “Home” screen:

a. Select “ECU View”.

b. Browse the list of controllers using the scroll arrows. Highlight “PCM/NGC III.”

c. Select “More Options”.

d. Select “ECU Flash”.

e. Highlight the PCM calibration shown on the screen.

f. Select “Update Controller”.

g. Follow the on-screen instructions and perform prompts as required.

h. When update is completed, select “OK”. Customer Satisfaction Notification D29 Page 8 Reprogram PCM – Electronic Throttle Control

Service Procedure (Continued)

19. Check all modules for Diagnostic Trouble Codes (DTC’s).

20. Continue with Section “B”- Install the Authorized Modifications Label.

B. Install the Authorized Modifications Label:

1. Type or print (with a ballpoint pen) the Customer Satisfaction Notification

number, dealer code and date on the Reprogram PCM with New Software Authorized Modifications Label (Figure 3). Cust. Sat. D29 2. Attach the label near the VECI label and then close the hood. Figure 3 Customer Satisfaction Notification D29 Page 9 Reprogram PCM – Electronic Throttle Control

Completion Reporting and Reimbursement

Use one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance PCM Update Previously Performed 08-D2-91-81 0.2 hours

Reprogram Powertrain Control Module 08-D2-91-82 0.8 hours

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

Parts Return

Not applicable.

Dealer Notification

Customer Satisfaction Notification D29 Page 10 Reprogram PCM – Electronic Throttle Control

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

Dealers should 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.

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 notification only and is strictly prohibited from all other use.

Owner Notification and Service Scheduling

All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by 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.

Dealers are encouraged to consider alternative scheduling and servicing approaches for this notification. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair.

Customer Satisfaction Notification D29 Page 11 Reprogram PCM – Electronic Throttle Control

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 DaimlerChrysler Corporation

CUSTOMER SATISFACTION NOTIFICATION REPROGRAM PCM - ELECTRONIC THROTTLE CONTROL

Dear: (Name) The satisfaction of our customers is very important to DaimlerChrysler. Because of this, we are requesting owners of some 2005 model year Chrysler 300 and Dodge Magnum vehicles equipped with a 2.7L engine to contact their dealer to have the following service performed.

The problem is... The Powertrain Control Module (PCM) software on your vehicle (VIN: xxxxxxxxxxxxxxxxx) may cause an intermittent loss of throttle control. If this occurs, your vehicle’s engine speed will be held at a relatively low level.

What your dealer DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do will do... this, your dealer will reprogram your vehicle’s PCM. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed.

What you must Simply contact your dealer right away to schedule a service appointment. do... Remember to bring this letter with you to your dealer.

If you need If you have questions or concerns which your dealer is unable to resolve, please help... contact DaimlerChrysler at 1-800-853-1403.

Please help us update our records, by filling out the enclosed prepaid postcard, if any of the conditions listed on the card apply to you or your vehicle. Be sure to print the last eight (8) characters of the VIN (VVVVVVVV) and notification code D29 on the postcard.

If you have already experienced this condition and have paid to have it repaired, you may send your original receipts and/or other adequate proof of payment to the following address for reimbursement: DaimlerChrysler, P.O. Box 610207, Port Huron, MI 48061-0207, Attention: Reimbursement.

We're sorry for any inconvenience, but we believe that this service will help to ensure your continuing satisfaction with your vehicle. Thank you for your attention to this important matter.

Customer Services Field Operations DaimlerChrysler Corporation D29

Revised: January 2005 Dealer Service Instructions for: Customer Satisfaction Notification D50 Radiator Isolator Brackets

Please remove and discard from your files all previous copies of Customer Satisfaction Notification D50 (dated November 2004) and replace it with this revised document. This revision includes additional repair procedure information to prevent breaking the radiator isolator bracket retaining bolts during removal.

Models

2005 (LX) Dodge Magnum and Chrysler 300 NOTE: This notification applies only to the above vehicles built through August 29, 2004 (MDH 0829XX).

Subject

The radiator isolator brackets on about 100,000 of the above vehicles may crack. If both isolator brackets crack, the radiator may rotate rearward in the vehicle and allow the upper radiator hose to contact the accessory drive pulleys. This could cause a cooling system leak and result in severe engine damage.

Repair

Both radiator isolator brackets must be replaced.

Parts Information

Each dealer, to whom vehicles in the notification were invoiced, will receive enough Radiator Isolator Bracket packages, P/N CEL0D500, to service about 10% of those vehicles. Each package contains two (2) isolator brackets.

Service Procedure

1. Open the hood.

2. Remove both upper radiator closure panels (Figure 1).

Figure 1 Customer Satisfaction Notification D50 Page 3 Radiator Isolator Brackets

Service Procedure (Continued)

3. The radiator isolator bracket bolts RADIATOR were originally installed with ISOLATOR BRACKET RADIATOR thread locking compound. Remove SIDE BOLT the upper radiator isolator bracket SHIELD bolts by “working” each bolt back and forth in small increments (Figure 2). This will prevent locking compound build-up which can cause the bolt to bind and break.

CAUTION: Failure to “work” the bolts back and forth can cause the bolt to break.

If a radiator isolator bracket bolt breaks during removal, use the following procedure to remove the Figure 2 – Left Side Shown broken bolt:

a. Install a 13mm 6-point socket onto the weld nut located on the engine side of the radiator core support

NOTE: If the driver’s side bolt is broke, remove the air cleaner housing.

b. Install a 3/8 inch breaker bar to the socket and shear off the weld nut from the core support by applying a twisting motion to nut with the breaker bar.

c. Discard the weld nut and broken bolt.

4. Remove the left and right upper side shield retainers and pull the side shields away from the isolator brackets (Figure 2).

5. Tilt the radiator forward and remove the left and right radiator isolator brackets (Figure 2).

6. Install the new isolator brackets and tilt the radiator back into position (Figure 2).

7. Install the original isolator bracket bolt(s). If a bolt broke during removal, install P/N 06104368AA bolt and a P/N 06505316AA flange nut to retain the new radiator isolator bracket.

8. Tighten the radiator isolator bracket retaining bolts to 125 in-lbs (14 N·m). Customer Satisfaction Notification D50 Page 4 Radiator Isolator Brackets

Service Procedure (Continued)

9. Position the radiator side shields and install the shield retainers.

10. Install both upper radiator closure panels (Figure 1). Ensure that the panels are interlocked where they meet in the center.

Completion Reporting and Reimbursement

Use the following labor operation number and time allowance:

Labor Operation Time Number Allowance Replace radiator isolator brackets 07-D5-01-82 0.3 hours

Related Operation: Extract broken bolt(s) from radiator core support 07-30-10-50 0.2 hours

Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions.

Dealer Notification

All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select TechCONNECT on the Service tab, click on “Search Bulletins/Recalls”, enter the notification code and then click on the “Search” button. Customer Satisfaction Notification D50 Page 5 Radiator Isolator Brackets

Owner Notification and Service Scheduling

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

Dealers should 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. 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 notification only and is strictly prohibited from all other use. Customer Satisfaction Notification D50 Page 6 Radiator Isolator Brackets

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 DaimlerChrysler Corporation

CUSTOMER SATISFACTION NOTIFICATION RADIATOR ISOLATOR BRACKETS

Dear: (Name) The satisfaction of our customers is very important to DaimlerChrysler. Because of this, we are requesting owners of some 2005 model year Chrysler 300/300C and Dodge Magnum vehicles to contact their dealer to have the following service performed. The problem is... The radiator isolator brackets on your vehicle (VIN: xxxxxxxxxxxxxxxxx) may crack. If both isolator brackets crack, the radiator may rotate rearward in the vehicle and allow the upper radiator hose to contact the accessory drive pulleys. This could cause a cooling system leak and result in severe engine damage. What your dealer DaimlerChrysler will repair your vehicle free of charge (parts and will do... labor). To do this, your dealer will replace the radiator isolator brackets. The work will take about ½ hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must Simply contact your dealer right away to schedule a service appointment. do... Ask the dealer to hold the parts for your vehicle or to order them before your appointment. Remember to bring this letter with you to your dealer. If you need If you have questions or concerns which your dealer is unable to resolve, help... please contact DaimlerChrysler at 1-800-853-1403. Please help us update our records, by filling out the enclosed prepaid postcard, if any of the conditions listed on the card apply to you or your vehicle. Be sure to print the last eight (8) characters of the VIN (VVVVVVVV) and notification code D50 on the postcard. If you have already experienced this condition and have paid to have it repaired, you may send your original receipts and/or other adequate proof of payment to the following address for reimbursement: DaimlerChrysler, P.O. Box 610207, Port Huron, MI 48061-0207, Attention: Reimbursement. We're sorry for any inconvenience, but we believe that this service will help to ensure your continuing satisfaction with your vehicle. Thank you for your attention to this important matter. Customer Services Field Operations DaimlerChrysler Corporation Notification Code D50

November 2004 Dealer Service Instructions for: Customer Satisfaction Notification D51 AntiAnti---FreezeFreeze Concentration Level

Models

2005 (LX) Chrysler 300 and Dodge Magnum NOTE: This notification applies only to the above vehicles built through September 9, 2004 (MDH 090900).

IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this notification.

Subject

The engine coolant on about 50,000 of the above vehicles may have a low (weak) anti-freeze concentration level. A low anti-freeze concentration level can cause the engine to overheat in cold ambient temperatures.

Repair

The engine coolant anti-freeze concentration must be tested and new coolant must be added to strengthen the concentration if necessary.

Parts Information

Part Number Description

05066386AA Antifreeze/Coolant, Mopar® (5 year/100,000 Mile Formula) (with Hybrid Organic Additive Technology (HOAT) corrosion inhibitors)

Special Tools

The following special tools apply to this service procedure:

8195 Coolant Funnel

8286* Refractometer

W-106* Ethylene Glycol Anti-Freeze Tester

* Either the refractometer or the supplied ethylene glycol anti-freeze tester can be used to perform this service procedure.

NOTE: One ethylene glycol anti-freeze tester (Part No. W-106) was shipped to all Chrysler, Dodge and Jeep® dealers free of charge through teamPSE (PentaStar Service Equipment) in November, 2004.

Additional testers may be ordered through teamPSE at dealer cost by calling 1-800-223-5623. Additional testers are NOT reimbursable by DaimlerChrysler.

CAUTION: Use only the testers listed above or other equivalent testers that are designed for “HOAT” long life anti-freeze. Customer Satisfaction Notification D51 Page 3 Anti-Freeze Concentration Level

Service Procedure

NOTE: This procedure allows the coolant concentration to be changed without introducing air into the engine’s cooling system.

CAUTION: These vehicles contain aluminum engine components which require special corrosion protection. Only Mopar Antifreeze/Coolant (5 year/100,000 Mile Formula) with Hybrid Organic Additive Technology (HOAT) corrosion inhibitors is recommended (P/N 05066386AA).

1. Use the provided coolant tester (P/N W-106 or equivalent) or a refractometer (Special Tool #8286) to check the coolant concentration in the engine’s cooling system. A proper concentration will have a freeze protection reading of -34ºF (-37ºC) or lower.

2. If the coolant concentration is within -34ºF (-37ºC) or lower, no further action is required. Return the vehicle to the customer.

3. If the coolant is not within the proper range, use the chart below to determine how much coolant must be drained and how much new (undiluted) coolant must be added in order to bring the freeze protection to the appropriate -40º F (-40º C) concentration.

COOLANT CONCENTRATION CORRECTION CHART The amount of coolant to be drained and the amount of new (undiluted) coolant to add in order to bring the freeze protection to approximately -40ºF (-40ºC) Amount of Coolant Amount of Coolant to Amount of Coolant Coolant to Drain and New Drain and New to Drain and New Concentration level Coolant to Add Coolant to Add Coolant to Add 2.7L Engine 3.5L Engine 5.7L Engine 0ºF (-18ºC) 2.7 Qt. (2.5L) 2.9 Qt. (2.7L) 4.0 Qt. (3.8L) -5ºF (-21ºC) 2.3 Qt. (2.2L) 2.5 Qt. (2.4L) 3.5 Qt. (3.4L) -10ºF (-24ºC) 2.0 Qt. (1.9L) 2.1 Qt. (2.0L) 3.0 Qt. (2.9L) -15ºF (-26ºC) 1.6 Qt. (1.5L) 1.8 Qt. (1.7L) 2.5 Qt. (2.4L) -20ºF (-29ºC) 1.3 Qt. (1.2L) 1.4 Qt. (1.3L) 2.0 Qt. (1.9L) -25ºF (- 32ºC) 1.0 Qt. (0.9L) 1.0 Qt. (1.0L) 1.5 Qt. (1.4L) -30ºF (-35ºC) 0.6 Qt. (0.6L) 0.7 Qt. (0.7L) 1.0 Qt. (0.9L) -33ºF (-36ºC) 0.4 Qt. (0.4L) 0.4 Qt. (0.4L) 0.6 Qt. (0.6L) -34ºF (-37ºC) or lower No Action Required No Action Required No Action Required Customer Satisfaction Notification D51 Page 4 Anti-Freeze Concentration Level

Service Procedure (Continued)

4. Correct the coolant concentration using the procedure below:

a. Note the coolant level in the engine coolant bottle.

b. Pour the appropriate amount of new (undiluted) coolant (Refer to Coolant Concentration Correction Chart) into a clean container.

c. Carefully remove the engine coolant bottle pressure cap.

WARNING: Hot, pressurized coolant Figure 1 can cause injury by scalding.

d. Attach funnel tool (Special Tool #8195) to the engine coolant bottle opening (Figure 1).

e. Open the radiator draincock to drain out the same amount of coolant as you are adding. Add new coolant (measured amount from the clean container) into the funnel while the coolant is draining from the radiator. Do not allow the coolant level to go below the “MIN” line on the vehicle coolant bottle.

CAUTION: It is important to add new coolant at the same time the old coolant is being drained. Always keep the coolant level above the “MIN” line in the coolant bottle while correcting the coolant concentration. This will prevent air from entering the cooling system and eliminate the need to purge air from the cooling system.

f. Close the radiator draincock (hand tighten only) when the required amount of new coolant has been added and the coolant is at the original level in the bottle.

g. Remove the funnel from the engine coolant bottle and install the pressure cap.

5. Dispose of the old coolant that was drained from the vehicle in accordance with state and local environmental laws. Customer Satisfaction Notification D51 Page 5 Anti-Freeze Concentration Level

Completion Reporting and Reimbursement

Use one of the following labor operation numbers and time allowances:

Labor Operation Time Number Allowance Check anti-freeze concentration 07-D5-11-81 0.2 hours

Check anti-freeze concentration and adjust as required 07-D5-11-82 0.3 hours

Add the cost of the anti-freeze plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions.

Dealer Notification

All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select TechCONNECT on the Service tab, click on “Search Service Bulletins/Recalls”, enter the notification code and then click on the “Search” button.

Owner Notification and Service Scheduling

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

Dealers should 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.

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 DaimlerChrysler Corporation

CUSTOMER SATISFACTION NOTIFICATION – ANTI-FREEZE CONCENTRATION LEVEL

Dear: (Name) The satisfaction of our customers is very important to DaimlerChrysler. Because of this, we are requesting owners of some 2005 model year Chrysler 300 and Dodge Magnum vehicles to contact their dealer to have the following service performed.

The problem is... The engine coolant in your vehicle (VIN: xxxxxxxxxxxxxxxxx) may have a low (weak) anti-freeze concentration level. A low anti-freeze concentration level can cause the engine to overheat in cold ambient temperatures.

What your dealer DaimlerChrysler will repair your vehicle free of charge (parts and will do... labor). To do this, your dealer will test the coolant concentration level and adjust the mixture as required. The work will take about ½ hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed.

What you must Simply contact your dealer right away to schedule a service appointment. do... Remember to bring this letter with you to your dealer.

If you need If you have questions or concerns which your dealer is unable to resolve, help... please contact DaimlerChrysler at 1-800-853-1403.

We're sorry for any inconvenience, but we believe that this service will help to ensure your continuing satisfaction with your vehicle. Thank you for your attention to this important matter.

Customer Services Field Operations DaimlerChrysler Corporation Notification Code D51

November 2004 Dealer Service Instructions for: Customer Satisfaction Notification D49 Compact Spare Wheel

Models

2005 (LX) Chrysler 300 and Dodge Magnum NOTE: This notification applies only to the above vehicles equipped with All Wheel Drive (AWD) built through October 19, 2004 (MDH 101920).

IMPORTANT: Many of the vehicles within the above build period have already been repaired and, therefore, have been excluded from this recall.

Subject

The wheel for the compact spare on about 950 of the above vehicles may contact the front suspension lower control arm ball joint stud during certain vehicle maneuvers.

Repair

The compact spare wheel must be replaced with a revised wheel that provides additional clearance to the ball joint stud.

Parts Information

Each dealer, to whom vehicles in the notification were invoiced, will receive enough compact spare wheels to service 100 % of those vehicles.

Part Number Description CEA0D490 Wheel, Compact Spare

Service Procedure

1. Open the trunk/liftgate.

2. On Dodge Magnum models, remove the stowage tray and floor liner (if equipped).

3. On Dodge Magnum models, fold up the tri-fold floor by lifting the handle.

4. Lift the access cover using the pull strap (Figure 1).

5. Remove the fastener securing the spare tire and wheel assembly to the vehicle (Figure 1).

Figure 1 – Magnum Shown Customer Satisfaction Notification D49 Page 3 Compact Spare Wheel

Service Procedure (Continued)

6. Remove the spare tire and wheel assembly from the vehicle.

7. Using an appropriate tire machine, dismount the tire from the rim.

CAUTION: To prevent personal injury, always follow the tire machine manufacturer’s operating instructions and safety precautions.

8. Destroy the original compact spare wheel to prevent it from being put back into service.

9. Using an appropriate tire machine, install the original tire onto the new compact spare wheel.

NOTE: It is not necessary to balance the compact spare tire and wheel assembly.

10. Inflate the tire to 60 p.s.i. (420 kpa).

11. Place the spare tire and wheel assembly back into its storage compartment (Figure 1).

12. Install the fastener securing the spare tire to the vehicle (Figure 1).

13. Close the spare tire access cover.

14. On Dodge Magnum models, unfold the tri-fold floor.

15. On Dodge Magnum models, install the stowage tray and floor liner (if equipped).

16. Close the trunk/liftgate. Customer Satisfaction Notification D49 Page 4 Compact Spare Wheel

Completion Reporting and Reimbursement

Labor Operation Time Number Allowance Replace compact spare wheel 22-D4-91-82 0.4 hours

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

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

Dealer Notification

All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select TechCONNECT on the Service tab, click on “Search Service Bulletins/Recalls”, enter the notification code and then click on the “Search” button.

Owner Notification and Service Scheduling

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

Customer Satisfaction Notification D49 Page 5 Compact Spare Wheel

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. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer notification letter. 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 should 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. 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 notification 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 DaimlerChrysler Corporation

CUSTOMER SATISFACTION NOTIFICATION – COMPACT SPARE WHEEL

Dear: (Name) The satisfaction of our customers is very important to DaimlerChrysler. Because of this, we are requesting owners of some 2005 model year Chrysler 300 and Dodge Magnum vehicles equipped with All-Wheel Drive (AWD) to contact their dealer to have the following service performed.

The problem is... The compact spare wheel on your vehicle (VIN: xxxxxxxxxxxxxxxxx) may contact the front suspension lower control arm ball joint stud during certain vehicle maneuvers.

What your dealer DaimlerChrysler will repair your vehicle free of charge (parts and will do... labor). To do this, your dealer will replace the compact spare wheel. The work will take about ½ hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed.

What you must Simply contact your dealer right away to schedule a service appointment. do... Ask the dealer to hold the part for your vehicle or to order it before your appointment. Remember to bring this letter with you to your dealer.

If you need If you have questions or concerns which your dealer is unable to resolve, help... please contact DaimlerChrysler at 1-800-853-1403.

We're sorry for any inconvenience, but we believe that this service will help to ensure your continuing satisfaction with your vehicle. Thank you for your attention to this important matter.

Customer Services Field Operations DaimlerChrysler Corporation Notification Code D49

December 2004 Dealer Service Instructions for: Customer Satisfaction Notification DD3636 Instrument Cluster Gauge Accuracy

Models

2005 (LX) Chrysler 300 and Dodge Magnum NOTE: This notification applies only to the above vehicles built from November 20, 2004 through December 2, 2004 (MDH 112000 through 120200). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall.

Subject

The instrument cluster on about 4,700 of the above vehicles may display inaccurate speedometer, tachometer, coolant temperature, and fuel gauge readings.

Repair

The instrument cluster gauges must be calibrated using the StarSCAN tool.

Parts Information

No parts are required to perform this service procedure.

Special Tools

The following existing special tools may be required to perform this repair:

CH9401* StarSCAN Tool

CH9404* StarSCAN Vehicle Cable

CH9409* StarSCAN Documentation Kit

CH9410* StarSCAN Ethernet Cable 12 ft.

CH9412* StarSCAN Software Update Device Kit

NPN TechCONNECT PC

NPN StarSCAN Software Update CD

* Part of CH9400 kit.

Service Procedure

IMPORTANT: The StarSCAN tool being used must be at software level 5.02 or higher. The StarSCAN software level is displayed in the upper right corner of the tool’s display screen.

1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts.

2. Connect the StarSCAN to the data link connector located below the steering column.

3. Turn the ignition key to the “RUN” position. Customer Satisfaction Notification D36 Page 3 Instrument Cluster Gauge Accuracy

Service Procedure (Continued)

4. Power ON the StarSCAN.

5. Starting at the StarSCAN “Home” screen, calibrate the instrument cluster gauges using the following procedure:

a. Select “ECU View”.

b. Browse the list displayed on the StarSCAN screen using the scroll arrows and highlight “CCN Cabin Compartment”.

c. Select “Misc. Functions”.

d. Select “Check Cluster Calibrations”.

e. Press the “Start” button on the screen.

f. Follow the on-screen instructions and perform prompts as required.

6. Check all modules for Diagnostic Trouble Codes (DTC’s) using the following procedure:

NOTE: Due to the calibration procedure, a DTC may be set in other modules (PCM, TCM, FCM, CCN, WCM, etc.) within the vehicle, if so equipped. Some DTC’s may cause the MIL to illuminate.

a. Press the “Show Short Cuts” button.

b. Press the “Home” button.

c. Press the “System View” button.

d. Press the “All DTC’s” button.

e. Press the “Clear All Stored DTC’s” button.

f. Press the “Yes” button.

7. Disconnect the StarSCAN tool from the vehicle data link connector.

8. Return the vehicle to the customer. Customer Satisfaction Notification D36 Page 4 Instrument Cluster Gauge Accuracy

Completion Reporting and Reimbursement

Use one of the following labor operation numbers and time allowances:

Labor Operation Time Number Allowance Instrument cluster gauge calibration previously performed 08-D3-61-81 0.2 hours

Calibrate the instrument cluster gauges 08-D3-61-82 0.2 hours

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

Dealer Notification

All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. This notification can be viewed on DealerCONNECT by selecting “Global Recall System” on the Service tab, then clicking on the description of this notification or by selecting TechCONNECT and “Search Bulletins/Recalls.”.

Owner Notification and Service Scheduling

Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Customer Satisfaction Notification D36 Page 5 Instrument Cluster Gauge Accuracy

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

Dealers should 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.

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 DaimlerChrysler Corporation

CUSTOMER SATISFACTION NOTIFICATION INSTRUMENT CLUSTER GAUGE ACCURACY

Dear: (Name) The satisfaction of our customers is very important to DaimlerChrysler. Because of this, we are requesting owners of some 2005 model year Chrysler 300 and Dodge Magnum vehicles to contact their dealer to have the following service performed.

The problem is... The instrument cluster on your vehicle (VIN: xxxxxxxxxxxxxxxxx) may display inaccurate speedometer, tachometer, coolant temperature, and fuel gauge readings.

What your dealer DaimlerChrysler will repair your vehicle free of charge (parts and will do... labor). To do this, your dealer will calibrate the gauges in your vehicle’s instrument cluster. The work will take less than ½ hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed.

What you must Simply contact your dealer right away to schedule a service appointment. do... Remember to bring this letter with you to your dealer.

If you need If you have questions or concerns which your dealer is unable to resolve, help... please contact DaimlerChrysler at 1-800-853-1403.

We're sorry for any inconvenience, but we believe that this service will help to ensure your continuing satisfaction with your vehicle. Thank you for your attention to this important matter.

Customer Services Field Operations DaimlerChrysler Corporation Notification Code D36

November, 2005 Dealer Service Instructions for: Safety Recall E14 Transmission Cup Plug Bracket

Models

2005-2006 (TJ) Jeep® Wrangler 2005-2006 (HB) Dodge Durango

2005-2006 (KJ) Jeep® Liberty 2005-2006 (ND) Dodge Dakota 2005-2006 (LX) Chrysler 300 and Dodge Magnum 2006 (LX) Dodge Charger

NOTE: This recall applies only to the above vehicles equipped with a 42RLE automatic transmission (sales code DG6) and a transmission build date code from TK2454 through TK1235. Many of the vehicles built within this transmission date range were repaired before shipment to dealers 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 cup plug that retains the automatic transmission parking pawl anchor shaft on about 253,000 of the above vehicles may be improperly installed. This could allow the park pawl anchor shaft to move out of position and prevent park engagement. If this occurs and the parking brake is not applied, the vehicle could roll away and cause an accident without warning.

Repair

A transmission cup plug bracket must be installed.

Parts Information

Part Number Description CBP1E140 Cup Plug Retention Bracket

Each dealer to whom vehicles in the recall were invoiced will receive enough Transmission Cup Plug Retention Brackets to service about 5% of those vehicles.

05013458AA Mopar ATF+4 Transmission Fluid (gallon - preferred) (05013457AA quart - optional) 05010884AA Mopar ATF-RTV (One tube will service about two vehicles)

Special Tool Information

The following Special Tools are required for LX models to perform this recall.

9336 Transmission Dipstick

CH9401* StarSCAN Tool

CH9404* StarSCAN Vehicle Cable

* Part of CH9400 kit.

Safety Recall E14 – Transmission Cup Plug Bracket Page 3

Service Procedure

A. Parking Pawl Test & Anchor Shaft Repositioning 1. On level ground, place transmission selector in “P” (park)

2. Release the parking brake (if applied).

3. Attempt to push the vehicle forward or backwards.

¾ If the vehicle will not roll (the transmission parking pawl is engaged), continue with Step 4.

¾ If the vehicle rolls several inches (the transmission pawl is not engaged), continue with Section B – Anchor Shaft Installation.

4. Place the transmission selector in “L1” (low).

5. Raise the vehicle on an appropriate hoist.

6. Remove the transmission skid plate (if so equipped).

7. Place a drain container, with a large opening, under transmission oil pan.

8. Loosen pan bolts and using a thin wide blade putty knife, separate the pan from the transmission case at one corner. Allow the fluid to drain and remove the transmission oil pan.

9. If a loose cup plug is found in the transmission oil pan, discard the cup plug.

10. Look into the rear drain slot (Figure 1).

¾ If you do not see the anchor shaft, continue with Section C – Cup Plug Bracket Installation.

¾ If the anchor shaft is visible, it has slid rearward out of position, continue with Figure 1 Step 11. Safety Recall E14 – Transmission Cup Plug Bracket Page 4

Service Procedure Continued

11. Insert a screwdriver into the rear drain slot and gently pry the anchor shaft back into the case. Use a pair of needle nose pliers and gently grip the shaft and guide it into the case if needed.

¾ If the anchor shaft is flush with the edge of the hole, continue with Section C – Cup Plug Bracket Installation.

¾ If the anchor shaft springs back out (not flush with the edge of the hole), continue with Step (12).

12. Clean the transmission outer case with soap and water at shifter shaft and electrical connectors and blow dry. This will prevent dirt and debris from falling into the transmission during disassembly.

13. Disconnect the transmission solenoid/pressure switch and transmission range sensor electrical connectors.

14. Disconnect the shifter linkage at the transmission.

15. Rotate the shifter shaft clockwise until it stops.

16. Remove the transmission oil filter bolts and remove the transmission filter. Place the transmission oil filter and bolts on a clean surface for reuse.

17. Remove the valve body bolts and pull the valve body down.

CAUTION: Do not drop the two piston accumulators and springs located on top of the valve body.

18. Place the valve body assembly, springs, accumulator, filter and bolts (valve body and filter) on a clean surface. Safety Recall E14 – Transmission Cup Plug Bracket Page 5

Service Procedure Continued

19. Pull down the parking pawl spring until it clears the anchor shaft (Figure 2).

20. Slide the anchor shaft forward into the front hole. Release the pawl spring.

21. Carefully install the valve body.

NOTE: Accumulator pistons and springs are BRACKET interchangeable. Figure 2 CAUTION: Be careful not to damage the accumulator piston seals.

22. Hand-start the valve body bolts EXCEPT the bolt for the bolt hole shown in Figure 3. This bolt will be installed later in Section C.

23. Tighten the valve body bolts to 105 in-lbs (12 N·m).

24. Install the transmission oil filter and tighten the transmission oil filter bolts to 40 in-lbs (5 N·m).

25. Rotate the shifter shaft counter clockwise to the L1 position and install and adjust the shifter linkage.

26. Attach the transmission solenoid/pressure switch and REAR VIEW (ADAPTOR/EXTENSION range sensor electrical REMOVED FOR VIEWING PURPOSES) connectors.

27. Continue with Section C – Cup Plug Figure 3 Bracket Installation. Safety Recall E14 – Transmission Cup Plug Bracket Page 6

Service Procedure Continued

B. – Anchor Shaft Install or Replace

Only vehicles found to have rolled several inches while in “P” (Park) as determined in Step 3 of Section “A”, require the following procedure. Very few vehicles are expected to require anchor shaft installation or replacement. 1. Clean the transmission outer case at shifter shaft and electrical connectors with soap and water and blow dry. This will prevent dirt and debris falling into the transmission during disassembly.

2. Disconnect the transmission solenoid/pressure switch and transmission range sensor electrical connectors.

3. Disconnect the shifter linkage at the transmission.

4. Rotate the shifter shaft clockwise until it stops.

5. Loosen the transmission oil pan bolts and using a thin wide blade putty knife, separate the pan from the transmission housing at one corner. Allow the fluid to drain, and remove the transmission oil pan.

6. If a loose cup plug is found in the transmission oil pan, discard the cup plug.

7. Remove the transmission oil filter bolts and remove the transmission oil filter. Place the transmission oil filter and bolts on a clean surface for reuse.

8. Remove the valve body bolts and lower the valve body.

CAUTION: Do not drop the two piston accumulators and springs which are located above the valve body.

9. Place the valve body assembly, springs, accumulator, filter and bolts (valve body and filter) on a clean surface.

Safety Recall E14 – Transmission Cup Plug Bracket Page 7

Service Procedure Continued

10. A. If the anchor shaft has not come completely out of the hole: Use a pair of needle nose pliers and gently work the shaft into the hole until it just comes out the

other side of the case. Continue with Step 13.

B. If the anchor shaft has come out of the hole and is visible in the drain hole: Use a magnet to extract it. Secure a tie wrap (P/N 04641780) to the anchor shaft about ¼” from one Figure 4 end as shown in Figure 4.

C. If you cannot see the anchor shaft: Obtain a new anchor shaft (P/N 04431999) and secure a tie wrap (P/N 04641780) to the anchor shaft about ¼” from one end as shown in Figure 4.

NOTE: If you cannot see the old anchor shaft, it has dislodged into the transmission adaptor or transmission extension housing. It is not necessary to remove the old anchor shaft as it will not Figure 5 harm the transmission, transmission adaptor, or the transmission extension housing.

11. Insert the anchor shaft-tie strap assembly, long end first through the drain slot (Figure 5). Rotate the assembly so that the short end faces the anchor shaft hole as shown in Figure 6.

Figure 6 Safety Recall E14 – Transmission Cup Plug Bracket Page 8

Service Procedure Continued

12. Carefully insert the short end into the anchor shaft hole and with a pair of needle nose pliers, gently work the shaft into the hole until it just comes out the other side of the case.

13. Push up the parking pawl bracket and slide the shaft forward to the pawl spring (Figure 2).

14. Pull down the parking pawl spring and slide the anchor shaft forward into the front hole. Release the pawl spring.

NOTE: The tie-strap will drop out of the transmission.

15. Carefully install the valve body.

NOTE: The accumulator pistons and springs are interchangeable.

CAUTION: Be careful not to damage the accumulator piston seals during installation.

16. Hand-start the valve body bolts EXCEPT the one bolt for the bolt hole as shown in Figure 3. This bolt will be installed later in Section C.

17. Tighten the valve body bolts to 105 in-lbs (12 N·m).

18. Install the transmission oil filter and tighten the transmission oil filter bolts to 40 in-lbs (5 N·m).

19. Rotate the shifter shaft counter clockwise to the L1 position and install and adjust the shifter linkage.

20. Attach the transmission solenoid/pressure switch and range sensor electrical connectors.

21. Continue with Section C – Cup Plug Retention Bracket Installation.

Safety Recall E14 – Transmission Cup Plug Bracket Page 9

Service Procedure Continued

C. – Cup Plug Bracket Installation

1. Remove the valve body attachment bolt as shown in Figure 7 (if not previously done).

2. Clean the oil pan and magnet. Wipe magnet with a clean dry cloth.

3. Clean transmission oil pan surface using a plastic scraper. Figure 7

CAUTION: Do not scratch the transmission case oil pan sealing surface.

4. Clean the one loose valve body attachment bolt with brake clean or equivalent to remove all oil.

5. Apply one drop of MOPAR Lock and Seal Adhesive (P/N 04318031) to the threads of the valve body bolt that was cleaned in Step 4, about 1/4" up from the bottom. Figure 8 CAUTION: Do not let the adhesive dry on the threads prior to installation.

6. Position the retention bracket into the rear drain slot. Make sure the tab of the bracket is centered in the cup plug or cup plug hole (Figure 8).

7. Install the valve body bolt and hand tighten (Figure 9).

NOTE: The retention bracket can be installed with or without a cup plug in the anchor shaft hole. Figure 9 Safety Recall E14 – Transmission Cup Plug Bracket Page 10

Service Procedure Continued

8. Using a screwdriver, gently pry between the transmission housing and the bracket until seated. This will insure the proper positioning of the anchor shaft with or without cup plug (Figure 10).

9. While prying gently with the screwdriver, tighten the valve body bolt to 105 in-lbs (12 N-m).

CAUTION: DO NOT OVER TIGHTEN. Figure 10

10. Apply 1/8” bead of Mopar ATF-RTV on the transmission oil pan.

11. Install the transmission oil pan and tighten the transmission oil pan bolts to 165 in-lbs (19 N·m).

12. Install the transmission skid plate (if so equipped).

13. Remove the dipstick (if not previously done) or the fill tube cap on LX models. Pour four quarts of Mopar ATF+4 Automatic Transmission Fluid into the fill tube opening.

14. For LX models only: Connect the cable of the StarSCAN tool (special tool CH9400) to the vehicle Data Link Connector (DLC).

15. Start the engine and allow it to idle for at least one minute. With parking and service brakes applied, move selector lever momentarily to each position, ending in the neutral position.

For LX models only, the ending position is in “P” (Park).

16. For all models except LX, check the transmission fluid level and add an appropriate amount to bring the transmission fluid level to the COLD – FULL mark on the dipstick.

17. For all models except LX, recheck the transmission fluid level after the transmission has reached normal operating temperature (180°F). Adjust the transmission fluid level as needed. Safety Recall E14 – Transmission Cup Plug Bracket Page 11

Service Procedure Continued

18. For LX models only – Use the following Transmission Fluid Level Check Procedure:

a) StarSCAN instructions to read transmission temperature. 1) Starting at the StarSCAN home screen, press OK 2) Select “ECU View”. 3) Select “TCM” 4) Select “Data Display” 5) Read the transmission oil temperature

b) Wipe off any oil from the Oil Dipstick (Special Tool 9336) and insert it into transmission fill tube until the dipstick tip contacts the bottom of the oil pan. Pull it out and read the oil level (each mark is 10 mm).

NOTE: The special tool dipstick will protrude from the fill tube when installed.

c) Using the 42 RLE Fluid Temperature Chart below, find the transmission temperature vertical line matching the temperature value on the StarSCAN tool. Move up the vertical temperature line until you arrive at your dipstick reading value.

Safety Recall E14 – Transmission Cup Plug Bracket Page 12

Service Procedure Continued

d) If you are below the full line, add transmission fluid. If you are above the line, remove some fluid. Repeat as necessary.

19. Disconnect the StarSCAN cable from the DLC and remove the StarSCAN tool from the vehicle.

20. To prevent dirt from entering transmission, make certain that dipstick or the fill tube cap is fully seated into the dipstick opening.

Completion Reporting and Reimbursement

Parking Pawl Test, Cup Plug Bracket Installation and Anchor Shaft Positioning, or Anchor Shaft Install or Replace. All except Wrangler (TJ) 21-E1-41-83 1.3 hours Wrangler (TJ) 1.4 hours

Related Operation: Transmission skid plate equipped. All 21-E1-41-50 0.2 hours except Wrangler (TJ).

Add the cost of the parts plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Safety Recall E14 – Transmission Cup Plug Bracket Page 13

Dealer Notification

All dealers will receive a copy of this dealer recall notification letter by mail. Two additional copies will be sent through the DCMMS. 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

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.

Safety Recall E14 – Transmission Cup Plug Bracket Page 14

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 DaimlerChrysler Corporation

SAFETY RECALL E14 TRANSMISSION CUP PLUG BRACKET

Dear: (Name) This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has decided that a defect, which relates to motor vehicle safety, exists in some 2005 and 2006 model year Dodge Durango, Dakota, Charger and Magnum, Jeep® Liberty and Wrangler, and Chrysler 300 vehicles equipped with an automatic transmission. The problem is... The cup plug that retains the park pawl anchor shaft in your vehicle’s transmission (VIN: xxxxxxxxxxxxxxxxx) may be improperly installed. This could allow the park pawl shaft to move out of position and prevent park engagement. If this occurs and the parking brake is not applied, the vehicle could roll away and cause an accident without warning. What your dealer DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do will do... this, your dealer will install a bracket in your transmission. The work will take about 1½ hours to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must Simply contact your dealer right away to schedule a service appointment. Ask the do to ensure your dealer to hold the part for your vehicle or to order it before your appointment. safety... Remember to bring this letter with you to your dealer. In addition, we recommend that you always apply the parking brake before exiting the vehicle. If you need If you have questions or concerns which your dealer is unable to resolve, please help... contact DaimlerChrysler at 1-800-853-1403. Please help us update our records, by filling out the enclosed prepaid postcard, if any of the conditions listed on the card apply to you or your vehicle. Be sure to print the last eight (8) characters of the VIN (VVVVVVVV) and notification code E14 on the postcard. If you have already experienced this condition and have paid to have it repaired, you may send your original receipts and/or other adequate proof of payment to the following address for reimbursement: DaimlerChrysler, P.O. Box 4639, Oak Ridge, TN 37831, Attention: Reimbursement. 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, 400 Seventh Street, S.W., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://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 DaimlerChrysler Corporation Notification Code E14 Note to lessors receiving this recall: Federal regulation requires that you forward this recall notice to the lessee within 10 days.

March 2007 Dealer Service Instructions for: Emissions Recall F47 Catalytic Converter and Reprogram PCM

Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin (TSB) #11-002-06 Rev A has been cancelled.

Model

2006 (LX) Chrysler 300, Dodge Magnum and Charger NOTE: This recall applies only to the above vehicles equipped with either a 2.7L or 3.5L engine (“G, T, R or V” in the 8th VIN position), with California Emissions or 50-States Emissions (sales code NAE or NAS), through November 10, 2005 (MDH: 111010).

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 mini catalytic converter on about 350 of the above vehicles may fail and damage the downstream catalytic converter. This may cause the vehicle to release air pollutants which exceed Federal and California standards.

Repair

The right and left front exhaust catalyst assemblies must be replaced and the PCM must be reprogrammed (flashed).

Parts Information

Each vehicle requires application of the following label:

Part Number Description 04275086AB Authorized Modifications Label

Due to the likelihood that the required Authorized Modifications Label is already in your parts inventory, no labels will be distributed to involved dealers initially. Labels may be ordered as needed to support scheduled repairs.

Front Exhaust Catalyst Assembly:

NOTE: The DealerCONNECT VIP function lists the appropriate part numbers fore each involved vehicle.

Trans Emissions Right Front Left Front Engine Drive Sales Sales Exhaust Catalyst Exhaust Catalyst (Sales Code) Train Code Code Assembly P/N Assembly P/N 2.7L (EER) DG6 04578466AA or 04578467AA or NAE RWD 3.5L (EGG) DGJ 04578466AB 04578467AB 3.5L (EGG) DG6 NAS RWD 68002134AA(*) 68002135AA(*) NAE 3.5L (EGG) DGJ AWD 04581754AE(*) 04581755AE(*) NAS

Each dealer, to whom vehicles in the recall were assigned, will receive enough right and left front exhaust catatlyst assemblies to service 100% of those vehicles. Parts denoted with an asterisk (*) will NOT be distributed initially because very few vehicles were built. Please order these parts only as needed.

Emissions Recall F47 – Catalytic Converter and Reprogram PCM Page 3

Special Tools

The following special tools are required to perform this repair:

¾ CH9401* StarSCAN Tool

¾ CH9404* StarSCAN Vehicle Cable

¾ CH9409* StarSCAN Documentation Kit

¾ CH9410* StarSCAN Ethernet Cable 12 ft.

¾ CH9412* StarSCAN Software Update Device Kit

¾ NPN TechCONNECT PC

* Part of CH9400 kit.

C-4907 Oxygen Sensor Socket Emissions Recall F47 – Catalytic Converter and Reprogram PCM Page 4

Service Procedure

A. Replace Right and Left Front Exhaust Catalyst Assemblies

1. Raise the vehicle on a suitable hoist.

2. Disconnect the electrical harness connector from the left downstream oxygen sensor.

3. Remove the right downstream oxygen sensor connector from the transmission support crossmember.

4. Disconnect the electrical harness connector from the right downstream oxygen sensor.

5. Remove both the left and right downstream oxygen sensors from the exhaust catalyst assemblies using special tool C-4907.

6. Remove the brace (if so equipped) at the rear of front exhaust catalyst assemblies (Figure 1).

RUBBER ISOLATORS

MUFFLER LEFT FRONT EXHAUST PIPE EXHAUST BRACE CATALYST (IF SO EQUIPPED) ASSEMBLY

RESONATOR

“Y” COLLECTOR PIPE

RIGHT FRONT EXHAUST CATALYST ASSEMBLY Figure 1 Emissions Recall F47 – Catalytic Converter and Reprogram PCM Page 5

Service Procedure (Continued)

7. Loosen the two clamps holding

the right and left front exhaust “Y” COLLECTOR PIPE

catalyst assemblies to the “Y” CLAMP CLAMP collector pipe (Figure 2).

8. Remove the front and rear resonator isolator hanger bolts.

9. Separate the remaining rubber isolator hangers from the LEFT TRANSMISSION RIGHT exhaust system EXHAUST MOUNT EXHAUST (Figure 1). CATALYST CROSSMEMBER CATALYST ASSEMBLY ASSEMBLY 10. Support the muffler and tailpipe Figure 2 assembly with a suitable jack.

11. Separate the exhaust system at the “Y” connector from the right and left exhaust catalyst assemblies (Figure 2).

12. Remove the left exhaust catalyst assembly heat shield and nuts at the exhaust manifold ball flange

13. Remove left exhaust catalyst assembly to exhaust manifold flange nuts.

14. Remove the right exhaust catalyst assembly to exhaust manifold flange nuts.

15. Remove both right and left exhaust catalyst assemblies from the vehicle.

16. Position the new left front exhaust assembly to the exhaust manifold and tighten the flange nuts to 106 in. lbs. (12 N·m).

17. Position the new right front exhaust assembly to the exhaust manifold and tighten the ball flange nuts to 106 in. lbs. (12 N·m).

18. Connect the right and left exhaust catalyst assemblies to the “Y” collector pipe (Figure 2). Emissions Recall F47 – Catalytic Converter and Reprogram PCM Page 6

Service Procedure (Continued)

19. Install the exhaust system rubber isolator onto the hangers.

20. Install the front and rear resonator isolator hanger bolts. Tighten the bolts to 215 in. lbs. (25 N·m).

21. Align the exhaust system so that the clearance between: a. Exhaust system and the fuel tank is a minimum of 5/8 in. (16 mm). b. Exhaust pipe and the tunnel reinforcement brace clearance is between 5/8” to 3/4” (16 mm to 20 mm).

22. Tighten the two band clamps at the “Y” collector pipe to 36 ft. lbs. (50 N·m).

23. Tighten the nuts to both the right and left front exhaust assembly ball flange joints to 25 ft. lbs. (34 N·m).

24. Install the right front exhaust pipe heat shield nuts at the exhaust manifold ball flange. Tighten the bolts to 98 in. lbs. (10 N·m).

25. Install the front exhaust pipe brace (if so equipped). Tighten the two bolts to 40 ft. lbs. (55 N·m).

26. Install both left and right downstream oxygen sensors and tighten to 30 ft. lbs. (40 N·m).

27. Connect the right electrical harness connector from the right downstream oxygen sensor.

28. Attach the right downstream oxygen sensor connector to the transmission support crossmember.

29. Connect the left electrical harness connector to the left downstream oxygen sensor.

30. Lower the vehicle. Continue to Section B – Reprogram the PCM.

Emissions Recall F47 – Catalytic Converter and Reprogram PCM Page 7

Service Procedure (Continued)

B. Reprogram the Powertrain Control Module

NOTE: This procedure must be performed with release 7.03 or later. A CD containing software release 7.03 was sent to each dealer at the end of January, 2007. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure. 1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge.

NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the headlamps and/or HVAC blower motor to lower the voltage. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop.

3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle.

4. Place the Ignition in the “RUN” position, then Power “ON” the StarSCAN.

5. Retrieve the old PCM part number. With the StarSCAN on the “Home” screen, follow the procedure below: a. Select “ECU View” b. Touch the screen to highlight “PCM” in the list of modules. c. Select “More Options”. d. Select “ECU Flash”. e. Record the “Part Number” displayed at the end of the “Resident flash file for” statement near the top of “Flash PCM” screen for later reference. Emissions Recall F47 – Catalytic Converter and Reprogram PCM Page 8

Service Procedure (Continued)

6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below: a. Select “Browse for New File”. Follow the on screen instructions. b. If the newly downloaded flash file “Part Number” description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 10. c. Highlight the listed calibration on the StarSCAN screen. d. Select “Download to Scantool”. e. Select "Close" after the download is complete, then select “Back” f. Highlight the listed calibration. g. Select "Update Controller" and follow the on screen instructions. h. When the update is completed, select “OK”.

7. Disconnect the CH9404 StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads “Vehicle Disconnected”, then press “OK”.

8. Reconnect the CH9404 StarSCAN vehicle cable to the vehicle.

9. Retrieve the PCM part number. With the StarSCAN on the “Home” screen, follow the procedure below: a. Select “ECU View”. b. Touch the screen to highlight “PCM” in the list of modules. c. Select “More Options”. d. Select “ECU Flash”. e. Verify the “Part Number” (displayed at the end of the “Resident flash file for” statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully. Emissions Recall F47 – Catalytic Converter and Reprogram PCM Page 9

Service Procedure (Continued)

10. Clear any Diagnostic Trouble Codes (DTCs) as follows: NOTE: Due to the PCM programming procedure, DTCs may be set in other modules (ABS, TCM, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. a. From the “Home” screen select “System View”. b. Select “All DTCs”. c. Press “Clear All Stored DTCs” if there are any DTCs shown on the list.

C. Install the Authorized Modifications Label:

1. Type or print (with a ballpoint pen) the necessary information shown in Figure 3 onto the Authorized Modifications Replace Catalysts and Reprogram PCM Label.

2. Attach the label near the VECI RECALL F47 label and close the hood.

Figure 3

D. Complete Proof of Correction Form for California Residents:

This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration.

Emissions Recall F47 – Catalytic Converter and Reprogram PCM Page 10

Completion Reporting and Reimbursement

Use the following labor operation number and time allowance:

Labor Operation Time Number Allowance Replace the right and left exhaust catalyst assemblies only. PCM already updated. 11-F4-71-82 1.1 hours

Replace the right and left exhaust catalyst assemblies and reprogram the PCM. 11-F4-71-83 1.3 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.

Parts Return

The old right and left front exhaust catalyst assemblies must be returned to the Warranty Material Return Center.

Dealer Notification

All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select “Global Recall System” on the Service tab, then click on the description of this notification.

Emissions Recall F47 – Catalytic Converter and Reprogram PCM Page 11

Owner Notification and Service Scheduling

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

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 DaimlerChrysler Corporation

EMISSIONS RECALL F47 – MINI CATALYTIC CONVERTER

Dear: (Name)

DaimlerChrysler has determined that some 2006 Chrysler 300, Dodge Magnum and Charger vehicles may be releasing air pollutants which exceed Federal and California standards.

The problem is... The mini catalytic converters on your vehicle (VIN: xxxxxxxxxxxxxxxxx) may fail and damage the downstream catalytic converter. What your dealer will DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, do... your dealer will replace the right and left exhaust catalytic converter assemblies and reprogram the powertrain control module on your vehicle. The work will take about 1 ½ hours to complete. However, additional time may be necessary depending on service schedules. What you must do... Simply contact your 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. If you need help... If you have questions or concerns which your dealer is unable to resolve, please contact DaimlerChrysler at 1-800-853-1403. California residents… The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is performed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof that the recall has been performed. 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 already experienced this condition and have paid to have it repaired, you may send your original receipts and/or other adequate proof of payment to the following address for reimbursement: DaimlerChrysler P.O. Box 4639 Oak Ridge, TN 37831, Attention: Reimbursement.

In order to ensure your full protection under the emission warranty made applicable to your vehicle by Federal law and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair, your vehicle may fail a state or local emission inspection test.

We are sorry for any inconvenience but trust that you understand our interest in clean air. Thank you for your attention to this important matter.

Customer Services Field Operations DaimlerChrysler Corporation Notification Code F47

NUMBER: 22-004-03

GROUP: Wheels and Tires

DATE: Sept. 26, 2003

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-001-02, DATED MARCH 11, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, MODEL YEARS, NOTES AND DISCUSSION.

SUBJECT: Chrome Wheel Care

MODELS:

2000 - 2003 (AB) Ram Van/Wagon 2002 - **2004** (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck **2004 (CS) Pacifica** 2002 - 2003 (DN) Durango 2002 - **2004** (DR) Ram Truck **2004 (HB) Durango** 2001 - **2004** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - **2004** (KJ) Liberty 1998 - **2004** (LH) Concorde/Intrepid/LHS/300M **2005 (LX) Magnum/300C 1998 - 2000 (NS) Town & Country 2002 - **2004** (PL) Neon 1999 - 2002 (PR) Prowler 2001 - **2004** (PT) PT Cruiser 2001 - **2004** (RS) Town & Country/Caravan 2001 - **2004** (ST) Sebring/Stratus Coupe **2002 - 2004** (TJ) Wrangler 2001 - **2004** (WJ) Grand Cherokee **2003 - 2004 (ZB) Viper** **2004 (ZH) Crossfire** 22-004-03 -2-

DISCUSSION: Chrome wheels should be cleaned regularly with mild soap and water to maintain their luster and prevent corrosion. Wash them with the same soap solution as the body of the vehicle.

Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels. Mopar Wheel Treatment, p/n 05066247AB – 12 oz. or 05066248AB – 5 gal., is recommended to remove normal brake dust, dirt, grease and grime.

NOTE: To clean extremely dirty wheels, Mopar Chrome Cleaner, p/n 04318013, is recommended.

Any of the “DO NOT USE” items listed below can damage or stain wheels and wheel trim.

DO NOT USE: • **Wheel cleaners that contain hydroflouric acid, biflouride compounds, sulfuric acid, or phosphoric acid.** • Any abrasive type cleaner • Any abrasive cleaning pad (such as steel wool) or abrasive brush • Any oven cleaner. • A car wash that has carbide tipped wheel-cleaning brushes.

CAUTION: Many commercial wheel cleaners contain acids that may harm the wheel surface. **Avoid all “wheel acid” type cleaners.**

CAUTION: **Any facility found using acid based wheel cleaners will void all wheel warranties, and all damage to customer wheels will be the facility’s responsibility.**

Refer to Global Warranty Bulletin D-01-22 for further information.

POLICY: Information Only NUMBER: 08-001-04

GROUP: Electrical

DATE: January 06, 2004

SUBJECT: Front Passenger Airbag Safety Precautions

OVERVIEW: This bulletin involves warnings prohibiting modifications to the front passenger seat assembly, related components, or trim cover.

MODELS:

2005 (CS) Pacifica 2004 - 2005 (HB) Durango 2004 - 2005 (KJ) Liberty 2005 (LX) 300C, 300N, Magnum 2005 (ND) Dakota 2005 (RS) Caravan, Town & Country 2005 (WK) Grand Cherokee

NOTE: This bulletin applies to vehicles equipped with the Occupant Classification System (OCS) for the right front passenger airbag.

DISCUSSION: The front passenger seat assembly contains critical components that affect the front passenger airbag deployment. Correctly functioning front passenger seat components are critical for the Occupant Classification System (OCS) to properly classify the front passenger and calculate the proper airbag deployment. Do not make any unapproved modifications to the front passenger seat components, assembly, or to the trim cover.

NOTE: Always follow the service information in TechCONNECT for the correct repair and/or diagnostic procedures when servicing the front passenger seat assembly, related parts, or trim cover.

Unapproved modifications or service procedures to the front passenger seat assembly, its related components, or trim cover may inadvertently change the airbag deployment in case of a frontal crash. THIS COULD RESULT IN DEATH OR SERIOUS INJURY TO THE FRONT SEAT PASSENGER IF THE VEHICLE IS INVOLVED IN AN ACCIDENT. A modified vehicle may not comply with required Federal Motor Vehicle Safety Standards (FMVSS).

The following requirements must be strictly adhered to: 08-001-04 -2-

1. DO NOT MODIFY THE FRONT PASSENGER SEAT ASSEMBLY OR COMPONENTS IN ANY WAY. 2. DO NOT MODIFY THE FRONT SEAT CENTER CONSOLE OR CENTER POSITION SEAT IN ANY WAY. 3. DO NOT USE PRIOR OR FUTURE MODEL YEAR SEAT TRIM COVERS NOT DESIGNATED FOR THE SPECIFIC MODEL BEING REPAIRED. ALWAYS USE THE CORRECT SEAT TRIM COVER SPECIFIED FOR THE VEHICLE. 4. DO NOT REPLACE THE SEAT TRIM COVER WITH AN AFTERMARKET TRIM COVER. 5. DO NOT ADD A SECONDARY TRIM COVER OTHER THAN THOSE APPROVED BY DAIMLERCHRYSLER/MOPAR. 6. AT NO TIME SHOULD ANY SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENT OR SRS RELATED COMPONENT OR FASTENER BE MODIFIED OR REPLACED WITH ANY PART EXCEPT THOSE WHICH ARE APPROVED BY DAIMLERCHRYSLER/MOPAR.

POLICY: Information Only NUMBER: 08-012-04

GROUP: Electrical

DATE: March 23, 2004

SUBJECT: Loss Of Communication DTC’s Set In Multiple Modules During New Vehicle Prep/Service

MODELS:

2005 (LX) 300/Magnum

DISCUSSION: Diodes in cavity 31 and/or cavity 32 and/or cavity 33 in the Rear Power Distribution Center (RPDC), located in the trunk next to the battery, may become dislodged when the RPDC cover is removed using excessive side loading/force. V6 engine equipped vehicles have two diodes in the RPDC (cavities 31 and 33). V8 engine equipped vehicles have Three diodes in the RPDC (cavities 31, 32 and 33).

If the cavity 31 diode becomes dislodged when the RPDC cover is removed, the following issues will occur: You will lose the ignition run feed to the following modules/components: Occupant Restraint Control (ORC) module, Automatic Temperature Control (ATC) control head, Manual Temperature Control (MTC) & ATC blower motor, High Intensity Discharge (HID) module & associated sensors/headlamps, and Parktronics module. Loss of communication Diagnostic Trouble Codes (DTC) with these modules will be set. The airbag light will be illuminated in the instrument cluster. The Front Control Module (FCM) will report B2124-ignition run control circuit open.

If the cavity 32 diode becomes dislodged when the RPDC cover is removed, the following issues will occur: All modules that are capable will set loss of communication DTC’s with the Transmission Control Module (TCM). The transmission will go into 2nd gear limp-in. The Anti-lock Brake System (ABS) light in the instrument cluster will be illuminated.

If the cavity 33 diode becomes dislodged when the RPDC cover is removed, no DTC’s or any operator noticeable vehicle functions are affected. The cavity 33 diode provides charging system over voltage protection.

Before installing the cover on the RPDC, make sure all diodes and fuses are securely seated by pressing down on them. If a diode became completely separated from the RPDC cavity be aware the diodes are keyed and can only be inserted in one direction, the diode “arrow symbol” on top of diodes in slots 31 and 32 point toward the spare tire, slot 33 diode “arrow symbol” points to the rear of the vehicle. Special care must be using when installing the cavity 33 diode to insure proper orientation as its terminals will make contact in the reversed position before the key prevents full insertion and will cause the cavity 5 fuse to fail.

POLICY: Information Only NUMBER: 08-013-04 REV. A

GROUP: Electrical

DATE: April 6, 2004

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-013-04, DATED MARCH 23, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.

SUBJECT: Recalibration Procedures Required After Battery Disconnect

MODELS:

2005 (LX) 300/Magnum

DISCUSSION: Express Windows and Electronic Stability Program (ESP) Steering Angle Sensor, require recalibration anytime the battery has been disconnected or has lost its charge. The following are the procedures to recalibrate each system:

Window Express Calibration For Vehicles So Equipped (BOTH front window switches labeled AUTO): 1. Turn the Ignition to the Run position. 2. Regardless of current window position, move the driver’s window upward until the window stalls in the full up position. Allow the window motor to stall for at least 2 seconds before releasing the switch. 3. Move the driver’s window downward until the window stalls in the full down position. Allow the window motor to stall for at least 2 seconds before releasing the switch. 4. Move the driver’s window upward until the window stalls in the full up position. Allow the window motor to stall for at least 2 second before releasing the switch. 5. Repeat step 2, 3 and 4 for the passenger’s window. 6. Verify the windows learned the calibration by operating the express down and up features on the windows. 7. Repeat this procedure if the calibration failed. If vehicle still fails, check the Driver’s Door Module (DDM) and Passenger’s Door Module (PDM) for Diagnostic Trouble Codes (DTCs) and correct as required.

ESP Steering Angle Sensor Calibration For Vehicles So Equipped (ESP on/off switch is present in center stack): 1. Start the Engine. 2. Turn the steering wheel right until the wheels locks full right. 3. Turn the steering wheel left until the wheels locks full left. 4. Turn the steering wheel right until the wheels are basically centered.

After recalibrating the above systems: 1. Cycle the ignition switch Off and back On, do not start the engine. 08-013-04 REV. A -2-

2. Use the StarSCAN to clear any DTCs from all modules. If the ABS DTC C121A is still active then repeat steps 2, 3, and 4 for ESP. If calibration continues to fail, diagnose and repair as necessary.

POLICY: Information Only NUMBER: 23-020-04

GROUP: Body

DATE: June 1, 2004

SUBJECT: Hood Secondary Catch Binding

OVERVIEW: This bulletin involves lubricating the hood secondary catch.

MODELS:

2005 (LX) 300/Magnum

SYMPTOM/CONDITION: When attempting to release the secondary hood catch the lever may bind and will not release unless wiggled up & down while pushing to the left. This condition only happens when the release lever is manually rotated by hand to the left (facing the front of the vehicle). Once the lever is released, the secondary hood catch will spring back to its normal position.

DIAGNOSIS: If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description AR 05019061AA Grease, MS-3274 (one tube will service more than 50 vehicles)

REPAIR PROCEDURE: 1. Unlatch and raise the hood. 2. Inject a pea size volume of grease between the brow and secondary catch, (Fig. 1). 23-020-04 -2-

Fig. 1 GREASE APPLICATION

1 - BROW 2 - APPLY GREASE HERE

3. Rotate the secondary lever to the left & right several times to distribute the grease and verify low effort actuation. 4. Close the hood. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-41-45-90 Lubricate Hood Latch 0.2 Hrs.

FAILURE CODE:

07 Binds, Sticks or Seized NUMBER: 23-012-04

GROUP: Body

DATE: April 27,2004

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-009-03, DATED APRIL 18, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF VEHICLE LINES AND MODEL YEARS AND AN INCREASE IN MATERIAL ALLOWANCE.

SUBJECT: Real Wood Trim Scratch Repair

OVERVIEW: This bulletin involves finesse sanding and polishing scratched real wood trim panels.

MODELS:

**2005 (CS) Pacifica** **2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan** 2001 -**2004** (LH) 300M/LHS/Concorde Limited **2005 (LX) 300/Magnum** 2002 - **2004** (WG) Grand Cherokee (International Markets) 2002 - **2004** (WJ) Grand Cherokee

NOTE: **This bulletin applies to vehicles equipped with sales codes CSY or SCW.**

SYMPTOM/CONDITION: Real wood trim steering wheels and interior trim panels may become scratched/damaged by sharp objects such as rings, keys, etc.

DIAGNOSIS: Visually inspect the wood trim if a scratch is present, the following Repair Procedure should be used.

NOTE: **Subject CS-vehicles have real wood steering wheel and shift knob. Subject JR-vehicles have real wood instrument panel bezels and on JR-convertible vehicles door trim panel spears. Subject LH-vehicles have real wood steering wheels, cluster and right side instrument panel trim bezels. Subject LX-vehicles have real wood door pulls, shift knobs and steering wheels. Subject WJ/WG-vehicles with an optional Overland package have real wood instrument panel spears/bezels, instrument panel upper center bezel, door trim panel spears and steering wheel.** 23-012-04 -2-

MATERIALS REQUIRED:

Qty. Part No. Description AR NPN Sand Paper, 400 Grit AR NPN Sand Paper, 600 Grit AR NPN Sand Paper, 1000 Grit AR NPN Sand Paper, 1500 Grit AR NPN Sand Paper, 2000 Grit AR NPN Compound, Polishing

REPAIR PROCEDURE: 1. Depending on the depth of the scratch, sand the scratched area with 400 grit or finer sandpaper. Use a linear (back and forth) sanding action, DO NOT use a circular motion. 2. Continue sanding until the scratched area is flush with the surrounding surface of the steering wheel/trim panel. 3. Use the next finest grit sandpaper to sand the scratched area until the linear scuff pattern is uniform with the finer grit. 4. Repeat step 3 until sanding with 2000 grit sandpaper is completed. 5. Polish the sanded area with polishing compound to return the surface to a high luster. 6. Clean any sanding/polishing residue from the vehicle. POLICY: Damage occurring during shipment is reimbursable via transportation claim. Damage occurring while in dealer inventory is dealer responsibility. Damage caused after the sale of the vehicle is not covered under warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-66-79-01 Finesse Sand, Buff and Polish - Steering Wheel 0.3 Hrs. Material Allowance **$4.15** 23-66-79-02 Finesse Sand, Buff and Polish - Instrument Panel 0.3 Hrs. Bezel Material Allowance **$4.15** 23-66-79-03 Finesse Sand, Buff and Polish - Door Trim Panel 0.3 Hrs. Material Allowance **$4.15** Related Operation 23-66-79-50 Each Additional 0.2 Hrs. Material Allowance **$2.04**

FAILURE CODE:

89 Scored or Scratched NUMBER: 02-004-04

GROUP: Suspension

DATE: June 15, 2004

SUBJECT: Suspension/Towing/Lifting Damage

MODELS:

2004 - 2005 (CS) Pacifica 2005 (LX) 300/Magnum

DISCUSSION: Damage to the front and rear suspension components can be caused by incorrect usage of the suspension for tie down during transportation of the vehicle. If correct vehicle jacking (lifting/hoisting) procedures are not followed, then damage may result to those suspension components where the jack has not been properly positioned.

When the vehicle requires towing, the vehicle should be secured using only the correct prescribed tie down locations. Refer to the service information available in TechCONNECT or the appropriate owner's manual in the “What to do in emergencies” section.

When the vehicle requires jacking/hoisting/lifting. Refer to the service information available in TechCONNECT or the appropriate owner's manual in the “What to do in emergencies” section.

Please provide a copy of this bulletin to all towing companies in your market area.

POLICY: Information Only. NUMBER: 08-016-04

GROUP: Electrical

DATE: April 27, 2004

THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.

THE StarSCAN SOFTWARE UPDATE CD CONTAINS ALL PREVIOUSLY RELEASED FLASH FILES PRIOR TO THE CD RELEASE DATE PRINTED ON THE CD LABEL.

FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2004.

SUBJECT: Premium Audio System Intermittent Output

OVERVIEW: This bulletin involves flash reprogramming the audio amplifier (AMP) with new software.

MODELS:

2005 (LX) 300/Magnum

NOTE: This bulletin applies to vehicles built prior to May 10, 2004 (MDH 0510XX) equipped with a premium audio system (Sales Code RC6 or RC7).

SYMPTOM/CONDITION: The audio system will occasionally not produce audio for an entire ignition cycle. The radio display and controls will work normally, but no sound will be produced. This Symptom/Condition is very difficult to reproduce on demand.

DIAGNOSIS: Using a StarSCAN™, check the p/n of the AMP. If the p/n is 05059073AI or 05059073AK, perform the Repair Procedure. If the p/n is other than 05059073AI or 05059073AK, this SB does not apply and further diagnosis is required. The flash will change the audio amplifier to p/n 05059073AL. 08-016-04 -2-

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NPN Battery Charger CH9401 StarSCAN™ Tool CH9404 StarSCAN™ Vehicle Cable CH9409 StarSCAN™ Documentation Kit CH9410 StarSCAN™ Ethernet Cable, 12 ft. CH9412 StarSCAN™ Software Update Device Kit TechCONNECT PC or equivalent StarSCAN™ Software Update CD

CAUTION: Be very careful to not interrupt the flash session. If the flash session is interrupted for any reason; loss of power to the tool, loss of communication with the tool or AMP, disconnects of any kind, may render the AMP unusable! Insure that the StarSCAN™ rests on a STABLE surface and that the cables are secured at both ends before beginning the flash session.

REPAIR PROCEDURE USING THE INTERNET TO RETRIEVE FLASH FILE: NOTE: The StarSCAN™ must be at version 4.06 or higher before this procedure can be performed.

NOTE: The StarSCAN™ diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN™ for your dealership's network. For instruction on setting up your StarSCAN™ for the dealer's network; refer to the StarSCAN™ Quick Start Networking Guide available on the www.dcctools.com website under the "download center".

NOTE: Make sure the StarSCAN™ is configured to the dealership's network before proceeding.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Retrieve the old AMP part number. Using the StarSCAN™ at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the AMP in the list of modules. c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference. 2. Connect the CH9410 StarSCAN™ ethernet cable to the StarSCAN™ and the dealer's network drop. 3. Connect the CH9404 StarSCAN™ vehicle cable to the StarSCAN™ and the vehicle (optional). 4. Power ON the StarSCAN™. -3- 08-016-04

5. Download the flash file from the internet to the StarSCAN™. Using the StarSCAN™ at the “Home” screen: a. Select “Flash Download” b. Select “Use connected vehicle” (StarSCAN™ must be connected to the vehicle) or “Enter information manually” (connection to the vehicle is not necessary). Press the “Next” button and follow the on screen instructions. c. Select the appropriate calibration. d. Select “Download to Scantool”. e. Select “Close”#after the download is complete. 6. Connect the CH9404 StarSCAN™ vehicle cable to the StarSCAN™ and the vehicle (if not already connected). 7. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 8. Download the file from StarSCAN™ to the vehicle. Using StarSCAN™ at the “Home” screen: a. Select “ECU View” b. Browse the list of controllers using the scroll arrows. Highlight the AMP. c. Select “More Options” d. Select “ECU Flash” e. Highlight the appropriate AMP “Calibration” from the list. f. Select “Update Controller” g. When update is completed, select “OK” NOTE: Due to the AMP programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the AMP only after all other modules have had their DTC's erased.

REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE FLASH FILE: NOTE: Before flashing this module, make sure the StarSCAN™ is operating at the latest level and this is the latest flash file available from the StarSCAN™ update CD. To determine the latest StarSCAN™ software version level available refer to www.dcctools.com website under the "Latest News" link.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

NOTE: For detailed information on the operation of the StarSCAN™, refer to the Quick Reference documentation provided in the StarSCAN™ documentation kit. In addition, more recent information may also be available at the www.dcctools.com website. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Retrieve the old AMP part number. Using the StarSCAN™ at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the AMP in the list of modules. c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference. 08-016-04 -4-

2. Insert the USB Key, into the USB port on the TechCONNECT or equivalent PC (Fig. 1).

Fig. 1 USB KEY AND TECHCONNECT PC

1 - TechCONNECT PC 2 - ACCESS DOOR (ON FRONT OF TechCONNECT PC) 3 - USB KEY IN THE TechCONNECT PC USB PORT

3. Insert the StarSCAN™ Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN™ Software Update CD will start automatically. a. Select “Controller Flash”. b. Follow the on screen instructions. 4. At the “Select the type of information you wish to enter.” screen: a. If the old “Part Number” was recorded in Step #1, proceed to Step #5. b. If the old “Part Number” is not known, proceed to Step #6. 5. Select “Enter part number”. a. Follow the on screen instructions. Enter the “Part Number” (use capital letters) recorded in Step #1 when prompted to do so. Follow the on screen instructions. Select “Next” after each step. Select “Finish” after completing the last step. b. Proceed to Step #7. 6. Select “Enter YME Information”. a. Follow the on screen instructions. Select “Next” after each step. Select “Finish” after completing the last step. b. Proceed to Step #7. 7. Using the mouse highlight the appropriate “Calibration”. a. Select “Save to USB” b. Follow the on screen instructions. Select “Next” after each step . Select “Finish” after completing the last step. 8. With the StarSCAN™ powered OFF, connect the USB Key and Gender Changer to the StarSCAN™ USB port, (Fig. 2). -5- 08-016-04

Fig. 2 USB KEY, GENDER CHANGER, AND StarSCAN TOOL

1 - StarSCAN™ TOOL 2 - GENDER CHANGER 3 - USB KEY

9. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 10. Connect the StarSCAN™ to the vehicle. 11. Power ON the StarSCAN™. 12. Download the file from the USB key to the StarSCAN™. Using the StarSCAN™ at the “Home” screen: a. Select “Flash Download” b. Select “Use USB device” c. Follow the on screen instructions. Select “Next”#after each step . Select “Finish” after completing the last step. d. At the “Flash File List” screen, highlight the appropriate AMP “Calibration” e. Select “Download to Scantool” f. When the download is complete, select “Close” 13. Download the file from the StarSCAN™ to the vehicle. Using the StarSCAN™ at the “Home” screen: a. Select “ECU View” b. Browse the list of controllers using the scroll arrows. Highlight the AMP. c. Select “More Options” d. Select “ECU Flash” e. Highlight the appropriate AMP “Calibration” from the list. f. Select “Update Controller” g. When update is completed, select “OK” 08-016-04 -6-

NOTE: Due to the AMP programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the AMP only after all other modules have had their DTC's erased.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-19-61-95 Reprogram Audio Amplifier 0.3 Hrs.

FAILURE CODE:

FM Flash Module NUMBER: 23-024-04

GROUP: Body

DATE: June 29, 2004

THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL JULY 20, 2004.

SUBJECT: Lift Strap On The Cargo Tri-Fold Load Floor Detaches

OVERVIEW: This bulletin involves installing the load floor lift strap with a special rivet.

MODELS:

2005 (LX) Magnum

SYMPTOM/CONDITION: The cargo tri-fold load floor lift strap comes loose.

DIAGNOSIS: Visually inspect for a detached/loose load floor strap, if detached or loose perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description 1 05166302AA Rivet

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NPN Heavy Duty or Pneumatic Rivet Gun

REPAIR PROCEDURE: 1. Remove push pins from both sides of the load floor attaching the lift strap, if not already removed. 2. Attach lift strap with two piece rivet. 23-024-04 -2-

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-14-16-90 Install Tri-Fod Load Floor Strap With Rivet 0.2 Hrs.

FAILURE CODE:

K4 Loose NUMBER: 08-026-04

GROUP: Electrical

DATE: July 27, 2004

THIS BULLETIN IS BEING PROVIDED IN ADVANCE. THE SOFTWARE WILL BE AVAILABLE ON StarSCAN™ SOFTWARE UPDATE CD RELEASE 5.01, AUGUST 16, 2004.

A StarSCAN SOFTWARE UPDATE CD CONTAINS ALL PREVIOUSLY RELEASED FLASH FILES PRIOR TO THE CD RELEASE DATE PRINTED ON THE CD LABEL.

FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE WILL BE AVAILABLE ON StarSCAN INTERNATIONAL UPDATE CD 5.01 IN SEPTEMBER, 2004.

SUBJECT: Ambient Temperature Display Slow to Update/Erroneous Diagnostic Trouble Codes/Instrument Cluster Display Language Correction

OVERVIEW: This bulletin involves reprogramming the Cabin Compartment Node (CCN) with new software, version 3.61 or higher.

MODELS:

2005 (LX) 300/Magnum

SYMPTOM/CONDITION: Temperature Display The outside temperature display located in the cluster will show an inaccurate reading (typically off more than 10 degrees F.) but will eventually update. Update time will appear to be delayed and could take longer than one hour depending on driving conditions. A vehicle speed in excess of 32 kph (20 mph) for three consecutive minutes is presently required for an update to occur.

Erroneous DTC(s) Airbag indicator DTC B1202 may be set even though the airbag indicator lamp does not stay illuminated after bulb check. If the vehicle is a built up export (BUX) Chrysler sedan it may set a rear wiper indicator B1225 or B1226.

Instrument Cluster Language Some CCNs have a provision to select language in the reconfigurable display. The French translations for some of the displayed messages are indecipherable. 08-026-04 -2-

DIAGNOSIS: If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure.

SPECIAL TOOLS/EQUIPMENT REQUIRED:

REPAIR PROCEDURE USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN must be at version 5.01 or higher before the repair procedure can be performed.

NOTE: The StarSCAN diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN for your dealership's network. For instruction on setting up your StarSCAN for the dealer's network; refer to the StarSCAN Quick Start Networking Guide available on the www.dcctools.com website under the "download center".

NOTE: Make sure the StarSCAN is configured to the dealership's network before proceeding.

7. Select “Download to Scantool”. 8. Select “Close” after the download is complete. Proceed to Step #11. 9. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop (if not already connected). 10. Download the flash file from the Internet to the StarSCAN. Using the StarSCAN at the “Home” screen: a. Select “Flash Download”. b. Select “Enter information manually”. Press the “Next” button and follow the on screen instructions. c. Select the appropriate calibration. d. Select “Download to Scantool”. e. Select “Close” after the download is complete. 11. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle (if not already connected). 12. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 13. Download the file from StarSCAN to the vehicle. Using StarSCAN at the “Home” screen: a. Select “ECU View” b. Browse the list of controllers using the scroll arrows. Highlight the CCN. c. Select “More Options” d. Select “ECU Flash” e. Highlight the appropriate CCN “Calibration” from the list. f. Select “Update Controller” g. When update is completed, select “OK” NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (TCM, PCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased.

REPAIR PROCEDURE USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN must be at version 5.01 or higher before the repair procedure can be performed.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

1. Retrieve the old CCN part number. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the CCN in the list of modules. c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference. 2. Insert the USB Key, into the USB port on the TechCONNECT or equivalent PC (Fig. 1).

Fig. 1 USB KEY AND TECHCONNECT PC

1 - TechCONNECT PC 2 - ACCESS DOOR (ON FRONT OF TechCONNECT PC) 3 - USB KEY IN THE TechCONNECT PC USB PORT

3. Insert the StarSCAN Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN Software Update CD will start automatically. a. Select “Controller Flash”. b. Follow the on screen instructions. 4. At the “Select the type of information you wish to enter.” screen: a. If the old “Part Number” was recorded in Step #1, proceed to Step #5. b. If the old “Part Number” is not known, proceed to Step #6. 5. Select “Enter part number”. a. Follow the on screen instructions. Enter the “Part Number” (use capital letters) recorded in Step #1 when prompted to do so. Follow the on screen instructions. Select “Next” after each step . Select “Finish” after completing the last step. b. Proceed to Step #7. 6. Select “Enter YME Information”. a. Follow the on screen instructions. Select “Next” after each step. Select “Finish” after completing the last step. b. Proceed to Step #7. -5- 08-026-04

7. Using the mouse highlight the appropriate “Calibration” a. Select “Save to USB” b. Follow the on screen instructions. Select “Next” after each step. Select “Finish” after completing the last step. 8. With the StarSCAN powered OFF, connect the USB Key and Gender Changer to the StarSCAN USB port (Fig. 2).

Fig. 2 USB KEY, GENDER CHANGER, AND StarSCAN TOOL

1 - StarSCAN™ TOOL 2 - GENDER CHANGER 3 - USB KEY

13. Download the file from the StarSCAN to the vehicle. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Browse the list of controllers using the scroll arrows. Highlight the CCN. c. Select “More Options” d. Select “ECU Flash” e. Highlight the appropriate CCN “Calibration” from the list. f. Select “Update Controller” g. When update is completed, select “OK” NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (TCM, PCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-19-61-99 Reprogram CCN 0.4 Hrs.

FAILURE CODE:

FM Flash Module NUMBER: 09-013-04

GROUP: Engine

DATE: August 6, 2004

SUBJECT: Gasoline Engine Oil Quality And Viscosity Grades

MODELS:

2005 (ND) Dakota 2005 (CS) Pacifica 2005 (DR) Ram Truck 2005 (HB) Durango 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2005 (KJ) Liberty 2005 (LX) 300/Magnum 2005 (PL) Neon 2005 (PT) PT Cruiser 2005 (RS) Town & Country/ Caravan/Voyager 2005 (TJ) Wrangler 2005 (WK) Grand Cherokee

NOTE: This information applies to U.S. and Canada markets only.

NOTE: For additional information and vehicles not covered by this Service Bulletin refer to the service information or the Owner Manual. 09-013-04 -2-

DISCUSSION: This bulletin involves the engine oil to be used to service Chrysler Group gasoline engines. This symbol, found on the front of the container, means that the oil quality has been certified by the American Petroleum Institute (API) (Fig. 1).

Fig. 1 API SYMBOL Only use API Certified engine oils that meet the requirements of Chrysler's Material Standard MS-6395. MS-6395 contains requirements, not addressed by API Certification, that provide additional protection for Chrysler Group engines. All Chrysler Group gasoline engines, irrespective of model year, should be serviced with API Certified engine oils meeting MS-6395. Chrysler Group Engines are developed, certified and filled with engine oil of the designated viscosity grade, meeting MS-6395, and should be serviced with the correct viscosity grade engine oil. The following table contains the correct viscosity grades for the 2005 model year.

Engine Oil Type 2.0L SOHC 5W-20 2.0L DOHC 5W-30 2.4L DOHC 5W-30 2.4L Turbo 5W-30 2.7L 5W-20 or 5W-30 Check Oil Cap for proper usage 3.3L 5W-20 3.5L 10W-30 3.7L 5W-30 3.8L 5W-20 4.0L 10W-30 4.7L 5W-30 5.7L 5W-20

POLICY: Information Only. NUMBER: 23-031-04

GROUP: Body

DATE: August 11, 2004

SUBJECT: "A" Pillar Interior Trim Molding Color

OVERVIEW: This bulletin involves replacing the lighter color “A” Pillar interior trim molding.

MODELS:

2005 (LX) 300/Magnum

NOTE: This bulletin applies to vehicles built between July 19, 2004 and July 30, 2004 (MDH 0719XX - 0730XX).

SYMPTOM/CONDITION: The vehicle operator may describe that the A Pillar interior trim moldings vary in color from side to side.

DIAGNOSIS: Inspect the “A” Pillar interior trim moldings. If the “A” Pillar interior trim moldings vary in color from side to side, perform the Repair Procedure. Replace only the side that does not have a speckled appearance.

PARTS REQUIRED:

Qty. Part No. Description AR (1) 0UM02BDXAC Molding, Windshield (Right) AR (1) 0UM03BDXAC Molding, Windshield (Left)

SPECIAL TOOLS/EQUIPMENT REQUIRED:

C-4755 Trim Stick

REPAIR PROCEDURE: 1. Replace the “A” Pillar interior trim molding that does not have a speckled appearance. Refer to the service information on TechCONNECT. Refer to 23 - Body/Interior/A-Pillar Trim - Removal. 23-031-04 -2-

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-20-16-90 Replace A-Pillar Interior Trim 0.2 Hrs.

FAILURE CODE:

CJ Off Color NUMBER: 08-021-04

GROUP: Electrical

DATE: May 25, 2004

SUBJECT: Erroneous Radio Diagnostic Trouble Code (DTC)

MODELS:

2005 (LX) 300/Magnum

DISCUSSION: Navigation radios (Sale Code REC, p/n 56038646AJ, or Sales Code REJ, p/n 05091508AE) may log internal DTC B221E (Radio Internal Mechanical Failure) when the ignition is turned on, even though the CD/DVD mechanism is working properly and the vehicle operator has not experienced a CD/DVD malfunction.

The internal DTC B221E will be displayed as a "Stored" DTC. Sometimes, multiple B221E DTC's are displayed. They should all be in "Stored" status.

Do not replace REC or REJ navigation radios based solely on the radio internal DTC B221E. In most cases, this is an erroneous DTC with REC AJ level parts and REJ AE level parts. Ignore all internal B221E DTC's in an LX vehicle and do not replace REC or REJ radios, unless a CD/DVD mechanical failure is confirmed.

POLICY: Information Only NUMBER: 23-018-04

GROUP: Body

DATE: May 18, 2004

SUBJECT: Left Front Door Glass Run Distortion

OVERVIEW: This bulletin involves seating the glass run in the B-pillar channel and possibly replacing the door glass.

MODELS:

2005 (LX) 300/Magnum

NOTE: This bulletin applies to vehicles built prior to May 1, 2004 (MDH 0501XX).

SYMPTOM/CONDITION: When the left front door glass is raised the outboard lip of glass run puckers along the B-pillar.

DIAGNOSIS: Visually inspect the outboard lip of glass run with the glass in the full up position, if the glass run is puckered, perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description AR (1) 05065487AB Glass, Left Front Door

REPAIR PROCEDURE: 1. Lower glass to full down position. 2. Push rubber glass run rearward to fully seat in B-pillar channel. 3. Fold outer lip of glass run rearward into proper position. 4. Cycle window up/down 6 to 8 times. 5. If glass run puckers again, use the service procedures available on TechCONNECT to replace door glass. NOTE: Door Speaker removal is not required.

NOTE: If the water shield gets torn during glass replacement, repair or replace the watershield. 23-018-04 -2-

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-30-10-90 Inspect / Align Glass Run in B-pillar Channel 0.2 Hrs. 23-30-10-91 Replace Left Front Door Glass 0.5 Hrs.

FAILURE CODE:

27 Damaged NUMBER: 23-038-04

GROUP: Body

DATE: September 23, 2004

SUBJECT: Rear Door Glass Binds

OVERVIEW: This bulletin involves inspecting and refitting or replacing a rear door glass run and insuring the glass is properly installed in the glass run.

MODELS:

2005 (LX) 300/Magnum

SYMPTOM/CONDITION: Door glass binds or stalls, usually in the up direction.

DIAGNOSIS: If the window regulator moves the rear window partially through full travel and the window stalls, the window is likely mis-installed in the rear glass run below the window sill, perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description AR (1) 05065188AD Glass Run, Right Rear Door AR (1) 05065189AD Glass Run, Left Rear Door

REPAIR PROCEDURE: 1. Remove rear door glass using the procedures outlined in TechCONNECT. 2. Pull the glass run out of the 'C' flag channel at the rear of the door. 3. Spread the glass run open and inspect the sealing lip at the base of the glass run. 4. If the lip is cut or torn, replace the glass run using the procedures outlined in TechCONNECT, otherwise, reinstall the glass run into the channel. 5. Install the glass, making sure the window is engaged properly in the glass run. 23-038-04 -2-

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-33-20-90 Inspect and Refit Rear Door Glass Run - One 0.4 Hrs. Door 23-33-20-91 Replace Rear Door Glass Run - One Door 0.5 Hrs.

FAILURE CODE:

07 Binds, Sticks or Siezed NUMBER: 08-031-04 REV. A

GROUP: Electrical

DATE: September 29, 2004

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-031-04, DATED SEPTEMBER 8, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL CONDITION AND REVISED PART NUMBER.

SUBJECT: Instrument Cluster Language (Non-English) **And/Or Metric Display** Selection Is Not Saved

OVERVIEW: This bulletin involves replacing the radio.

MODELS:

2005 (LX) 300/Magnum

NOTE: This bulletin applies to vehicles built prior to September 29, 2004 (MDH 0929XX).

SYMPTOM/CONDITION: Non-English language customers will not have their language selection retained and the instrument cluster display will revert back to English after the ignition key is turned off and accessory delay times out. **Also, customers that select the “Metric” units display option may default to “U.S.” units after an engine start.**

DIAGNOSIS: LANGUAGE: Select a language other than English in the instrument cluster display. Cycle the ignition switch to the OFF position and open the drivers door to end the accessory delay. Close the drivers door and turn the ignition switch to the ON position. Check the instrument cluster display language. If the display is in English, the radio must be replaced. If the display is in the language previously selected, vehicle is operating correctly.

U.S./METRIC: Select metric in the instrument cluster display. Cycle the ignition switch to the OFF position and remove the key. Open the drivers door to end the accessory delay. Close the drivers door and wait 10 seconds to allow the BUS to go to “sleep”. Start the engine and check the instrument cluster display for U.S./Metric, if the metric setting is kept repeat the U.S./Metric Diagnosis 5 times to insure the condition does not exist in the vehicle. If the display reverts to U.S. at engine start the radio must be replaced. 08-031-04 REV. A -2-

PARTS REQUIRED:

Qty. Part No. Description AR (1) **Z5091523AI** Radio, Exchange RAK with Black Knobs AR (1) **Z5064032AI** Radio, Exchange RAK with Chrome Knobs

REPAIR PROCEDURE: 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - REMOVAL service information on TechCONNECT). 3. Remove the radio mounting fasteners. CAUTION: Pulling the antenna cable straight out of the radio without pulling on the locking antenna connector could damage the cable or radio. 4. Disconnect the antenna cable by pulling the locking antenna connector away from the radio. 5. Disconnect the electrical harness connector and remove radio. 6. Connect the electrical harness and antenna cable to the replacement radio. 7. Position the radio into the instrument panel and install mounting fasteners. 8. Install the instrument panel center bezel (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - INSTALLATION service information on TechCONNECT). 9. Connect the battery negative cable. NOTE: A battery reconnect procedure must be performed anytime the battery has been disconnected. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - STANDARD PROCEDURE) or Service Bulletin 08-013-04 Rev. A. 10. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-60-02-99 Replace Radio 0.3 Hrs.

FAILURE CODE:

58 Internal Defect NUMBER: 21-006-04 REV. A

GROUP: Transmission

DATE: October 6, 2004

THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-006-04, DATED APRIL 27, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES UPDATES FOR THE REPAIR PROCEDURES, PART NUMBERS, LABOR OPERATION TIMES AND A NOTE.

SUBJECT: Shudder During Shifts

OVERVIEW: This bulletin involves flushing the transmission and **replacing the transmission fill tube**.

MODELS:

2005 (LX) 300/Magnum

NOTE: **This bulletin applies to vehicles equipped with a 42RLE transmission (Sales Code DG6) built before August 29, 2004**.

SYMPTOM/CONDITION: Shudder felt during shifts. The shudder is most noticeable with partial application of torque converter clutch in 3rd and 4th gear.

DIAGNOSIS: 1. Test drive the vehicle to verify the condition. 2. Visually inspect the Automatic Transmission Fluid (ATF) for water contamination (use a service dipstick, Miller Special Tool 9336). ATF contaminated with water will have a milky appearance but may not be readily apparent at lower concentration levels, 0.5% water concentration will cause shift shudder. The visual inspection may not be conclusive. 3. Document result of the visual inspection on the repair order. 4. Perform the Repair Procedure if the shift quality test drive confirmed shift shudder exists regardless of the outcome of the visual inspection. 21-006-04 REV. A -2-

PARTS REQUIRED:

Qty. Part No. Description AR (8-10) 05013457AA Fluid, Automatic Transmission, MS-9602 ATF+4, Qt. AR (2) 05013458AA Fluid, Automatic Transmission, MS-9602 ATF+4, Gal. **1 04591879AD Tube, Transmission Oil Filler 2.7L Engine** **1 04593634AA Tube, Transmission Oil Filler 3.5L Engine** **1 4810021 Grommet**

SPECIAL TOOLS/EQUIPMENT:

9336 Dipstick **8254 Installer, Seal (Grommet)** NPN Transmission Fluid Exchanger, available through Team PSE

REPAIR PROCEDURE WITH FLUID EXCHANGER: If a fluid exchanger is not available, skip to the Double Flush Procedure 1. Flush the ATF using a fluid exchanger. Follow the fluid exchanger directions. 2. Raise the vehicle on an appropriate hoist. 3. **Remove the dipstick tube cap**. 4. **Remove the bolt holding the transmission fill tube to the transmission (Fig. 1)**.

Fig. 1 REMOVE TRANSMISSION FILL TUBE

1 - TRANSMISSION 2 - TRANSMISSION FILL TUBE 3 - BOLT

5. **Remove the transmission fill tube from the transmission **. 6. **Remove the grommet from the transmission if it did not come out with the fill tube in the previous ster.**. 7. **Using special tool 8254 install the new grommet**. -3- 21-006-04 REV. A

8. **Install the new fill tube**. 9. **Install the bolt holding the transmission fill tube to the transmission (Fig. 1)**. 10. Set the transmission fluid level: a. Actuate the service brake. Start engine and let it run at idle speed in selector lever position "P". b. Shift through the transmission modes several times with the vehicle stationary and the engine idling. c. Remove the dipstick tube cap. d. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine running. e. Push the Oil Dipstick 9336 into transmission fill tube until the dipstick tip contacts the oil pan and pull out again, read oil level, repeat if necessary. f. Check transmission oil temperature using the StarSCAN™. g. The transmission Oil Dipstick 9336 has indicator marks every 10mm. Determine the height of the oil level on the dipstick and using the height, the transmission temperature, and the Transmission Fluid Graph (Fig. 2), determine if the transmission oil level is correct. h. Add or remove oil as necessary and recheck the oil level. i. Once the oil level is correct, install the dipstick tube cap. WARNING:Risk of accident from vehicle starting off by itself when engine running. Risk of injury from contusions and burns if you insert your hands into the engine when it is started or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly fastened and close-fitting work clothes. Do not touch hot or rotating parts.

NOTE: The dipstick will protrude from the fill tube when installed. 21-006-04 REV. A -4-

Fig. 2 42RLE FLUID TEMPERATURE CHART 11. Drive the vehicle until the transmission fluid is at normal operating temperature to confirm that the shift shudder has been eliminated. 12. With the vehicle on a level surface, the engine running at curb idle speed, the gear selector in PARK, and the parking brake applied, check the transmission fluid level. DOUBLE FLUSH REPAIR PROCEDURE: The double flush ensures a more comprehensive replacement of contaminated fluid than a single flush by circulating residual fluid from the torque converter not removed in the initial flush. 1. Raise the vehicle on an appropriate hoist. 2. Remove the oil pan and drain the ATF. 3. Install the transmission oil pan. 4. Lower the vehicle leaving the rear wheels off the ground. 5. Fill the transmission with MS-9602 ATF+4 (approximately 3 - 4 qts). 6. Start the engine. 7. Shift the transmission into drive and lightly accelerate the engine speed to allow the transmission to upshift through gears. 8. Apply the brakes and stop the wheels from turning. 9. Shift the transmission into reverse and release the brakes. Let the wheels turn for approximately 5 seconds. 10. Apply the brakes and stop the wheels from turning. 11. Repeat steps 7 - 10 two more times and turn off the engine and place the transmission in park. 12. Stop the engine. -5- 21-006-04 REV. A

13. Raise the vehicle. 14. Remove the transmission oil pan and drain the ATF. 15. Clean the transmission and oil pan mating surfaces. 16. Apply ATF-RTV, p/n 05010884AA to the transmission oil pan sealing flange. 17. Install the transmission oil pan. Torque the fasteners to 20 Nm (175 in. lbs.). 18. **Remove the dipstick tube cap**. 19. **Remove the bolt holding the transmission fill tube to the transmission (Fig. 1)**. 20. **Remove the transmission fill tube from the transmission **. 21. **Remove the grommet from the transmission if it did not come out with the fill tube in the previous ster.**. 22. **Using special tool 8254 install the new grommet**. 23. **Install the new fill tube**. 24. **Install the bolt holding the transmission fill tube to the transmission (Fig. 1)**. 25. Set the transmission fluid level: a. Actuate the service brake. Start engine and let it run at idle speed in selector lever position "P". b. Shift through the transmission modes several times with the vehicle stationary and the engine idling. c. Remove the dipstick tube cap. d. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine running. e. Push the Oil Dipstick 9336 into transmission fill tube until the dipstick tip contacts the oil pan and pull out again, read oil level, repeat if necessary. f. Check transmission oil temperature using the StarSCAN™. g. The transmission Oil Dipstick 9336 has indicator marks every 10mm. Determine the height of the oil level on the dipstick and using the height, the transmission temperature, and the Transmission Fluid Graph (Fig. 2), determine if the transmission oil level is correct. h. Add or remove oil as necessary and recheck the oil level. i. Once the oil level is correct, install the dipstick tube cap. WARNING:Risk of accident from vehicle starting off by itself when engine running. Risk of injury from contusions and burns if you insert your hands into the engine when it is started or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly fastened and close-fitting work clothes. Do not touch hot or rotating parts.

NOTE: The dipstick will protrude from the fill tube when installed. 26. Drive the vehicle until the transmission fluid is at normal operating temperature to confirm that the shift shudder has been eliminated. 27. With the vehicle on a level surface, the engine running at curb idle speed, the gear selector in PARK, and the parking brake applied, check the transmission fluid level. 21-006-04 REV. A -6-

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 21-10-15-91 **Flush Transmission Using Fluid Exchanger and **1.2 Hrs.** Replace Fill Tube and Grommet** 21-10-15-92 **Flush Transmission Using Double Flush **1.5 Hrs.** Method and Replace Fill Tube and Grommet**

FAILURE CODE:

68 Noisy NUMBER: 08-033-04

GROUP: Electrical

DATE: October 15, 2004

SUBJECT: Left Front Door Speaker Cut Out At Highway Speed

OVERVIEW: This bulletin involves flash reprogramming the audio amplifier with revised software (05059073AN).

MODELS:

2005 (LX) Magnum/Chrysler Touring (International Markets)

NOTE: This bulletin applies to Magnum vehicles equipped with Boston Acoustics audio system (Sales Code RC6).

SYMPTOM/CONDITION: The left front door speaker seems to cut out at highway speeds. The audio image seems to pull to the right at high speeds.

DIAGNOSIS: 1. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 2. Retrieve the audio amplifier part number. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the appropriate controller in the list of modules. c. Select “More Options”. d. Select “ECU Flash” e. Record the "Part Number", displayed on the “flash audio amplifier” screen. If the part number is 05059073AA through and including 05059073AM, perform the Repair Procedure. If the part number is 05059073AN or higher this bulletin does not apply and further diagnosis is required. 08-033-04 -2-

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NPN Battery Charger CH9401 StarSCAN Tool CH9404 StarSCAN Vehicle Cable CH9409 StarSCAN Documentation Kit CH9410 StarSCAN Ethernet Cable, 12 ft. CH9412 StarSCAN Software Update Device Kit TechCONNECT PC or equivalent Latest StarSCAN Software Update CD

FLASH PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN must be at version 4.07 or higher before the "Using The Internet To Retrieve The Flash File" repair procedure can be performed.

NOTE: Make sure the StarSCAN is configured to the dealership's network before proceeding.

NOTE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop (optional). -3- 08-033-04

3. Retrieve the audio amplifier part number. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the appropriate controller in the list of modules. c. Select “More Options”. d. Select “ECU Flash” e. Record the "Part Number", displayed on the “flash audio amplifier” screen, for later reference. 4. If the StarSCAN is connected to the dealer's network drop and the vehicle, proceed to Step #5. If the StarSCAN is not connected to the dealer's network drop and the vehicle, proceed to Step #10 5. select “Browse for new file”. 6. Select the appropriate flash file. 7. Select “Download to Scantool”. 8. Select “Close” after the download is complete. Proceed to Step #11. 9. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop (if not already connected). 10. Download the flash file from the Internet to the StarSCAN. Using the StarSCAN at the “Home” screen: a. Select “Flash Download”. b. Select “Enter information manually”. Press the “Next” button and follow the on screen instructions. c. Select the appropriate flash file. d. Select “Download to Scantool”. e. Select “Close” after the download is complete. 11. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle (if not already connected). 12. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 13. Download the flash file from StarSCAN to the vehicle. Using StarSCAN at the “Home” screen: a. Select “ECU View” b. Browse the list of module using the scroll arrows. Highlight the audio amplifier. c. Select “More Options” d. Select “ECU Flash” e. Highlight the appropriate flash file from the list. f. Select “Update” g. When update is completed, select “OK” NOTE: Due to the audio amplifier programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased.

FLASH PROCEDURE - USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: Before flashing any module, make sure the StarSCAN is operating at the latest level and this is the latest flash file available from the StarSCAN update CD. To determine the latest StarSCAN software version level available refer to www.dcctools.com website under the "Latest News" link. 08-033-04 -4-

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

NOTE: For detailed information on the operation of the StarSCAN, refer to the Quick Reference documentation provided in the StarSCAN documentation kit. In addition, more recent information may also be available at the www.dcctools.com website. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Retrieve the audio amplifier part number. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the audio amplifier in the list of modules. c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference. 2. Insert the USB Key, into the USB port on the TechCONNECT or equivalent PC (Fig. 1).

Fig. 1 USB KEY AND TechCONNECT PC

1 - TechCONNECT PC 2 - ACCESS DOOR (ON FRONT OF TechCONNECT PC) 3 - USB KEY IN THE TechCONNECT PC USB PORT

5. Select “Enter part number”. a. Follow the on screen instructions. Enter the “Part Number” (use capital letters) recorded in Step #1 when prompted to do so. Follow the on screen instructions. Select “Next” after each step . Select “Finish” after completing the last step. b. Proceed to Step #7. 6. Select “Enter YME Information”. a. Follow the on screen instructions. Select “Next” after each step. Select “Finish” after completing the last step. b. Proceed to Step #7. 7. Using the mouse highlight the appropriate “Calibration” a. Select “Save to USB” b. Follow the on screen instructions. Select “Next”#after each step . Select “Finish” after completing the last step. 8. With the StarSCAN powered OFF, connect the USB Key and Gender Changer to the StarSCAN USB port (Fig. 2).

Fig. 2 USB KEY, GENDER CHANGER, AND StarSCAN TOOL

1 - StarSCAN™ TOOL 2 - GENDER CHANGER 3 - USB KEY

9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the StarSCAN to the vehicle. 11. Power ON the StarSCAN. 08-033-04 -6-

12. Download the file from the USB key to the StarSCAN. Using the StarSCAN at the “Home” screen: a. Select “Flash Download” b. Select “Use USB device” c. Follow the on screen instructions. Select “Next”#after each step . Select “Finish” after completing the last step. d. At the “Flash File List” screen, highlight the appropriate audio amplifier “Calibration” e. Select “Download to Scantool” f. When the download is complete, select “Close” 13. Download the file from the StarSCAN to the vehicle. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Browse the list of controllers using the scroll arrows. Highlight the audio amplifier. c. Select “More Options” d. Select “ECU Flash” e. Highlight the appropriate audio amplifier module “Calibration” from the list. f. Select “Update Controller” g. When update is completed, select “OK” NOTE: Due to the audio amplifier programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-19-62-90 Reprogram Audio Amplifier 0.3 Hrs.

FAILURE CODE:

FM Flash Module NUMBER: 08-034-04

GROUP: Electrical

DATE: October 20, 2004

THE SOFTWARE IS AVAILABLE VIA THE INTERNET TODAY AND WILL BE AVAILABLE ON THE StarSCAN CD DATED NOVEMBER, 2004.

SUBJECT: Flash: Vehicle Theft Security System - No Horn During Alarm On International Models

OVERVIEW: This bulletin involves flash reprogramming the Front Control Module (FCM) using the StarSCAN.

MODELS:

2005 (LX) 300/300 Touring (International Markets)

NOTE: This bulletin applies to International Market vehicles built on July 24, 2004 through and including October 4, 2004 (MDH 8024XX - 1004XX).

SYMPTOM/CONDITION: In vehicles containing Vehicle Theft Alarm System (VTSS) (Sales Code LSA), the vehicle may not sound the horn as an audible alert during a theft event.

DIAGNOSIS: 1. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 2. Retrieve the FCM part number. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the FCM in the list of modules. c. Select “More Options”. d. Select “ECU Flash” e. Record the "Part Number", displayed on the “flash FCM” screen. If the FCM p/n is 05026021AA, perform the Repair Procedure. If the part number is 05026021AB or higher this bulletin does not apply and further diagnosis is required. 08-034-04 -2-

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NOTE: Make sure the StarSCAN is configured to the dealership's network before proceeding.

9. Download the flash file from the Internet to the StarSCAN. Using the StarSCAN at the “Home” screen: a. Select “Flash Download”. b. Select “Enter information manually”. Press the “Next” button and follow the on screen instructions. c. Select the appropriate flash file. d. Select “Download to Scantool”. e. Select “Close” after the download is complete. 10. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle (if not already connected). 11. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 12. Download the flash file from StarSCAN to the vehicle. Using StarSCAN at the “Home” screen: a. Select “ECU View” b. Browse the list of module using the scroll arrows. Highlight the FCM module. c. Select “More Options” d. Select “ECU Flash” e. Highlight the appropriate module flash file from the list. f. Select “Update Controller” g. When update is completed, select “OK” NOTE: Due to the FCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased.

FLASH PROCEDURE - USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: Before flashing this module, make sure the StarSCAN is operating at the latest level and this is the latest flash file available from the StarSCAN update CD. To determine the latest StarSCAN software version level available refer to www.dcctools.com website under the "Latest News" link.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

NOTE: For detailed information on the operation of the StarSCAN, refer to the Quick Reference documentation provided in the StarSCAN documentation kit. In addition, more recent information may also be available at the www.dcctools.com website. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Retrieve the old FCM part number. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the PCM in the list of modules. c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference. 08-034-04 -4-

2. Insert the USB Key, into the USB port on the TechCONNECT or equivalent PC (Fig. 1).

Fig. 1 USB KEY AND TechCONNECT PC

1 - TechCONNECT PC 2 - ACCESS DOOR (ON FRONT OF TechCONNECT PC) 3 - USB KEY IN THE TechCONNECT PC USB PORT

3. Insert the StarSCAN Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN Software Update CD will start automatically. a. Select “Download Controller Flash”. b. Follow the on screen instructions. 4. At the “Select a method for looking up controller flash updates.” screen: a. If the old “Part Number” was recorded in Step #1, proceed to Step #5. b. If the old “Part Number” is not known, proceed to Step #6. 5. Select “Enter part number”. a. Follow the on screen instructions. Enter the “Part Number” (use capital letters) recorded in Step #1 when prompted to do so. Follow the on screen instructions. Select “Next” after each step . Select “Finish” after completing the last step. b. To select the controller flash proceed to Step #7. 6. Select “Enter YME Information”. a. Follow the on screen instructions. Select “Next” after each step. Select “Finish” after completing the last step. b. To select the controller flash proceed to Step #7. 7. Using the mouse highlight the appropriate flash file. Select “Next”. a. When prompted, save the flash file to the USB key. b. Continue to follow the on screen instructions. Select “Next”#after each step . Select “Finish” after completing the last step. 8. With the StarSCAN powered OFF, connect the USB Key and Gender Changer to the StarSCAN USB port (Fig. 2). -5- 08-034-04

Fig. 2 USB KEY, GENDER CHANGER, AND StarSCAN TOOL

1 - StarSCAN™ TOOL 2 - GENDER CHANGER 3 - USB KEY

9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the StarSCAN to the vehicle. 11. Power ON the StarSCAN. 12. Download the file from the USB key to the StarSCAN. Using the StarSCAN at the “Home” screen: a. Select “Flash Download” b. Select “Use USB device” c. Follow the on screen instructions. Select “Next”#after each step . Select “Finish” after completing the last step. d. At the “Flash File List” screen, highlight the appropriate FCM “Calibration” e. Select “Download to Scantool” f. When the download is complete, select “Close” 13. Download the file from the StarSCAN to the vehicle. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Browse the list of controllers using the scroll arrows. Highlight the FCM module. c. Select “More Options” d. Select “ECU Flash” e. Highlight the appropriate FCM module “Calibration” from the list. f. Select “Update Controller” g. When update is completed, select “OK” 08-034-04 -6-

NOTE: Due to the FCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-19-08-94 Reprogram Front Control Module 0.5 Hrs.

FAILURE CODE:

FM Flash Module NUMBER: 23-044-04

GROUP: Body

DATE: October, 22, 2004

THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL NOVEMBER 8, 2004.

SUBJECT: Puncture In Carpet At Drivers Footrest

OVERVIEW: This bulletin involves replacing the carpet and installing a foam block in the drivers footrest.

MODELS:

2005 (LX) 300/Magnum

SYMPTOM/CONDITION: Puncture in carpet at footrest, usually due to high heel shoe.

DIAGNOSIS: Visually inspect the carpet at the driver's footrest area, if a puncture exists, perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description 1 04784045AA Block, Foam Footrest AR (1) 0UU87BD1AD Carpet, Left Front Trim Code P1 AR (1) 0UU87XDVAC Carpet, Left Front Trim Code DD or D1

REPAIR PROCEDURE: 1. Remove cowl extension trim (slim piece next to instrument panel). Insert a trim stick in the middle under the part, then raise trim stick up to the upper attachment, and pry to disengage clip. Repeat for lower attachment (Fig. 1). 23-044-04 -2-

Fig. 1 TRIM REMOVAL

1 - COWL EXTENSION TRIM (RIGHT SIDE SHOWN) 2 - COWL SIDE/FRONT SCUFF TRIM (RIGHT SIDE SHOWN) 3 - DRIVERS FOOTREST

2. Remove cowl side/front scuff trim starting at the B-pillar, by pulling upward. 3. Remove the left front carpet using the procedure outlined in TechCONNECT. 4. Insert foam block, p/n 04784045AA, into the footrest tool access cavity. The foam block is lightly press-fitted. 5. Install the left front carpet using the procedure outlined in TechCONNECT. 6. Reinstall carpet, and trim components. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation Description Amount No: 23-21-15-92 Replace Carpet and Install Foam Block 0.6 Hrs.

FAILURE CODE:

X2 Split, Cut or Torn NUMBER: 19-010-04

GROUP: Steering

DATE: November 29, 2004

SUBJECT: Power Steering Fluid Contamination

MODELS:

2004 - 2005 (CS) Pacifica 2004 - 2005 (DR/DH) Ram Truck 2004 - 2005 (HB) Durango 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004 - 2005 (KJ) Liberty 2005 (LX) 300/Magnum 2004 - 2005 (PL) Neon/SRT4 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2004 - 2005 (ST) Sebring Coupe/Stratus Coupe 2004 - 2005 (TJ) Wrangler 2004 - 2005 (ZB) Viper

DISCUSSION: Do not use fluids or supplements that contain Teflon as they will cause a restriction at the filter in the power steering fluid reservoir, causing severe damage to the steering system. The power steering fluid used in Chrysler Group vehicles is an engineered product, the addition of ANY unapproved fluids or supplements can interfere with the proper function of the fluid and cause damage to the steering system. To ensure the performance and durability of Chrysler Group steering systems, use only Mopar Power Steering Fluid +4, ATF+4 Automatic Transmission Fluid, or equivalent (MS-9602), in the power steering system.

POLICY: Information Only. NUMBER: 23-048-04

GROUP: Body

DATE: November 18, 2004

SUBJECT: A-Pillar Molding Fit/Wind Noise

OVERVIEW: This bulletin involves adjusting the position of the exterior A-pillar molding.

MODELS:

2005 (LX) 300/Magnum

SYMPTOM/CONDITION: A turbulence sound may be heard in the area of the A-pillar(s) at highway speeds. Some vehicles may have been built with the exterior A-pillar molding out of position. A wind noise may be created when the molding is either over flush to the roof panel, or over flush to the body-side aperture, (Fig. 1), both of which create a gap between the molding and sheet metal.

DIAGNOSIS: Inspect the exterior A-pillar moldings, if either are over flush to the roof panel, (Fig. 1) or over flush to the body-side aperture, which creates a gap between the molding and sheet metal perform the Repair Procedure.

Fig. 1 A-PILLAR MOLDING OVERFLUSH TO ROOF PANEL

1 - MOLDING OVER FLUSH TO ROOF AND A-PILLAR 23-048-04 -2-

REPAIR PROCEDURE: 1. Grip the A-pillar molding (beginning at the top near roof) with your fingers and pry upward to disengage the molding from the clips, (Fig. 2).

Fig. 2 A-PILLAR MOLDING REMOVAL

1 - MOLDING RETAINING CLIP

2. Continue toward the hood, prying until all (4) clips are disengaged. 3. Install the molding properly so that it is touching the body aperture along the entire length of the molding and is flush to under flush at the roof panel, (Fig. 3).

Fig. 3 PROPER MOLDING FIT -3- 23-048-04

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-02-65-90 Molding, Windshield A-Pillar - One or Both Sides 0.2 Hrs. - Remove and Reposition

FAILURE CODE:

8X Windnoise NUMBER: 25-001-04

GROUP: 25 - EMISSIONS CONTROL

DATE: November 22, 2004

SUBJECT: Evaporative Systems Service

MODELS:

1996 - 2005 All Chrysler Group Vehicles

DISCUSSION: The Evaporative Emissions Systems on today's vehicles are comprised of sophisticated components, all of which must be operational for the system to perform properly. To remain operational all components must be properly maintained and serviced as describe in the appropriate service information available on TechCONNECT. All worn, damaged, or inoperative evaporative emissions components must be replaced with new, unused components available from DaimlerChrysler. In addition all evaporative emissions hoses both pre-formed and straight must be replaced in their entirety. Under no circumstances should a worn or damaged hose be repaired. Any attempt to repair a worn or damaged hose may result in a future repeat failure of the same hose, and the customer may experience a repeat condition. Hoses must be replaced with new assemblies when available or approved bulk hose when the assemblies are not available. The approved service procedure, using new MOPAR service components, is the only way to ensure that a repair of the evaporative emission system will be permanent. This is very important to ensure that the evaporative emission system functions properly for the useful life of the vehicle.

POLICY: Information Only. NUMBER: 18-003-05

GROUP: Vehicle Performance

DATE: January 12, 2005

THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.

THE StarSCAN SOFTWARE UPDATE CD CONTAINS ALL PREVIOUSLY RELEASED FLASH FILES PRIOR TO THE CD RELEASE DATE PRINTED ON THE CD LABEL.

FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD FEBRUARY, 2005.

SUBJECT: Flash: Headlights Fluctuation and/or Interior Lamps Fluctuation

OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software.

MODELS:

2005 (LX) Chrysler 300/Magnum

NOTE: This bulletin applies to vehicles equipped with a 2.7L or 3.5L engine (sales code EER or EGG) that were built between June 28, 2004 (MDH 0628XX) and January 8 XX, 2005 (MDH 0108XX).

SYMPTOM/CONDITION: The vehicle operator may experience headlight fluctuation and/or interior lamp fluctuation. This condition will occur after a cold start, while the vehicle is idling, under heavy electrical load and a slight throttle tip-in. This condition could also be described as the headlights and/or interior lamps changing intensity at a steady rate. DTC P0563 - Battery Voltage High may also be stored in the PCM.

DIAGNOSIS: Using a Scan Tool (StarSCAN) with the appropriate diagnostic procedures on TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present other then the one listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the customer describes the Symptom/Condition, perform the Repair Procedure. 18-003-05 -2-

PARTS REQUIRED:

Qty. Part No. Description 1 04275086AB Label, Authorized Modification

SPECIAL TOOLS/EQUIPMENT REQUIRED:

REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN must be at version 4.06 or higher before the "Using The Internet To Retrieve The Flash File" repair procedure can be performed.

NOTE: Make sure the StarSCAN is configured to the dealership's network before proceeding.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Retrieve the old PCM part number. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the PCM in the list of modules. c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle (optional). 4. Power ON the StarSCAN. 5. Download the flash file from the internet to the StarSCAN. Using the StarSCAN at the “Home” screen: -3- 18-003-05

a. Select “Flash Download” b. Select “Use connected vehicle” (StarSCAN must be connected to the vehicle) or “Enter information manually” (connection to the vehicle is not necessary). Press the “Next” button and follow the on screen instructions. c. Select the appropriate calibration. d. Select “Download to Scantool”. e. Select “Close” after the download is complete. 6. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle (if not already connected). 7. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 8. Download the file from StarSCAN to the vehicle. Using StarSCAN at the “Home” screen: a. Select “ECU View” b. Browse the list of controllers using the scroll arrows. Highlight the PCM. c. Select “More Options” d. Select “ECU Flash” e. Highlight the appropriate PCM “Calibration” from the list. f. Select “Update Controller” g. When update is completed, select “OK” NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased.

NOTE: The following step is required by law. 9. Type the necessary information on the “Authorized Modification Label” p/n 04275086AB and attach near the VECI label (Fig. 1).

Fig. 1 AUTHORIZED MODIFICATION LABEL

1 - ENGINE CONTROL MODULE P/N (INSERT P/N) USED 2 - CHANGE AUTHORITY: TSB XX-XXX-XX 3 - DEALER CODE: XXXXX 4 - DATE: XX-XX-XX

REPAIR PROCEDURE - USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH 18-003-05 -4-

FILE: NOTE: Before flashing this module, make sure the StarSCAN is operating at the latest level and this is the latest flash file available from the StarSCAN update CD. To determine the latest StarSCAN software version level available refer to www.dcctools.com website under the "Latest News" link.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

NOTE: For detailed information on the operation of the StarSCAN, refer to the Quick Reference documentation provided in the StarSCAN documentation kit. In addition, more recent information may also be available at the www.dcctools.com website. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Retrieve the old PCM part number. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the PCM in the list of modules. c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference. 2. Insert the USB Key, into the USB port on the TechCONNECT or equivalent PC (Fig. 2).

Fig. 2 USB KEY AND TECHCONNECT PC

1 - TechCONNECT PC 2 - ACCESS DOOR (ON FRONT OF TechCONNECT PC) 3 - USB KEY IN THE TechCONNECT PC USB PORT -5- 18-003-05

Fig. 3 USB KEY, GENDER CHANGER, AND StarSCAN

1 - StarSCAN® TOOL 2 - GENDER CHANGER 3 - USB KEY

9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the StarSCAN to the vehicle. 18-003-05 -6-

11. Power ON the StarSCAN. 12. Download the file from the USB key to the StarSCAN. Using the StarSCAN at the “Home” screen: a. Select “Flash Download” b. Select “Use USB device” c. Follow the on screen instructions. Select “Next”#after each step . Select “Finish” after completing the last step. d. At the “Flash File List” screen, highlight the appropriate PCM “Calibration” e. Select “Download to Scantool” f. When the download is complete, select “Close” 13. Download the file from the StarSCAN to the vehicle. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Browse the list of controllers using the scroll arrows. Highlight the PCM. c. Select “More Options” d. Select “ECU Flash” e. Highlight the appropriate PCM “Calibration” from the list. f. Select “Update Controller” g. When update is completed, select “OK” NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased.

NOTE: The following step is required by law. 14. Type the necessary information on the “Authorized Modification Label” p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-19-45-97 Reprogram Powertrain Control Module 0.8 Hrs.

FAILURE CODE:

15 Calibration NUMBER: 23-006-05

GROUP: Body

DATE: February 2, 2005

SUBJECT: Ash Tray Will Not Open, Will Not Stay Closed, And/Or Opens/Closes With Inconsistent Speed

OVERVIEW: This bulletin involves repositioning the floor heat duct and/or wiring in the center console and replacing the ashtray assembly if necessary.

MODELS:

2005 - 2006 (LX) 300/Magnum

SYMPTOM/CONDITION: The ash tray will not open, will not stay closed or combination of both, and/or has overly slow (greater than 1 second) or overly fast (less than (.5 seconds) opening times.

DIAGNOSIS: If the vehicle operator describes the Symptom above, perform the Repair Procedure.

PARTS REQUIRED: EDIT

Qty. Part No. Description AR (1) 0XB12DX9AC Ash Tray, W/Heated Seats, W/O Chrome Bar AR (1) 0XB13DX9AC Ash Tray, W/O Heated Seats, W/O Chrome Bar AR (1) 04595968AB Ash Tray, W/Heated Seats, W/Chrome Bar AR (1) 04595969AB Ash Tray, W/O Heated Seats, W/Chrome Bar

REPAIR PROCEDURE: 1. Remove the chrome shifter ring using a fiber trim stick. 2. Remove the front console rubber mat. 3. Remove the two front shifter bezel screws. 4. Remove the shifter bezel using a fiber trim stick by prying up around the perimeter of bezel. 5. Remove ash tray using a fiber trim stick by prying at perimeter of ash tray housing. 6. Apply parking brake. 7. Shift the transmission to drive. 8. If equipped with heated seats disconnect the wiring to the switches and rotate the ash tray out of the opening. 23-006-05 -2-

9. With ash tray hanging loose use a light to view the floor duct on the right side of the console, using your hand to push the wiring harness down and forward to ensure it is not pushing the duct up. Then use hand pressure to push the floor duct down and to the right. 10. Install the ash tray, pay close attention to ensure all wiring to the ash tray is not interfering the ash tray movement. 11. Function the ash tray, if problem is eliminated, skip to step 14. 12. If the problem still exists, remove the ash tray and disconnect the wiring. 13. Use the appropriate p/n from the Parts Required section and Install a new ash tray. 14. Install the shifter bezel. 15. Install the two front shifter bezel screws. Tighten them to 3.5 Nm (12.6 in. lbs.). 16. Install the front console rubber mat. 17. Install the chrome shifter ring. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-11-05-90 Reposition Heat Duct and Wiring and/or 0.2 Hrs. Replace Ash Tray

FAILURE CODE:

61 Intermittent Operation NUMBER: 24-004-05

GROUP: Heating & Air Conditioning

DATE: February 11, 2004

THIS BULLETIN SUPERSEDES SERVICE BULLETIN 24-005-04, DATED OCTOBER 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE UPDATED SYMPTOMS/CONDITIONS AND BUILD DATES.

THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.

THE StarSCAN SOFTWARE UPDATE CD CONTAINS ALL PREVIOUSLY RELEASED FLASH FILES PRIOR TO THE CD RELEASE DATE PRINTED ON THE CD LABEL.

FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD MARCH, 2005.

SUBJECT: Flash: Poor Or Intermittent A/C Performance

OVERVIEW: This bulletin involves verifying the proper A/C system charge and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software.

MODELS:

2005 (LX) 300/Magnum

NOTE: This bulletin should be performed on all subject vehicles that come into the dealerships.

NOTE: **This bulletin applies to vehicles with a 2.7L or 3.5L engine (sales code EER or EGG) built on or before August 19, 2004 (MDH 0819XX)**.

NOTE: **This bulletin applies to vehicles with a 5.7L engine (sales code EZB) built before January 31, 2005, 2005 (MDH 0131XX)**. 24-004-05 -2-

SYMPTOM/CONDITION: The vehicle operator may experience on of the following: • A/C cut-out • A/C cut-out at low speeds • **A/C cut-out at highway speeds 5.7L engine** • Poor A/C performance DIAGNOSIS: Using a Scan Tool (StarSCAN) verify that the A/C system has no diagnostic trouble codes (DTC's). If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. Check the A/C pressure to ensure that it is at the proper level. Be sure the pressure is not under filled or over filled because this may also contribute to the poor A/C performance.

NOTE: If the system is under charged or over charged it is still necessary to perform the flash procedure. If the vehicle operator describes the Symptom/Condition perform the Repair Procedure.

NOTE: There are two methods to download flash files to StarSCAN. The first method (NEW) is to download the flash files to the StarSCAN from the internet. The second method is to download the flash files from the StarSCAN Software Update CD.

PARTS REQUIRED:

Qty. Part No. Description 1 04275086AB Label, Authorized Modification

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII® connection. Use this cable whenever a flash is being performed.

REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: -3- 24-004-05

NOTE: The StarSCAN must be at version 4.07 or higher before the "Using The Internet To Retrieve The Flash File" repair procedure can be performed.

NOTE: Make sure the StarSCAN is configured to the dealership's network before proceeding.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle. 2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop (optional). 3. Retrieve the old PCM part number. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the PCM in the list of modules. c. Select “More Options”. d. Select “ECU Flash” e. Record the "Part Number", displayed on the “Flash PCM” screen, for later reference. 4. If the StarSCAN is connected to the dealer's network drop and the vehicle, proceed to Step #5. If the StarSCAN is not connected to the dealer's network drop and the vehicle, proceed to Step #10 5. select “Browse for new file”. 6. Select the appropriate calibration. 7. Select “Download to Scantool”. 8. Select “Close” after the download is complete. Proceed to Step #11. 9. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop (if not already connected). 10. Download the flash file from the Internet to the StarSCAN. Using the StarSCAN at the “Home” screen: a. Select “Flash Download”. b. Select “Enter information manually”. Press the “Next” button and follow the on screen instructions. c. Select the appropriate calibration. d. Select “Download to Scantool”. e. Select “Close” after the download is complete. 11. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle (if not already connected). 12. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 13. Download the file from StarSCAN to the vehicle. Using StarSCAN at the “Home” screen: a. Select “ECU View” 24-004-05 -4-

b. Browse the list of controllers using the scroll arrows. Highlight the PCM. c. Select “More Options” d. Select “ECU Flash” e. Highlight the appropriate PCM “Calibration” from the list. f. Select “Update Controller” g. When update is completed, select “OK” NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. From the “Home” screen select “System View”, then select “All DTC's”. Select the “Clear All Stored DTC's” if there are any DTC's stored.

NOTE: The following step is required by law. 14. Type the necessary information on the “Authorized Modification Label” p/n 04275086AB and attach near the VECI label (Fig. 1).

Fig. 1 AUTHORIZED MODIFICATION LABEL

1 - POWERTRAIN CONTROL MODULE P/N (INSERT P/N) USED 2 - CHANGE AUTHORITY: TSB XX-XXX-XX 3 - DEALER CODE: XXXXX 4 - DATE: XX-XX-XX

REPAIR PROCEDURE - USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: Before flashing this module, make sure the StarSCAN is operating at the latest level and this is the latest flash file available from the StarSCAN update CD. To determine the latest StarSCAN software version level available refer to www.dcctools.com website under the "Latest News" link.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted. -5- 24-004-05

NOTE: For detailed information on the operation of the StarSCAN, refer to the Quick Reference documentation provided in the StarSCAN documentation kit. In addition, more recent information may also be available at the www.dcctools.com website. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Retrieve the old PCM part number. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the PCM in the list of modules. c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference. 2. Insert the USB Key, into the USB port on the TechCONNECT or equivalent PC (Fig. 2).

Fig. 2 USB KEY AND TECHCONNECT PC

1 - TechCONNECT PC 2 - ACCESS DOOR (ON FRONT OF TechCONNECT PC) 3 - USB KEY IN THE TechCONNECT PC USB PORT

b. Proceed to Step #7. 6. Select “Enter YME Information”. a. Follow the on screen instructions. Select “Next” after each step. Select “Finish” after completing the last step. b. Proceed to Step #7. 7. Using the mouse highlight the appropriate “Calibration” a. Select “Save to USB” b. Follow the on screen instructions. Select “Next”#after each step . Select “Finish” after completing the last step. 8. With the StarSCAN powered OFF, connect the USB Key and Gender Changer to the StarSCAN USB port (Fig. 3).

Fig. 3 USB KEY, GENDER CHANGER, AND StarSCAN

1 - StarSCAN® TOOL 2 - GENDER CHANGER 3 - USB KEY

13. Download the file from the StarSCAN to the vehicle. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Browse the list of controllers using the scroll arrows. Highlight the PCM. c. Select “More Options” d. Select “ECU Flash” e. Highlight the appropriate PCM “Calibration” from the list. f. Select “Update Controller” g. When update is completed, select “OK” NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. From the “Home” screen select “System View”, then select “All DTC's”. Select the “Clear All Stored DTC's” if there are any DTC's stored.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-19-48-95 Check A/C System Pressure and Reprogram 1.0 Hrs. Powertrain Control Module

FAILURE CODE:

15 Calibration NUMBER: 08-014-05

GROUP: Electrical

DATE: February 17, 2005

SUBJECT: Mopar Accessory Remote Starter Inoperative Due To Hood Switch

OVERVIEW: This bulletin involves replacing the hood switch for the remote starting system.

MODELS:

2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (HB) Durango 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004 - 2005 (KJ) Liberty 2005 (LX) 300/Magnum 2005 (ND) Dakota 2004 - 2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RS) Town & Country/Caravan 2005 (WK) Grand Cherokee

NOTE: This bulletin applies to vehicles equipped with a Mopar Accessories Remote Starter.

SYMPTOM/CONDITION: The vehicle operator may experience one or more of the following conditions: • When the transmitter is pressed twice for start, the vehicle horn will "chirp" once but the vehicle engine will not remote start. • When the transmitter is pressed twice for start, the vehicle horn will "chirp" twice, indicating a problem with the remote start system and the vehicle engine will not start. • When the transmitter is pressed twice for start, the vehicle will "chirp" once, the engine will start and then turn off. NOTE: The technician may not be able to verify the symptom(s) because it may be an intermittent condition. 08-014-05 -2-

DIAGNOSIS: If the vehicle operator describes one or more of the Symptom/Conditions, perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description 1 05140473AA Switch, Hood

REPAIR PROCEDURE: 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. Locate and disconnect the ground lead for the hood switch at the cowl. 4. Locate and disconnect the soldered joint on the other wire to the remote start hood switch. 5. Remove the remote start hood switch.(Fig. 1).

Fig. 1 HOOD SWITCH LOCATION - TYPICAL

1 - HOOD 2 - REMOTE START HOOD SWITCH 3 - REMOTE START HOOD SWITCH WIRING HARNESS

6. Install the new hood switch, p/n 05140473AA. 7. Solder the appropriate wire to the remote start hood switch back into the vehicle wiring harness. Refer to the service information available in TechCONNECT. Reference: Service Info, 8 - Electrical/Wiring Diagram Information/Wire - Standard Procedure - Wire Splicing. 8. Connect the ground lead for the hood switch at the cowl. 9. Connect the negative battery cable and reset the clock. 10. Close the hood. 11. With key and remote in hand, insure all the doors are closed and locked. 12. From outside the vehicle, press the transmitter button to remote start the engine. The vehicle should "chirp" once and then start. If the vehicle engine starts, no further action is necessary. -3- 08-014-05

If the vehicle engine does not start, further diagnosis may be necessary. For diagnostic assistance with the remote starter system call 1.800.34MOPAR. Be prepared to furnish the last eight digits of the VIN, date of purchase for the remote start kit and the part number of the remote starter kit.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-99-25-90 Replace Hood Switch For Remote Starter System 0.3 Hrs.

FAILURE CODE:

14 Short or Open NUMBER: 18-011-05

GROUP: Vehicle Performance

DATE: February 22, 2005

THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.

THE StarSCAN SOFTWARE UPDATE CD CONTAINS ALL PREVIOUSLY RELEASED FLASH FILES PRIOR TO THE CD RELEASE DATE PRINTED ON THE CD LABEL.

SUBJECT: Flash - Engine Roughness or Idle Fluctuation

OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software.

MODELS:

2005 (LX) Chrysler 300/Magnum

NOTE: This bulletin applies to vehicles equipped with a 2.7L or 3.5L engine (sales code EER or EGG) that were built before February 17, 2005 (MDH 0217XX).

SYMPTOM/CONDITION: Engine or RPM undershooting while slowing to a stop. This condition may be more prevalent when holding steering wheel against stop or in parking lot maneuvers.

DIAGNOSIS: Using a Scan Tool (StarSCAN) with the appropriate Diagnostic Procedures in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin.

If the vehicle operator describes or the technician experiences the Symptom/Condition, perform the Repair Procedure. 18-011-05 -2-

PARTS REQUIRED:

Qty. Part No. Description 1 04275086AB Label, Authorized Modification

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NOTE: Make sure the StarSCAN is configured to the dealership's network before proceeding.

NOTE: The following step is required by law. 9. Type the necessary information on the “Authorized Modification Label” p/n 04275086AB and attach near the VECI label (Fig. 1).

Fig. 1 AUTHORIZED MODIFICATION LABEL

1 - ENGINE CONTROL MODULE P/N (INSERT P/N) USED 2 - CHANGE AUTHORITY: TSB XX-XXX-XX 3 - DEALER CODE: XXXXX 4 - DATE: XX-XX-XX 18-011-05 -4-

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

NOTE: For detailed information on the operation of the StarSCAN, refer to the Quick Reference documentation provided in the StarSCAN documentation kit. In addition, more recent information may also be available at the www.dcctools.com website. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Retrieve the old PCM part number. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the PCM in the list of modules. c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference. 2. Insert the USB Key, into the USB port on the TechCONNECT or equivalent PC (Fig. 2).

Fig. 2 USB KEY AND TECHCONNECT PC

1 - TechCONNECT PC 2 - ACCESS DOOR (ON FRONT OF TechCONNECT PC) 3 - USB KEY IN THE TechCONNECT PC USB PORT -5- 18-011-05

Fig. 3 USB KEY, GENDER CHANGER, AND StarSCAN

1 - StarSCAN® TOOL 2 - GENDER CHANGER 3 - USB KEY

9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the StarSCAN to the vehicle. 18-011-05 -6-

11. Power ON the StarSCAN. 12. Download the file from the USB key to the StarSCAN. Using the StarSCAN at the “Home” screen: a. Select “Flash Download” b. Select “Use USB device” c. Follow the on screen instructions. Select “Next”#after each step . Select “Finish” after completing the last step. d. At the “Flash File List” screen, highlight the appropriate PCM “Calibration” e. Select “Download to Scantool” f. When the download is complete, select “Close” 13. Download the file from the StarSCAN to the vehicle. Using the StarSCAN at the “Home” screen: a. Select “ECU View” b. Browse the list of controllers using the scroll arrows. Highlight the PCM. c. Select “More Options” d. Select “ECU Flash” e. Highlight the appropriate PCM “Calibration” from the list. f. Select “Update Controller” g. When update is completed, select “OK” NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. From the “Home” screen select “System View”, then select “All DTC's”. Select the “Clear All Stored DTC's” if there are any DTC's stored.

NOTE: The following step is required by law. 14. Type the necessary information on the “Authorized Modification Label” p/n 04275086AB and attach near the VECI label (Fig. 1). -7- 18-011-05

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-19-42-97 Reprogram Powertrain Control Module 0.8 Hrs.

FAILURE CODE:

15 Calibration NUMBER: 23-011-05

GROUP: Body

DATE: February 26, 2005

THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MARCH 14, 2005.

SUBJECT: Rear Grab-Handle Bezel Broken At Screw Boss

OVERVIEW: This bulletin involves replacing both rear grab handles, brackets and screws.

MODELS:

2005 (LX) 300/Magnum

NOTE: This bulletin applies to vehicles built on and between July 18, 2004 and August 12, 2004 (MDH 0718XX - 0812XX).

SYMPTOM/CONDITION: The rear grab handle(s) is loose, rattling, or broken at the screw mount boss. The break/crack is due to a rust inhibitor wash that was temporarily used on the grab handle bracket that causes handle plastic to become brittle and break/crack.

DIAGNOSIS: Inspect rear grab handles for secure mounting to body and/or obvious looseness. If the grab handle(s) is broken/cracked, perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description 1 05175965AA Package, Rear Grab Handle Repair The package includes: 1 - 1AH101D1AA Handle, Right 1 - 1AH111D1AA Handle, Left 4 - 05175964AA Bracket, Grab Handle 4 - 05137531AA Screw Grab Handle

REPAIR PROCEDURE: 1. Remove the door seal along the headliner near the grab handle. 2. Remove the 2 screws p/n 05137531AA, that attach the grab handle and discard them. 3. Disconnect the lamp connector and remove the grab handle assembly. 23-011-05 -2-

4. Remove one screw, p/n 05137532AA, that attaches a steel bracket to the plastic retainer. Remove and discard the steel bracket and install a replacement steel bracket, p/n 05175964AA, only finger tighten the screw at his time. Repeat for the other screw and bracket. 5. Align the 2 clips in the roof (behind the plastic retainer) vertically so that the clips are not pinched between the standoff ribs of the plastic retainer and vehicle sheet metal. Torque the 2 screws, p/n 05137532AA, to 1.9 - 2.2 Nm (16 - 20 in. lbs.). 6. Connect the lamp wire to the grab handle assembly. 7. Install 2 new screws, p/n 05137531AA, through the grab handle to the steel brackets, p/n 05175964AA, torque to 1.9 - 2.2 Nm (16 - 20 in. lbs.). 8. Install the door seal. 9. Repeat steps 1-8 for the other side handle. NOTE: Always replace both handles, brackets and screws.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-42-10-91 Install Rear Grab Handle Package 0.4 Hrs.

FAILURE CODE:

P8 New Part NUMBER: 23-012-05

GROUP: Body

DATE: February 26, 2005

SUBJECT: Rattle Sound From The Headliner, Rear Shelf Or C- Pillar

OVERVIEW: This bulletin involves removing a foam block from the rear of the sunroof module.

MODELS:

2005 (LX) 300

NOTE: This bulletin applies to Chrysler 300's that are equipped with a sunroof (sales code GWA) built on or between October 4, 2004 and February 5, 2005.

SYMPTOM/CONDITION: A rattle/buzz sound is heard in the rear of the vehicle when driven over a washboard, dirt and or rough road. The rattle may sound like it is coming from the headliner, rear shelf or C-pillar areas of the vehicle.

DIAGNOSIS: Drive the vehicle over a rough road to reproduce the rattle/buzz sound. When the sound is present, press up on the headliner immediately behind the center of the sunroof opening. If applying pressure reduces or eliminates the buzz/rattle sound, perform the Repair Procedure.

REPAIR PROCEDURE: 1. Close the sunroof and sunshade. 2. Gently pull down on the headliner and shine a light in between the roof and headliner. Inspect the rear of the sunroof module for 1x1x3 inch green foam blocks. If the sunroof module has only one green foam block in the center DO NOT remove it. This foam block configuration is not the source of the rattle/buzz sound and this service bulletin does not apply - further diagnosis is required. Open and close the sunshade to ensure it operates smoothly. If the sunroof module has three 1x1x3 inch green foam blocks on the back of the module continue with the Repair Procedure. 3. Fold the rear seat backs down to improve access. 4. Carefully unclip the left and unstick the right headliner attachments at the rear of the headliner. 5. With the rear of the headliner detached, gently pull down on the headliner. 6. Reach in between the headliner and roof panel and remove the center 1x1x3 inch green foam block. 7. Install the two rear headliner attachments. 23-012-05 -2-

8. Return the rear seat backs to their upright position. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-30-56-91 Inspect and Remove Foam Block 0.2 Hrs.

FAILURE CODE:

68 Noisy NUMBER: 08-017-05

GROUP: Electrical

DATE: March 16, 2005

SUBJECT: Headlamps Remain On After Delay Time Out

OVERVIEW: This bulletin involves flash updating the Front Control Module (FCM) with new software.

MODELS:

2005 (LX) 300/Magnum

NOTE: This bulletin applies to vehicles equipped with Auto Headlamps (Sales Code LMG).

SYMPTOM/CONDITION: Dead or weak battery due to headlamps remaining on. Vehicles equipped with auto headlamps may enter into a headlamp delay (lighted departure) mode in which the headlamps do not turn off after the customer programed time limit (0, 30 sec., 60 sec., 90 sec.) This condition only occurs when the headlamp switch is changed from ON to AUTO after the ignition is turned off.

DIAGNOSIS: Use the StarSCAN® tool to check the FCM p/n. Reflash FCM if the p/n has NIK level AJ and earlier for FCM p/n 56038742, or AB and earlier for FCM p/n's 05026021 and 56040698.

SPECIAL TOOLS/EQUIPMENT REQUIRED:

FLASH PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The latest released version of the StarSCAN® software must be installed on the StarSCAN® tool before the "Using The Internet To Retrieve The Flash File" repair procedure can be performed.

NOTE: The StarSCAN® diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. For instruction on setting up your StarSCAN® for the dealer's network; refer to the StarSCAN® Quick Start Networking Guide available on the www.dcctools.com website under the "download center".

NOTE: Make sure the StarSCAN® is configured to the dealership's network before proceeding.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle. 2. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN® and the dealer's network drop (optional). 3. Retrieve the old FCM part number. Using the StarSCAN® at the “Home” screen: a. Select “ECU View”. b. Touch the screen to highlight the appropriate controller in the list of modules. c. Select “More Options”. d. Select “ECU Flash” e. Record the "Part Number", displayed on the “Flash FCM” screen, for later reference. 4. If the StarSCAN® is connected to the dealer's network drop and the vehicle, proceed to Step #5. If the StarSCAN® is not connected to the dealer's network drop and the vehicle, proceed to Step #10. 5. select “Browse for new file”. 6. Select the appropriate flash file. 7. Select “Download to Scantool”. 8. Select “Close” after the download is complete. Proceed to Step #11. 9. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN® and the dealer's network drop (if not already connected). 10. Download the flash file from the Internet to the StarSCAN®. Using the StarSCAN® at the “Home” screen: a. Select “Flash Download”. b. Select “Enter information manually”. Press the “Next” button and follow the on screen instructions. c. Select the appropriate flash file. d. Select “Download to Scantool”. e. Select “Close” after the download is complete. 11. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle (if not already connected). 12. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. -3- 08-017-05

13. Download the flash file from StarSCAN® to the vehicle. Using StarSCAN® at the “Home” screen: a. Select “ECU View”. b. Browse the list of module using the scroll arrows. Highlight the FCM. c. Select “More Options”. d. Select “ECU Flash”. e. Highlight the appropriate module flash file from the list. f. Select “Update Controller”. g. When update is completed, select “OK”. NOTE: Due to the FCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. From the “Home” screen select “System View”, then select “All DTC's”. Select the “Clear All Stored DTC's” if there are any DTC's stored.

FLASH PROCEDURE - USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: Before flashing this module, make sure the StarSCAN® is operating at the latest software version and that this latest software version is available from the latest StarSCAN® update CD. To determine the latest StarSCAN® software version level available refer to www.dcctools.com website under the "Latest News" link.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

Fig. 1 USB KEY AND TechCONNECT PC

1 - TechCONNECT PC 2 - ACCESS DOOR (ON FRONT OF TechCONNECT PC) 3 - USB KEY IN THE TechCONNECT PC USB PORT

3. Insert the StarSCAN® Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN® Software Update CD will start automatically. a. Select “Controller Flash”. b. Follow the on screen instructions. 4. At the “Select the type of information you wish to enter.” screen: a. If the old “Part Number” was recorded in Step #1, proceed to Step #5. b. If the old “Part Number” is not known, proceed to Step #6. 5. Select “Enter part number”. a. Follow the on screen instructions. Enter the “Part Number” (use capital letters) recorded in Step #1 when prompted to do so. Follow the on screen instructions. Select “Next” after each step. Select “Finish” after completing the last step. b. Proceed to Step #7. 6. Select “Enter YME Information”. a. Follow the on screen instructions. Select “Next” after each step. Select “Finish” after completing the last step. b. Proceed to Step #7. 7. Using the mouse highlight the appropriate “Calibration” a. Select “Save to USB”. b. Follow the on screen instructions. Select “Next”#after each step. Select “Finish” after completing the last step. 8. With the StarSCAN® powered OFF, connect the USB Key and Gender Changer to the StarSCAN® USB port (Fig. 2). -5- 08-017-05

Fig. 2 USB KEY, GENDER CHANGER, AND StarSCAN® TOOL

1 - StarSCAN™ TOOL 2 - GENDER CHANGER 3 - USB KEY

9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the StarSCAN® to the vehicle. 11. Power ON the StarSCAN®. 12. Download the file from the USB key to the StarSCAN®. Using the StarSCAN® at the “Home” screen: a. Select “Flash Download”. b. Select “Use USB device”. c. Follow the on screen instructions. Select “Next”#after each step . Select “Finish” after completing the last step. d. At the “Flash File List” screen, highlight the appropriate FCM “Calibration”. e. Select “Download to Scantool”. f. When the download is complete, select “Close”. 13. Download the file from the StarSCAN® to the vehicle. Using the StarSCAN® at the “Home” screen: a. Select “ECU View”. b. Browse the list of controllers using the scroll arrows. Highlight the FCM. c. Select “More Options”. d. Select “ECU Flash”. e. Highlight the appropriate FCM“Calibration” from the list. f. Select “Update Controller”. g. When update is completed, select “OK”. 08-017-05 -6-

NOTE: Due to the FCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. From the “Home” screen select “System View”, then select “All DTC's”. Select the “Clear All Stored DTC's” if there are any DTC's stored.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-19-65-91 Reprogram FCM 0.5 Hrs.

FAILURE CODE:

15 Calibration NUMBER: 08-018-05

GROUP: Electrical

DATE: March 18, 2005

SUBJECT: Compass Display Does Not Update

OVERVIEW: This bulletin involves flash reprogramming the Electronic Overhead Module (EOM).

MODELS:

2005 (LX) 300/Magnum 2005 (WK) Grand Cherokee

SYMPTOM/CONDITION: The compass heading indication does not change as the vehicle direction changes.

DIAGNOSIS: If the vehicle operator describes the Symptom, perform the Repair Procedure.

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NOTE: Make sure the StarSCAN® is configured to the dealership's network before proceeding.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle. 2. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN® and the dealer's network drop (optional). 3. Retrieve the old EOM part number. Using the StarSCAN® at the “Home” screen: a. Select “ECU View”. b. Touch the screen to highlight the appropriate controller in the list of modules. c. Select “More Options”. d. Select “ECU Flash” e. Record the "Part Number", displayed on the “Flash EOM” screen, for later reference. 4. If the StarSCAN® is connected to the dealer's network drop and the vehicle, proceed to Step #5. If the StarSCAN® is not connected to the dealer's network drop and the vehicle, proceed to Step #10. 5. select “Browse for new file”. 6. Select the appropriate flash file. 7. Select “Download to Scantool”. 8. Select “Close” after the download is complete. Proceed to Step #11. 9. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN® and the dealer's network drop (if not already connected). 10. Download the flash file from the Internet to the StarSCAN®. Using the StarSCAN® at the “Home” screen: a. Select “Flash Download”. b. Select “Enter information manually”. Press the “Next” button and follow the on screen instructions. c. Select the appropriate flash file. d. Select “Download to Scantool”. e. Select “Close” after the download is complete. 11. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle (if not already connected). 12. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. -3- 08-018-05

13. Download the flash file from StarSCAN® to the vehicle. Using StarSCAN® at the “Home” screen: a. Select “ECU View”. b. Browse the list of module using the scroll arrows. Highlight the EOM. c. Select “More Options”. d. Select “ECU Flash”. e. Highlight the appropriate module flash file from the list. f. Select “Update Controller”. g. When update is completed, select “OK”. NOTE: Due to the EOM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. From the “Home” screen select “System View”, then select “All DTC's”. Select the “Clear All Stored DTC's” if there are any DTC's stored. 14. Use the procedures outline in TechCONNECT, 8-Electrical/Overhead Console/Electronic Vehicle Info Center/Standard Procedure, to reprogram the compass variance and compass calibration.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

Fig. 1 USB KEY AND TechCONNECT PC

1 - TechCONNECT PC 2 - ACCESS DOOR (ON FRONT OF TechCONNECT PC) 3 - USB KEY IN THE TechCONNECT PC USB PORT

Fig. 2 USB KEY, GENDER CHANGER, AND StarSCAN® TOOL

1 - StarSCAN® TOOL 2 - GENDER CHANGER 3 - USB KEY

9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the StarSCAN® to the vehicle. 11. Power ON the StarSCAN®. 12. Download the file from the USB key to the StarSCAN®. Using the StarSCAN® at the “Home” screen: a. Select “Flash Download”. b. Select “Use USB device”. c. Follow the on screen instructions. Select “Next”#after each step . Select “Finish” after completing the last step. d. At the “Flash File List” screen, highlight the appropriate EOM “Calibration”. e. Select “Download to Scantool”. f. When the download is complete, select “Close”. 13. Download the file from the StarSCAN® to the vehicle. Using the StarSCAN® at the “Home” screen: a. Select “ECU View”. b. Browse the list of controllers using the scroll arrows. Highlight the EOM. c. Select “More Options”. d. Select “ECU Flash”. e. Highlight the appropriate EOM “Calibration” from the list. f. Select “Update Controller”. g. When update is completed, select “OK”. 08-018-05 -6-

NOTE: Due to the EOM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using “ECU View” from the Home screen, record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. From the “Home” screen select “System View”, then select “All DTC's”. Select the “Clear All Stored DTC's” if there are any DTC's stored. 14. Use the procedures outline in TechCONNECT, 8-Electrical/Overhead Console/Electronic Vehicle Info Center/Standard Procedure, to reprogram the compass variance and compass calibration. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-19-47-98 Reprogram FCM 0.4 Hrs.

FAILURE CODE:

15 Calibration NUMBER: 08-020-05

GROUP: Electrical

DATE: March 23,2005

THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL APRIL 4, 2005.

SUBJECT: Customer Would Prefer A Louder Warning Tone From The Park Assist System

OVERVIEW: This bulletin involves replacing the park assist display assembly.

MODELS:

2005 (CS) Pacifica 2005 (LX) 300 2005 (RS) Town and Country/Caravan 2005 (RG) Chrysler Voyager (International Markets) 2005 (WK) Grand Chrokee

NOTE: This bulletin applies to vehicles equipped with sales code XAA.

SYMPTOM/CONDITION: Customer states they would prefer that the park assist display audible warning tone be louder.

DIAGNOSIS: If customer describes the condition, perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description 1 56046042AA Display Assy, Parking Assist

REPAIR PROCEDURE: 1. Use the procedures outlined in TechCONNECT, under: Service Info tab, 8 - Electrical / Chime/Buzzer / Park Assist Display to replace the park assist display, p/n 56046042AA. 08-020-05 -2-

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-20-05-91 Replace Park Assist Display 0.3 Hrs.

FAILURE CODE:

58 Internal Defect NUMBER: 23-007-05 REV. A

GROUP: Body

DATE: March 12, 2005

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-007-05, DATED FEBRUARY 3, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISIONS TO THE REPAIR PROCEDURE, PARTS REQUIRED AND TIME ALLOWANCE.

SUBJECT: Rear Shelf Speaker Buzz/Rattle Sound

OVERVIEW: This bulletin involves installing isolating foam between the rear shelf trim and the body.

MODELS:

2005 (LX) 300

SYMPTOM/CONDITION: Sounds like the rear shelf speaker is buzzing, distorted or rattling (usually on the right side) with low end frequency audio output.

DIAGNOSIS: Reproduce the condition using a test signal or the customers media (recommended). Sit in the back seat and push down on the rear shelf trim. If applying this pressure reduces or eliminates the buzz/rattle sound, perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description 2 05019058AA Tape, Foam (Component of BSR Kit 05019062AA) **1 82300234 RTV**

REPAIR PROCEDURE: 1. Fold the right rear seat back down. 2. Remove the right side seat bolster. 3. Remove the right side lower C-pillar trim. 4. Fold the left rear seat back down. 5. Remove the left side seat bolster. 6. Remove the left side lower C-pillar trim. 7. Remove the attachments and pull the rear shelf trim panel forward. 8. If the vehicle is not equipped with a subwoofer speaker, **remove the subwoofer plug. 23-007-05 REV. A -2-

9. Apply RTV, p/n 82300234, to the portion of the flange of the subwoofer plug that contacts the rear shelf sheet metal panel and install the plug.** 10. Apply foam tape, p/n 05019058AA, directly to the rear shelf sheet metal panel, (Fig. 1).

Fig. 1 REAR SHELF

1- SUBWOOFER PLUG, IF EQUIPPED 2 - APPLY FOAM TAPE HERE

11. Install the interior trim and verify that the buzz/rattle sound is eliminated. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-20-72-90 Install Foam **0.4 Hrs.**

FAILURE CODE:

67 Rattles NUMBER: 23-018-05

GROUP: Body

DATE: March 11, 2005

SUBJECT: Pop/Snap Sound On Right Side Of Instrument Panel

OVERVIEW: This bulletin involves removing the right Instrument Panel (I/P) retainer to cowl plenum fastener.

MODELS:

2005 (LX) 300/Magnum

SYMPTOM/CONDITION: Loud snap/pop sound on the right side of the I/P. The sound is typically heard within the first mile of driving after the vehicle has sat 4 hours or more. The sound is normally a single snap/pop that sounds like a stone hitting the windshield on the right side.

DIAGNOSIS: If the vehicle operator describes the condition, perform the Repair Procedure.

REPAIR PROCEDURE: 1. Use a fiber trim stick, such as special tool c-4755, to unclip the I/P defroster cover on the right side. The Magnum will also require the removal the right "A" pillar molding before the defroster cover can be unclipped. 2. With the right side of the defroster cover unclipped, lift the cover up to gain tool access to the right side I/P retainer to cowl plenum fastener. The fastener is forward on the retainer and to the right of the defroster opening. 3. Use a 7 mm flex socket to remove the right I/P retainer to cowl plenum fastener. 4. Install the I/P defrost cover and make sure the clips are fully engaged into the I/P retainer. NOTE: When unclipping the defrost cover the clips may stay in the retainer. The clips must be reattached to the defrost cover tabs before installation of the cover. 5. Install the right "A" pillar molding (Magnum only). 23-018-05 -2-

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-11-14-96 Fastner Removal 0.2 Hrs.

FAILURE CODE:

68 Noisy NUMBER: 23-022-05

GROUP: Body

DATE: April 2, 2005

SUBJECT: Low Gloss Interior Trim

MODELS:

2005 - 2006 (CS) Pacifica 2005 - 2006 (DH/DR) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (JR) Sebring Convertible/Sebring Sedan/ Stratus Sedan 2005 - 2006 (KJ) Cherokee/Liberty 2006 (LE) 300/Charger/Magnum (International Markets) 2005 - 2006 (LX) 300/Charger/Magnum 2005 - 2006 (ND) Dakota 2005 - 2006 (PL) Neon 2005 - 2006 (PT) Chrysler PT Cruiser 2005 - 2006 (RG) Chrysler Voyager (International Markets) 2005 - 2006 (RS) Town & Counrty/Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (WH) Grand Cherokee (International Markets) 2005 - 2006 (WK) Grand Cherokee 2005 - 2006 (ZB) Viper

PARTS REQUIRED:

Qty. Part No. Description AR 05174395AA MOPAR Satin Select Interior Treatment 23-022-05 -2-

DISCUSSION: All Chrysler, Dodge, and Jeep vehicles are designed with a low gloss interior trim. This low gloss finish maintains pleasing aesthetics, as well as to minimize glare of the instrument panel into the windshield. This low gloss finish should not be altered with a medium or high gloss interior treatment solution such as MOPAR Protector's or other Armor All-like products.

Instead, MOPAR Satin Select, p/n 05174395AA, which has been specifically developed to remove minor surface contamination and maintain the low gloss appearance should be used for interior trim treatment.

To use MOPAR Satin Select low gloss finish to treat interior trim, shake the bottle prior to application. Spray on a clean, lint free towel or microfiber towel, and wipe while surface is cool. MOPAR Satin Select is safe for use on plastic, vinyl and leather and provides UV protection.

POLICY: Information Only NUMBER: 19-002-05

GROUP: Steering

DATE: March 22, 2005

THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MARCH 28, 2005.

SUBJECT: Variable Steering Effort In Cold Temperatures

OVERVIEW: This bulletin involves replacing the steering column shaft boot.

MODELS:

2005 (LX) 300/Magnum

SYMPTOM/CONDITION: Variation in steering efforts during ambient temperatures of -7°C (20°F) and below. The symptom is temporary lasting no more than 5 minutes of driving and is caused by the stiffness of the steering column shaft boot. The boot softens as the vehicle is driven and warms up.

DIAGNOSIS: If the vehicle operator describes the Symptom, perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description 1 05170263AA Kit, Steering Column Shaft Boot AR (1) 4897151AB or Cleaner, MOPAR Brake Parts 4897150AB

REPAIR PROCEDURE: 1. Use the service information available on TechCONNECT to remove the steering column. 2. Remove the steering column shaft boot. 3. Clean off all old grease from the steering column shaft using MOPAR Brake Parts Cleaner, p/n 4897151AB or 4897150AB or equivalent. The old grease is not compatible with new boot material. 4. Install new boot (pregreased) onto the steering column shaft 5. Use the service information available on TechCONNECT to install the steering column assembly. 19-002-05 -2-

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 19-21-05-92 Replace Steering Column Shaft Boot 0.9 Hrs.

FAILURE CODE:

YE High Effort NUMBER: 08-024-05

GROUP: Electrical

DATE: May 4, 2005

SUBJECT: Radio Communication Equipment Installation Recommendations

MODELS:

2001 - 2003 (AB) Ram Van/Wagon 2001 - 2004 (AN) Dakota 2001 - 2002 (BR/BE) Ram Pick Up 2004 - 2006 (CS) Pacifica 2005 - 2006 (DH) Ram Pick Up - Heavy Duty 2001 - 2003 (DN) Durango 2002 - 2006 (DR) Ram Pick Up 2004 - 2006 (HB) Durango 2001 - 2006 (JR) Stratus/Sebring 2002 - 2006 (KJ) Liberty/Cherokee 2006 (LE) Chrysler 300 (International Markets) 2001 - 2004 (LH) Intrepid/Concorde/300M 2005 - 2006 (LX) 300/Magnum/Charger 2005 - 2006 (ND) Dakota 2001 - 2005 (PL) Neon 2001 - 2002 (PR) Prowler 2002 (PG) PT Cruiser (International Markets) 2001 - 2006 (PT) PT Cruiser 2001 (R1) Dakota (International Markets) 2001 - 2006 (RS/RG) Town & Country/Caravan/Voyager 2001 - 2002 (SR) Viper RT/10 & GTS Coupe 2001 - 2005 (ST) Stratus Coupe/Sebring Coupe 2001 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 2001 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 08-024-05 -2-

2006 (XK/XH) Commander 2001 (XJ) Cherokee 2003 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster

DISCUSSION: The information contained in this guide has been prepared for use by persons installing two-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication. It is not possible to cover all of the possible installations of two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held responsible for incidental or consequent damages arising out of the use of the information contained herein. Installations and modifications are solely the customer's responsibility

The installation recommendations presented here are intended to supplement the radio manufacturer's instructions. To assist in properly installing communications equipment in DaimlerChrysler vehicles, the following information is provided. Always use good installation practices (see The American Radio Relay League (ARRL) Handbook or other standard reference).

Test the entire installation for anomalies, especially drivetrain and brake control before extensive driving. If any problems occur the owner's first line of contact is the vehicle dealer. The literature supplied with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the problem.

CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor, put body sealer over the underbody projections. Stamped acorn nuts, filled with sealer are available at most body shops for this purpose. This will keep moisture out of the carpet and insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and behind the instrument panel. Do not drill holes. Instead, use an awl to pierce the hole. Not only is damage less likely, but the extruded sheet metal will resist strip out much better.

If you mount the radio under the instrument panel, be sure that there is no interference with proper operation of the foot controls. Mount the control head or front panel (especially the microphone cable) so that it is clear of the steering wheel and steering column controls and passenger airbag. If the unit is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and energy absorbing materials in the knee blocker (the lower part of the Instrument Panel). A communications speaker (with or without DSP), directed toward the operator, will enhance intelligibility under mobile conditions.

Many factory entertainment radios have a “mute audio” input that may be used with the Push-To-Talk (PTT) line to mute the audio system during transmit. This information is usually in the service manual.

Try the installation out before you start drilling holes (Velcro or other hook-and-loop is useful).

POWER WIRING -3- 08-024-05

To reduce the hazard of working on the vehicle, disconnect the NEGATIVE battery cable before beginning work.

NOTE: Some components may lose short-term memory (e.g.: engine or transmission adaptive parameters, radio presets etc.) after an extended length of time without battery power. For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the interior power distribution center or the power outlet or cigar lighter feed may be used. Use an appropriate jumper terminal at the socket or splice (solder and heat shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery positive) lead at the battery or at the power distribution center or at the positive jump-start post, if equipped. If ignition switching is desired, use a relay to prevent overloading the ignition switch. Appropriate terminals should be used. If a terminal is exposed to the weather, solder and apply a commercial protectant (wheel bearing grease is an acceptable alternative) to retard corrosion. The power lead should be fused as close to the battery as practical to protect the wiring and the vehicle! If the power connection is underhood, use a weatherproof fuse holder. These are usually available from a trailer supply or marine dealer.

Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher underhood temperatures in modern vehicles. Route the underhood wiring away from all hot areas, away from the exhaust, radiator, A/C liquid line and engine. Along body sheet metal is usually the coolest location.

DO NOT FUSE THE GROUND LEAD! If the ground-side fuse were to open, the entire supply current would be conducted by an alternate current return path, which may cause the feed line to overheat, with possible resulting damage.

For low or medium power installations, connect the ground (battery negative) to body sheet metal near the power feed point. If you use a screw through the floor, use body sealer over the underbody projection. For high power installations, connect the ground (battery negative) lead at the battery connection to the body. This is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so diameter area of body panel where the ground lead is to be connected. An awl is the best tool to use to pierce a starting hole for a #12 or 5mm, minimum, plated ground screw. A flat ring terminal of the proper size for the screw with separate serrated washer (not a split or SAE) lock washer should be used between the terminal and the screw head, not between the terminal and the surface. As above, some grease or protectant should be used if the connection is in an unprotected area.

It may be possible to route power wires through the hood gutter into the door gap, into the passenger compartment. If the power cable must pass through the dash panel, try to find an existing hole with a grommet that is unused. If none is available, pull the carpet back from under the dash panel in the passenger footwell in the cabin. Locate a place where there are no other components on either side, as high up as possible. An awl is the best tool to use to punch a small hole through to the engine compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or commercial body sealer on both sides. Seal any extra holes that you may have made. 08-024-05 -4-

Dress the underhood wiring so that it is safe from all hazards, which include the following: exhaust manifold, steering shaft, throttle linkage, fans, etc. Provide a outside drip loop where wires pass through the compartment panels and tie wrap or tape as required keeping the wires where you put them.

CABLING Route control cables under the floor mats, inside the corner where the floor pan meets the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats or carpet and padding. For most left hand drive vehicles, use the right side for best separation to the main body harness which is usually on the left side.

Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible.

REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which must be pierced to pass the cable through.

Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back and cushion, taking care that the cable is not pinched by the seat cushion when there is someone sitting in the seat. On some vehicles, there may be a channel for wiring at this location. Newer vehicles have seatbacks that fold down, which may provide a very simple pass through method. Watch for and avoid pinch points!

For remote control radios, a sheet of 1/2" plywood one or two inches larger than the radio, is a good method to mount the transceiver to the shelf. It provides a good mounting surface, some shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic modules located in the rear of the vehicle.

In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22 watts (@70% efficiency). Do not obstruct the cooling air flow.

TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way as the control and power cables. Route flat along body sheet metal wherever possible to avoid sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some cases, additional grounded shielding between the transmission line and the vehicle wiring may be helpful. It is important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at VHF and above. Mechanical pressure on the cable can cause degradation or even short circuits. Do not rely on the obsolete military 'RG' designations as an indicator of quality.

Cut off excess transmission line, coiling forms a choke balun, and terminate in the correct connector. -5- 08-024-05

The use of N, BNC or C connectors are recommended over "UHF" (PL-259/SO-239) connectors. A small amount of silicone dielectric grease (not the white heat sink compound) in the connector (after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize losses.

ANTENNA LOCATION Antenna location is the most important consideration in any mobile installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the center of the roof. Antenna mounting location must not cause radiation into the passenger compartment.

NOTE: There may be GPS, cellular, satellite radio or newer technology antennas located in or on the vehicle. They may contain sensitive low noise amplifiers (LNAs), operating at 0.9, 1.575 and/or 2.3GHz. If you are unsure of interactions, test with a temporary installation (a magnetic mount will do) before committing to a permanent hole. Deck lid installation is not recommended. Glass-mounted antennas should be mounted at the very top edge of the clear portion of the glass away from the heater grid. Vehicles with printed-on-glass (active) antennas may be damaged by through-glass installations.

NOTE: Composite panels, such as roof or deck lid may contain hidden receiving or transmitting antennas. For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are an accomplished antenna experimenter. HF antennas should be mounted to the body or frame steel for a good counterpoise as well as structural strength. 2" x 3" aluminum architectural tubing (or 2" x 4" U-channel for heavy HF antennas) may be cut and welded into many simple structures to mount HF antennas, and it is easily modeled by using 2x4s. Aluminum bumpers are heavily anodized for corrosion protection and the coating (aluminum oxide) is very hard as well as non-conductive. A small grinder with a coarse stone will break through the anodized coating for electrical connection.

Remember for all monopole antennas, the vehicle is the other half of the radiator. At HF the vehicle may be shorter than a quarter wavelength, resulting in some significant unbalanced currents flowing on the body.

ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass or body-lip mounts for anything other than for low power or temporary installations. Most of these alternate antennas will reflect some power back at the feed point. Much of this will be radiated from the feed line inside the passenger compartment, and may be picked up by the vehicle wiring.

For deck lid installations for HF or low VHF (6m), the deck lid should be bonded to the body across the hinges with short, wide tinned braid straps or thin brass strip. They must connect to clean sheet metal at both ends. For AM/SSB and even some FM installations, the hood should be bonded to the body. In some cases, the doors may need to be bonded as well

Glass-mount antennas may not work or will only work very poorly in vehicles with metallized glass (Electrically-heated windshields or some solar reflective glass). 08-024-05 -6-

Non-metallic bodies (e.g., Viper) require a half-wavelength antenna or a ground plane with radius equal to a quarter-wavelength for a quarter-wave antenna. Copper or brass are the best choices, but aluminum or even steel may be used. Install on the inside of the body panel with a good adhesive or tape and provide a good RF connection to the coax shield at the feed point. Screen, mesh or thin sheet stock, even copper or aluminum tape may be used. Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay one-quarter wavelength away from edges, including sunroof openings. For VHF and UHF, a good quality "NMO" (New MOtorola) base or other mount with feed line (center conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in antenna selection and is the best choice for electrical and mechanical considerations. Use the proper hole saw 3/4" for NMO, Motorola P/N 0180356B77) or have it done professionally if you are not comfortable with power tools. Consider roof reinforcements and the sunroof mechanism for interference to the base and to the feed line. The dome lamp opening often provides convenient access at or near the center of the roof. Hole plugs are available, for use at sale or trade-in, if you expect to remove the antenna base.

To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or plastic banding ½" to ¾" wide) and guide to the desired corner. Pull the banding through, leaving 6" which can be taped to the transmission line (easier without the connector, but possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the hole, then seat the base and screw on the outside ring, O-ring down. A little silicone grease helps maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small amount of silicone grease to the contact and insulator surface of the base. This will help exclude water, but must be renewed periodically. Tip: if you remove your antenna to go through the car wash, there are caps available to exclude water during the process.

In most vehicles, RG-58 sized cable will fit between the pillar trim and body sheet metal. If necessary, the technique used on the roof can also be used to snake the cable down the inside the pillar.

All radio installations must follow the personal exposure recommendations in FCC Bulletin 65.

Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely important.

POLICY: Information Only NUMBER: 21-002-05 REV. A

GROUP: Transmission

DATE: May 7, 2005

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-002-05, DATED JANUARY 14, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL PART AND REVISED REPAIR PROCEDURES FOR 2004 SPRINTER VEHICLES. SUBJECT: Automatic Transmission Fluid (ATF) Weepage

OVERVIEW: This bulletin aids in diagnosis and repair of automatic transmission fluid weepage.

MODELS:

2005 (LX) 300/Magnum 2004-2005 (VA) Sprinter 2005 (WK) Grand Cherokee 2004 - 2005 (ZH) Crossfire Coupe/Crossfire Roadster

NOTE: This bulletin applies to vehicles equipped with a NAG1 automatic transmission (sales code DGJ or DGU).

SYMPTOM/CONDITION: Transmission fluid may be wicking in the right front corner of the transmission oil pan area.

DIAGNOSIS: If the vehicle exhibits the Symptom/Condition, inspect the 13-pin connector plug guide bushing as a possible source of the transmission fluid weepage. If the weepage appears to be coming from above the transmission oil pan gasket, DO NOT REPLACE THE TRANSMISSION OIL PAN GASKET, perform the appropriate Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description 1 52108323AB O-Ring, Transmission 1 52108324AB O-Ring, Transmission (AR) 05127382AA Transmission Fluid Sprinter and Crossfire Coupe/Crossfire Roadster 21-002-05 REV. A -2-

Qty. Part No. Description (AR) 05013457AA Transmission Fluid 300/Magnum and Grand Cherokee **AR (1) 05166827AA Plug, Adapter - 2004 Sprinter Only**

LX VEHICLE REPAIR PROCEDURE: 1. Disconnect and isolate the negative battery cable. 2. Raise the vehicle on a suitable hoist. 3. Disconnect the 13-pin connector plug by turning the bayonet lock of the connector guide bushing counter clockwise (Fig. 1). 4. Place a suitable drain pan under the connector guide bushing to catch transmission fluid that may drain during the next step. 5. Using a 7 mm socket, loosen the bronze bolt securing the connector guide bushing. The bronze bolt is located in the center of the connector guide bushing (Fig. 2).

Fig. 1 CONTROL HARNESS CONNECTOR

1 - BAYONET LOCK OF THE CONNECTOR GUIDE BUSHING 2 - 13 PIN CONNECTOR PLUG -3- 21-002-05 REV. A

Fig. 2 BOLT SECURING THE CONNECTOR GUIDE BUSHING

1 - CATALYTIC CONVERTER (ZH AND WK MODELS ONLY) 2 - BAYONET LOCK 3 - BRONZE BOLT 4 - TRANSMISSION OIL PAN

6. Remove the connector guide bushing from the transmission. 7. If there is a locator tab present, using side cutter pliers, remove the locator tab on the connector guide bushing (Fig. 3). 21-002-05 REV. A -4-

Fig. 3 BUSHING LOCATOR TAB LOCATION

1 - BAYONET LOCK 2 - LOCATOR TAB 3 - O-RING (2) 4 - CONNECTOR GUIDE BUSHING

8. Using transmission fluid, lubricate and place 1 p/n 52108323AB o-ring and 1 p/n 52108324AB o-ring on the connector guide bushing. NOTE: The o-rings are two different sizes. Be careful to place the new o-rings in the correct location. 9. Install the connector guide bushing in the transmission. 10. Tighten the bronze bolt securing the guide bushing in place. Tighten the bronze bolt to 2.5 N·m +/- 0.2 N·m ( 22 in. lbs +/- 2 in. lbs.) (Fig. 2). 11. Connect the 13-pin plug connector. Secure the connector by turning the bayonet lock of the connector guide bushing clockwise. 12. Clean the area of any residual transmission fluid which may be present as a result of the repair. 13. Lower the vehicle. 14. Connect the negative battery cable and reset the clock. NOTE: Be sure to use the correct transmission fluid, Mopar p/n 05013457AA. 15. Check the transmission fluid and adjust as necessary. Refer to the service information available in TechCONNECT. Reference: Service Info, 21 - Transmission/Transaxle/Automatic - NAG1/Fluid - Standard Procedure. VA VEHICLE REPAIR PROCEDURE: 1. Disconnect and isolate the negative battery cable. 2. Raise the vehicle on a suitable hoist. 3. Disconnect the 13-pin connector plug by turning the bayonet lock of the connector guide bushing counter clockwise (Fig. 1). -5- 21-002-05 REV. A

4. Place a suitable drain pan under the connector guide bushing to catch transmission fluid that may drain during the next step. 5. Using a 7 mm socket, loosen the bronze bolt securing the connector guide bushing. The bronze bolt is located in the center of the connector guide bushing (Fig. 2). 6. Remove the connector guide bushing from the transmission. 7. **2004 VA vehicles go to Step #8. 2005 VA vehicles go to Step #9.** 8. **Install a new connector guide bushing, p/n 05166827AA, in the transmission. Proceed to Step #12.** 9. If there is a locator tab present, using side cutter pliers, remove the locator tab on the connector guide bushing(Fig. 3). 10. Using transmission fluid, lubricate and place 1 p/n 52108323AB o-ring and 1 p/n 52108324AB o-ring on the connector guide bushing. NOTE: The o-rings are two different sizes. Be careful to place the new o-rings in the correct location. 11. Install the connector guide bushing in the transmission. 12. Tighten the bronze bolt securing the guide bushing in place. Tighten the bronze bolt to 2.5 N·m +/- 0.2 N·m ( 22 in. lbs +/- 2 in. lbs.) (Fig. 2). 13. Connect the 13-pin plug connector. Secure the connector by turning the bayonet lock of the connector guide bushing clockwise. 14. Clean the area of any residual transmission fluid which may be present as a result of the repair. 15. Lower the vehicle. 16. Connect the negative battery cable. NOTE: Be sure to use the correct transmission fluid, Mopar p/n 05127382AA. 17. Check the transmission fluid and adjust as necessary. Refer to the service information available in TechCONNECT. Reference: Service Info, 21 - Transmission/Transaxle/Automatic - NAG1/Fluid - Standard Procedure. WK VEHICLE REPAIR PROCEDURE: 1. Disconnect and isolate the negative battery cable. 2. Raise the vehicle on a suitable hoist. 3. Remove the bolt and loosen the screw securing the 13 pin connector heat shield in the right front corner of the transmission assembly (Fig. 4). Remove the heat shield. 21-002-05 REV. A -6-

Fig. 4 13 PIN CONNECTOR HEAT SHIELD

1 - LOOSEN SCREW 2 - 13 PIN CONNECTOR HEAT SHIELD 3 - REMOVE BOLT

4. Disconnect the 13-pin connector plug by turning the bayonet lock of the connector guide bushing counter clockwise (Fig. 1). 5. Place a suitable drain pan under the connector guide bushing to catch transmission fluid that may drain during the next step. 6. Using a 7 mm socket, loosen the bronze bolt securing the connector guide bushing. The bronze bolt is located in the center of the connector guide bushing (Fig. 2). 7. Remove the connector guide bushing from the transmission. 8. If there is a locator tab present, using side cutter pliers, remove the locator tab on the connector guide bushing (Fig. 3). 9. Using transmission fluid, lubricate and place 1 p/n 52108323AB o-ring and 1 p/n 52108324AB o-ring on the connector guide bushing. NOTE: The o-rings are two different sizes. Be careful to place the new o-rings in the correct location. 10. Install the connector guide bushing in the transmission. 11. Tighten the bronze bolt securing the guide bushing in place. Tighten the bronze bolt to 2.5 N·m +/- 0.2 N·m ( 22 in. lbs +/- 2 in. lbs.) (Fig. 2). 12. Connect the 13-pin plug connector. Secure the connector by turning the bayonet lock of the connector guide bushing clockwise. 13. Position the 13 pin connector heat shield and install the bolt and tighten the screw securing the heat shield in the right front corner of the transmission assembly (Fig. 4). 14. Clean the area of any residual transmission fluid which may be present as a result of the repair. 15. Lower the vehicle. 16. Connect the negative battery cable. NOTE: Be sure to use the correct transmission fluid, Mopar p/n 05013457AA. -7- 21-002-05 REV. A

17. Check the transmission fluid and adjust as necessary. Refer to the service information available in TechCONNECT. Reference: Service Info, 21 - Transmission/Transaxle/Automatic - NAG1/Fluid - Standard Procedure. ZH VEHICLE REPAIR PROCEDURE: 1. Disconnect and isolate the negative battery cable. 2. Raise the vehicle on a suitable hoist. 3. Disconnect the oxygen sensor harness connectors and reposition the oxygen sensor harness out of the way (Fig. 5). 4. Remove the oxygen sensor heat shield bolts and the heat shield (Fig. 5). 5. Remove the bolt and loosen the screw securing the 13 pin connector heat shield in the right front corner of the transmission assembly (Fig. 4). Remove the heat shield and set it aside. 6. Disconnect the 13-pin connector plug by turning the bayonet lock of the connector guide bushing counter clockwise (Fig. 1). 7. Place a suitable drain pan under the connector guide bushing to catch transmission fluid that may drain during the next step. 8. Using a 7 mm socket, loosen the bronze bolt securing the connector guide bushing. The bronze bolt is located in the center of the connector guide bushing (Fig. 2). 9. Remove the connector guide bushing from the transmission. 10. If there is a locator tab present, using side cutter pliers, remove the locator tab on the connector guide bushing (Fig. 3). 11. Using transmission fluid, lubricate and place 1 p/n 52108323AB o-ring and 1 p/n 52108324AB o-ring on the connector guide bushing. NOTE: The o-rings are two different sizes. Be careful to place the new o-rings in the correct location.

Fig. 5 OXYGEN SENSOR HEAT SHIELD

1 - OXYGEN SENSOR CONNECTORS 2 - HEAT SHIELD BOLTS

12. Install the connector guide bushing in the transmission. 21-002-05 REV. A -8-

13. Tighten the bronze bolt securing the guide bushing in place. Tighten the bronze bolt to 2.5 N·m +/- 0.2 N·m ( 22 in. lbs +/- 2 in. lbs.) (Fig. 2). 14. Connect the 13-pin plug connector. Secure the connector by turning the bayonet lock of the connector guide bushing clockwise. 15. Position the 13 pin connector heat shield and install the bolt and screw securing the heat shield in the right front corner of the transmission assembly (Fig. 4). 16. Position the oxygen sensor heat shield onto the transmission housing and install the screw and bolt which secure the shield in place.(Fig. 5). 17. Connect the oxygen sensor harness connectors and secure the wiring harness in the oxygen sensor heat shield (Fig. 5). 18. Clean the area of any residual transmission fluid which may be present as a result of the repair. 19. Lower the vehicle. 20. Connect the negative battery cable. NOTE: Be sure to use the correct transmission fluid, Mopar p/n 05127382AA. 21. Check the transmission fluid and adjust as necessary. Refer to the service information available in TechCONNECT. Reference: Service Info, 21 - Transmission/Transaxle/Automatic - NAG1/Fluid - Standard Procedure. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation Description Amount No: 21-10-20-90 Guide Bushing Seals, Replace 0.4 Hrs. **21-10-19-90 Adapter Plug/Guide Bushing, Replace 0.4 Hrs 2004 VA Only**

FAILURE CODE:

71 Oil Leak NUMBER: 21-009-05

GROUP: Transmission

DATE: March 22, 2005

SUBJECT: MIL Illumination For DTC's P0750, P0755, P0760, P0765, P0846, P0871 or P0841

OVERVIEW: This bulletin involves replacing the transmission solenoid/pressure switch assembly and 10-way wiring pigtail harness.

MODELS:

2004 (AN) Dakota 2004 - 2005 (HB) Durango 2003 - 2005 (KJ) Liberty 2003 - 2005 (KJ) Cherokee (International Markets) 2005 (LX) 300/Magnum 2005 (ND) Dakota 2003 - 2005 (TJ) Wrangler

NOTE: This bulletin applies to vehicles equipped with a 42 RLE automatic transmission (sales code DG6).

SYMPTOM/CONDITION: The vehicle operator may experience a MIL for one or more of the following DTC's: • P0750 - LR Solenoid Circuit • P0755 - 2-4 or 2C Solenoid Circuit • P0760 - OD Solenoid Circuit • P0765 - UD Solenoid Circuit • P0846 - 2-4 or 2C Pressure Switch Rationality • P0871 - OD Pressure Switch Rationality • P0841 - LR Pressure Switch Rationality DIAGNOSIS: Disconnect the transmission solenoid/pressure switch assembly connector and inspect the harness connector and assembly connector for any signs of moisture or corrosion. If there are signs of moisture in the connectors or the presence of corrosion, perform the appropriate Repair Procedure. If no moisture or corrosion is visable at the harness or assembly connector, further diagnosis is necessary, this service bulletin does not apply. 21-009-05 -2-

PARTS REQUIRED:

Qty. Part No. Description 1 05102405AA Wiring 10-way Pigtail Harness 1 05143151AA Solenoid/Pressure Switch Assembly

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NPN Battery Charger 05019912AA Crimping Tool CH9401 StarSCAN® Tool CH9404 StarSCAN® Vehicle Cable CH9409 StarSCAN® Documentation Kit StarSCAN® Software Update CD CH2002 General Purpose Interface Bus Cable Assembly CH6000A Scan Tool (DRBIII®) CH7000A/7001A J1962 Cable with red DRBIII® connector

AN/HB/ND REPAIR PROCEDURE: 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. Raise the vehicle on a suitable hoist. 4. Remove the transfer case skid plate, if equipped. Refer to the detailed removal procedures available in TechCONNECT, under: Service Info,13 - Frames & Bumpers/Frame/Transfer Case Skid Plate - Removal. 5. Place a suitable service jack under the transmission crossmember. 6. Remove the bolts securing the transmission crossmember to the frame and lower transmission assembly approximately 51 - 102 mm (2 - 4 in.) 7. Disconnect the rear oxygen sensor. 8. Disconnect the transmission solenoid/pressure switch connector (Fig. 1).

Fig. 1 SOLENOID/PRESSURE SWITCH ASSEMBLY -3- 21-009-05

9. Disconnect the wiring harness routing clip(s) at the top of the transmission. Pull the wiring harness down on the right side of the transmission. 10. Proceed to the WIRING HARNESS REPAIR PROCEDURE: Step #1 11. Reconnect the transmission solenoid/pressure switch assembly connector. 12. Connect the rear oxygen sensor connector. 13. Secure the wiring harness routing clip(s) at the top of the transmission. 14. Install the four bolts securing the transmission crossmember to the vehicle. Tighten the crossmember to frame bolts to 68 N·m (50 ft.lbs.). 15. Install the transfer case skid plate, if equipped. Refer to the detailed installation procedures available in TechCONNECT, under: Service Info,13 - Frames & Bumpers/Frame/Transfer Case Skid Plate - Installation. 16. Lower the vehicle. 17. Connect the negative battery cable and reset the clock. 18. Close the hood. 19. Using the DRB III® or StarSCAN® perform the Quick Learn Procedure and verify the solenoid is operating properly. KJ REPAIR PROCEDURE: 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. Raise the vehicle on a suitable hoist. 4. Place a suitable service jack under the transmission crossmember. 5. Remove the bolts securing the transmission crossmember to the frame and lower transmission assembly approximately 51 - 102 mm (2 - 4 in.) 6. Disconnect the transmission solenoid/pressure switch connector (Fig. 1). 7. Disconnect the wiring harness routing clip at the top of the transmission. 8. Disconnect the right rear oxygen sensor and cut the tie strap from the wiring harness conduit leading to the transmission solenoid/pressure switch connector. 9. Route the wiring harness in front of the transmission dipstick tube and pull the wiring harness down as far as possible on the right side of the transmission. 10. Proceed to the WIRING HARNESS REPAIR PROCEDURE: Step #1 11. Reposition the wiring harness back around the transmission dipstick tube and install new tie strap (7 in.) so that the wiring harness is in it's original position. 12. Reconnect the transmission solenoid/pressure switch assembly connector. 13. Reconnect the right rear oxygen sensor connector. 14. Secure the wiring harness routing clip at the top of the transmission. 15. Raise the transmission and install the six bolts securing the transmission crossmember to the vehicle. Tighten the crossmember to frame bolts to 68 N·m (50 ft.lbs.). 16. Lower the vehicle. 17. Connect the negative battery cable and reset the clock. 18. Close the hood. 19. Using the DRB III® perform the Quick Learn Procedure and verify the solenoid is operating properly. LX REPAIR PROCEDURE: 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. Raise the vehicle on a suitable hoist. 4. Place a suitable service jack under the transmission crossmember. 5. Remove the bolts securing the transmission crossmember to the frame and lower transmission assembly approximately 51 - 102 mm (2 - 4 in.) 6. Disconnect the input speed sensor connector, output speed sensor connector, and the transmission range sensor connector (Fig. 2). 21-009-05 -4-

Fig. 2 INPUT AND OUTPUT SPEED SENSORS AND TRANSMISSION RANGE SENSOR

1 - INPUT SPEED SENSOR 2 - OUTPUT SPEED SENSOR 3 - TRANSMISSION RANGE SENSOR

7. Disconnect the transmission solenoid/pressure switch connector (Fig. 1). 8. Disconnect the wiring harness routing clip at the top of the transmission. Pull the wiring harness to the right side of the vehicle. 9. Proceed to the WIRING HARNESS REPAIR PROCEDURE: Step #1 10. Reconnect the transmission solenoid/pressure switch assembly connector. 11. Connect the input speed sensor connector, output speed sensor connector, and the transmission range sensor connector. 12. Secure the wiring harness routing clip at the top of the transmission. 13. Install the four bolts securing the transmission crossmember to the vehicle. Tighten the crossmember to frame bolts to 68 N·m (50 ft.lbs.). 14. Lower the vehicle. 15. Connect the negative battery cable and reset the clock. 16. Close the hood. 17. Using the StarSCAN® perform the Quick Learn Procedure and verify the solenoid is operating properly. TJ REPAIR PROCEDURE: 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. Raise the vehicle on a suitable hoist. 4. Place a suitable service jack under the transmission crossmember. 5. Remove the transmission skid plate, if equipped. Refer to the detailed removal procedures available in TechCONNECT, under: Service Info, 13 - Frame & Bumpers/Frame/Front Skid Plate - Removal. 6. Remove the bolts securing the transfer case skid plate to the frame and lower the skid plate and transmission assembly approximately 51 - 102 mm (2 - 4 in.). 7. Loosen the skid plate to trans mount nuts (4). -5- 21-009-05

8. Disconnect the input speed sensor connector, output speed sensor connector, and the transmission range sensor connector (Fig. 2). 9. Disconnect the transmission solenoid/pressure switch connector (Fig. 1). 10. Disconnect the wiring harness routing clip at the top of the transmission. Pull the wiring harness to the driver's (left) side of the vehicle. 11. Proceed to the WIRING HARNESS REPAIR PROCEDURE: Step #1 12. Reconnect the transmission solenoid/pressure switch assembly connector. 13. Connect the input speed sensor connector, output speed sensor connector, and the transmission range sensor connector. 14. Secure the wiring harness routing clip at the top of the transmission. 15. Install the four bolts securing the transfer case crossmember to the vehicle. Tighten the crossmember to frame bolts to 68 N·m (50 ft.lbs.). 16. Tighten the nuts attaching the transmission mount to the transfer case skid plate to 35 N·m (26 ft. lbs.). 17. Install the transmission skid plate, if equipped. Tighten the crossmember to frame bolts to 74 N·m (55 ft. lbs.). 18. Lower the vehicle. 19. Connect the negative battery cable and reset the clock. 20. Close the hood. 21. Using the DRB III® perform the Quick Learn Procedure and verify the solenoid is operating properly. WIRING HARNESS AND SOLENOID REPAIR PROCEDURE: 1. Remove the tape from wiring harness conduit at the Solenoid/Pressure switch connector and pull the wiring out of the conduit about 4 inches from the connector. 2. Clearly mark the cavity locations on each wire 76 mm (3 in.) up from the transmission solenoid/pressure switch connector. Refer to the detailed wiring and connector diagrams available in TechCONNECT under: Wiring, 21 - Transmission/Transaxle, Automatic - 42 RLE, Solenoid/Pressure Switch Assy, Wiring Diagrams and Connector Pinout. 3. Measure up from the end of the transmission solenoid/pressure switch connector 25.4 mm (1 in.) and cut it off the connector. 4. Cut seven 18 gauge wires from the repair kit to 76 mm (3 in.). Cut one 14 gauge wire to 76 mm (3 in.). 5. Solder the one 14 gauge wire to the wiring harness wire marked for cavity number 3. Refer to the detailed service information available in TechCONNECT under: Service Info, 8 - Electrical/Wiring Diagram Information/Wire - Standard Procedure - Wire Splicing and the detailed wiring diagrams under: Wiring, 21 - Transmission/Transaxle/Automatic - 42RLE/Solenoid/Pressure Switch Assy/Wiring Diagrams. 6. Solder the seven 18 gauge wires to the wiring harness wires marked for cavities 1,2,4,5,6,7,and 10. 7. Place a piece of the heat shrink tubing over each wire and shrink it in place. 8. Insert two terminal plugs into the new connector in cavities 8 and 9. 9. Insert the terminals into the appropriate cavities in the new connector as marked. 10. Place wires back in conduit and tape up the wiring harness. 11. Replace the solenoid assembly, p/n 05143151AA. Refer to the detailed removal and installation procedures available in TechCONNECT, under: Service Info, 21 - Transmission/Transaxle/Automatic - 42RLE/Solenoid Pressure Switch Assembly. 12. KJ vehicles, proceed to KJ REPAIR PROCEDURE: Step #11. LX vehicles, proceed to LX REPAIR PROCEDURE: Step #10. AN/HB/ND vehicles, proceed to ND REPAIR PROCEDURE: Step #10. TJ vehicles, proceed to TJ REPAIR PROCEDURE: Step #12 21-009-05 -6-

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation Description Amount No: 08-90-99-94 Replace 10-Way Wiring Pigtail Harness and 2.2 Hrs. LX Solenoid/Pressure Switch assembly Bodies 2.3 Hrs. TJ Bodies 2.4 Hrs. AN, ND, KJ, HB Bodies

FAILURE CODE:

3T Terminals Corroded NUMBER: 08-034-05

GROUP: Electrical

DATE: June 30, 2005

SUBJECT: MIL Illumination, DTC's P0037, P0058, P0131, P0132, P0133, P0138, P0151, P0153, P0159

OVERVIEW: This bulletin involves repositioning the upstream Oxygen (O2) sensor connectors and replacing the wiring harness connector(s) and O2 sensor(s) as necessary.

MODELS:

2005 - 2006 (LX) 300/Magnum/Charger

NOTE: This bulletin applies to vehicles equipped with a 2.7L, 3.5L or 5.7L engine (sales code EER, EGG or EZB).

SYMPTOM/CONDITION: MIL Illumination due to one or more of the following DTC's: • P0037-O2 SENSOR 1/2 HEATER CIRCUIT LOW • P0058-O2 SENSOR 2/2 HEATER CIRCUIT HIGH • P0131-O2 SENSOR 1/1 CIRCUIT LOW • P0132-O2 SENSOR 1/1 CIRCUIT HIGH • P0133-O2 SENSOR 1/1 SLOW RESPONSE • P0138-O2 SENSOR 1/2 CIRCUIT HIGH • P0151-O2 SENSOR 2/1 CIRCUIT LOW • P0153-O2 SENSOR 2/1 SLOW RESPONSE • P0159-O2 SENSOR 2/2 SLOW RESPONSE The condition may be due to the cowl drain flowing water onto the connectors for the O2 sensor(s) at the center rear area of the engine. This leads to water intrusion into the wiring harness connector(s) which may lead to terminal corrosion and/or MIL illumination.

DIAGNOSIS: NOTE: If the vehicle is equipped with a 5.7L engine (sales code EZB) and was built on or before August 18, 2004 (MDH 0818XX), perform Service Bulletin 18-031-04 REV A as necessary before continuing with diagnosis. For 2.7L and 3.5L engines continue with the diagnosis. 1. Open the hood 08-034-05 -2-

2. Disconnect the O2 Sensor connectors and check for water intrusion and/or corrosion in both upstream O2 sensor connectors at the center rear area of the engine. a. If no water or corrosion is present, reposition the wiring harness connectors to the outboard edge of the valve cover away from the center of the engine. Tie strap the harnesses in place. If no water or corrosion was present, further diagnosis is required. This bulletin does not apply. b. If water is present but no corrosion, blow out the connector(s) and reposition the wiring harness to the outboard edge of the valve cover away from the center of the engine. Tie strap the harness in place. c. If corrosion is present, perform the Repair Procedure. PARTS REQUIRED:

Qty. Part No. Description AR (2) 05161925AA Wiring, 4 way AR (2) 56029049AA Sensor, Oxygen (2.7 & 3.5L engines) AR(2) 56028994AB Sensor, Oxygen (5.7L engine)

SPECIAL TOOLS/EQUIPMENT REQUIRED:

05019912AA Mopar Wire Crimping Tool (or equivalent) NPN Oxygen Sensor Socket (Snap-On YA8875 or equivalent)

REPAIR PROCEDURE: 2.7L and 3.5L Engines Replace O2 Sensor and Wiring Harness Connector 1. Remove the appropriate O2 sensor. Refer to the detailed removal procedures available in TechCONNECT, under: Service Info, 14 - Fuel System, Fuel Injection, O2 Sensor, Removal. NOTE: It may be necessary to disconnect the purge vacuum harness to gain better access to the harness connectors. 2. Replace the wiring harness connector, using kit p/n 05161925AA. Refer to the detailed removal procedures available in TechCONNECT, under: Service Info, 8 - Electrical, Wiring Diagram Information, Wire, Standard Procedures, Wire Splicing. 3. Install the new O2 sensor using the appropriate part number. Refer to the detailed removal procedures available in TechCONNECT, under: Service Info, 14 - Fuel System, Fuel Injection, O2 Sensor, Installation. 4. Reposition the wiring harness connectors to the outboard edge of the valve cover away from the center of the engine. Tie strap the harnesses in place. 5.7L Engine Replace O2 Sensor and Wiring Harness Connector 1. Release Fuel Pressure. Refer to the detailed removal procedures available in TechCONNECT, under: Service Info, 14 - Fuel System, Fuel Delivery, Standard Procedure - Fuel Pressure Release. WARNING:THE FUEL SYSTEM IS UNDER CONSTANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING FUEL RAIL, FUEL SYSTEM PRESSURE MUST BE RELEASED. 2. Disconnect the negative battery cable. -3- 08-034-05

3. Remove the intake manifold. Refer to the detailed removal procedures available in TechCONNECT, under: Engine, Manifolds, Manifold - Intake, Removal. 4. Remove the 3 engine harness retaining clips from the engine harness bracket. 5. Disconnect and remove the appropriate O2 sensor. Refer to the detailed removal procedures available in TechCONNECT, under: Service Info, 14 - Fuel System, Fuel Injection, O2 Sensor, Removal. 6. Pull the lower harness up to access the O2 harness connectors. 7. Replace the wiring harness connector, using kit p/n 05161925AA. Refer to the detailed removal procedures available in TechCONNECT, under: Service Info, 8 - Electrical, Wiring Diagram Information, Wire, Standard Procedures, Wire Splicing. 8. Install the new O2 sensor using the appropriate part number. Refer to the detailed removal procedures available in TechCONNECT, under: Service Info, 14 - Fuel System, Fuel Injection, O2 Sensor, Installation. 9. Reposition the wiring harness connectors to the outboard edge of the valve cover away from the center of the engine. Tie strap the harnesses in place. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-90-98-90 Inspect and Reposition O2 Harnesses 2.7, 3.5, 0.2 Hrs. 5.7L Engines 08-90-98-91 Inspect and Reposition O2 Harnesses, Repair One 0.8 Hrs. Harness, and Replace One Upstream O2 Sensor 2.7, And 3.5L Engines 08-90-98-92 Inspect and Reposition O2 Harnesses, Repair One 1.2 Hrs. Harness, and Replace One Upstream O2 Sensor 5.7 Engine 08-90-98-93 Inspect and Reposition O2 Harnesses, Repair 1.2 Hrs. Both Harnesses, and Replace Both Upstream O2 Sensors 2.7, And 3.5L Engines 08-90-98-94 Inspect and Reposition O2 Harnesses, Repair 1.5 Hrs. Both Harnesses, and Replace Both Upstream O2 Sensors 5.7 Engine

FAILURE CODE:

3T Terminal(s) Corroded NUMBER: 02-002-05

GROUP: Suspension

DATE: March 12, 2005

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-003-04, DATED MAY 25, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED REAR WHEEL DRIVE (RWD) SPECIFICATIONS, ADDITIONAL SPECIFICATIONS FOR ALL WHEEL DRIVE (AWD) AND AN ADDITIONAL MODEL YEAR.

SUBJECT: Right Lead/Revised Alignment Specifications

OVERVIEW: This bulletin involves adjusting the alignment to revised specifications.

MODELS:

2005 - **2006** (LX) 300/Charger/Magnum

SYMPTOM/CONDITION: The vehicle operator states the vehicle leads to the right.

DIAGNOSIS: Drive the car on a FLAT road. If the car tracks straight, the vehicle operator is experiencing crown sensitivity. If the vehicle tracks to the right, perform the Repair Procedure. Crown sensitivity can not be eliminated in all the cases.

NOTE: Before evaluating the vehicle, it is important to check the following: 1. Tire pressure - Adjust tire pressure (if necessary) in all four wheels to the pressure stated on the door placard. 2. Tire size & type - Verify that all four tires are the same size and type.

NOTE: When evaluating the vehicle, always drive the same road in both directions to get a feel for the effect of road crown & cross wind.

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NPN Alignment Equipment

REPAIR PROCEDURE: 1. Use the procedures outlined on TechCONNECT service info tab / 2-Suspension / Wheel Alignment, to set the wheel alignment to the specifications below. 02-002-05 -2-

NOTE: When aligning the front end to induce right caster bias (the vehicle will tend to track toward the side with the least positive caster), target the cross caster to be **-1.0 degrees and no more than -1.6 degrees for RWD and target the cross caster to be 0.6 degrees and no more than -1.2 degrees for AWD**. That means you will have more caster on the right than on the left. Cross camber should be set at +0.2 - +0.3 degree. That means you will have more camber on the left than on the right. Utilize the cradle shift method PRIOR to using the caster/camber adjustment bolt kit, p/n 05134117AA **for RWD, p/n 05161518AA for AWD**. The adjustment bolts only provide about 0.2 - 0.3 degree change and should only be used as a last resort. When shifting the cradle, the passenger side of the cradle will move forward in car and the driver's side will move rearward in car.

NOTE: After the cradle has been shifted, torque all 4 cradle bolts to 175Nm (130 ft. lbs.).

CAUTION: If an adjustment bolt is to be installed do not allow the bolt head to turn during disassembly or assembly, the cradle tension link joint or the lower control arm bushing inner metal sleeve will be destroyed and require replacement. THE NUT MUST BE UNTORQUED AND REMOVED, BEFORE THE BOLT. Once the nut is removed the bolt can be slid out. -3- 02-002-05

**REVISED ALIGNMENT SPECIFICATIONS

RWD AWD FRONT WHEEL PREFERRED ACCEPTABLE PREFERRED ACCEPTABLE ALIGNMENT SETTING RANGE SETTING RANGE CAMBER - LEFT 0° -0.50° to +0.50° 0° -0.50° to +0.50° CAMBER - -0.30° -0.80° to +0.20° -0.30° -0.80° to +0.20° RIGHT Cross-Camber 0.30° -0.25 to +1.00° 0.30° -0.25 to +1.00° (Maximum side-to-side difference) CASTER - LEFT +9.40° +8.40° to +4.50° +3.50° to +5.50° +10.40° CASTER - +10.40° +9.40° to 5.10° 4.10° to 6.10° RIGHT +11.40° Cross-Caster -1.00° -1.60 to -0.40° -0.60° -1.20° to 0.0 ° (Maximum side-to-side difference) INDIVIDUAL 0.05° 0.00° to +0.10° 0.05° 0.00° to +0.10° TOE TOTAL TOE (1) +0.10° 0.00° to +0.20° +0.10° 0.00° to +0.20° Maximum 0.00° 0.06° 0.00° 0.06° side-to-side difference RIDE HEIGHT - 328mm (12 7/8 318 to 346mm 352mm (13 7/8 342 to 362mm INDIVIDUAL in.) (12 1/2 to 13 3/8 in.) (13 1/2 to 14 1/4 in.) in.) CROSS RIDE 0 -12 to +12mm 0 -12 to +12mm HEIGHT (1/2 in.) (1/2 in.) REAR WHEEL ALIGNMENT CAMBER (2) -0.75° -1.25° to -0.25° -0.75° -1.25° to -0.25° Cross-Camber 0.00° -0.80 to 0.80° 0.00° -0.80 to 0.80° (Maximum side-to-side difference) TOE - Right 0.03° -0.12° to +0.18° 0.03° -0.12° to +0.18° TOE - Left 0.17° 0.02° to 0.32° 0.17° 0.02° to 0.32° THRUST 0.07° -0.08° to +0.22° 0.07° -0.08° to +0.22° ANGLE RIDE HEIGHT - 296mm (11 286 to 306mm 308mm (12 1/8 298 to 318mm 02-002-05 -4-

RWD AWD FRONT WHEEL PREFERRED ACCEPTABLE PREFERRED ACCEPTABLE ALIGNMENT SETTING RANGE SETTING RANGE INDIVIDUAL 5/8in.) (11 1/4 to 12 in.) in.) (11 3/4 to 12 1/2 in.) CROSS RIDE 0 -12 to +12mm 0 -12 to +12mm HEIGHT (1/2 in.) (1/2 in.)

NOTE: Vehicle height and suspension alignment values reflect after vehicle spring settling values, after the vehicle has been jounced at each corner.

NOTE: (1) TOTAL TOE is the sum of both left and right wheel toe settings. Positive toe is toe-in and negative toe is toe-out. (2) For reference only. These are non-adjustable angles.**

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 02-00-02-90 Set Front and Rear Toe / Center Steering Wheel 0.7 Hrs. 02-00-01-91 Alignment Using Cradle Adjustment and Set 1.0 Hrs. Front and Rear Toe / Center Steering Wheel

FAILURE CODE:

LM Leads Right NUMBER: 23-035-05

GROUP: Body

DATE: July 26, 2005

SUBJECT: Circular/Ring Marks On Glass

MODELS:

2005 - 2006 (CS) Pacifica 2005 - 2006 (DH/DR) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (JR) Sebring Sedan/Sebring Convertible/Stratus Sedan 2005 - 2006 (KJ) Liberty/Cherokee (International Markets) 2006 (LE) 300/Touring (International Markets) 2005 - 2006 (LX) 300/Charger/Magnum 2005 - 2006 (ND) Dakota 2005 (PL) Neon 2005 - 2006 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2005 - 2006 (RG) Chrysler Voyager (International Markets) 2005 -2006 (RS) Town & Country/Caravan 2005 (ST) Sebring Coupe/Stratus Coupe 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2005 - 2006 (WH) Grand Cherokee (International Markets) 2005 - 2006 (WK) Grand Cherokee 2006 (XH) Commander (International Markets) 2006 (XK) Commander 2005 - 2006 (ZB) Viper/Viper Coupe 2005 - 2006 (ZH) Crossfire/Crossfire Convertible

DISCUSSION: Circular patterns may appear on the glass which are visible mostly when the glass is moist or fogged up. The size varies from 2-6 inches and are typically described as “rings” or “circles” that won’t clean off with standard glass cleaners. 23-035-05 -2-

To determine if this type of mark(s) is present use a clean, moist cloth lightly wet the surface of the glass component. Carefully observe if these circular marks develop as the water from the cloth dissipates. Repeat this process on both the inside and outside of the glass component (if applicable) to identify which surface of glass (inside or outside) has the condition. If the marks are present on the outside of glass, this condition will naturally lessen with sunlight exposure and time. Customer concerns are mostly associated with this condition being present on the inside surface. If the customer wants the marks removed, they can be removed using a non-abrasive cleanser or polish. Appropriate materials are Calcium Carbonate (Bon Ami®) or a glass polish containing Cerium Oxide.

CAUTION: Do not use any materials containing quartz or silicate abrasives. Typical examples of abrasive cleansers include (Ajax®, Comet®, Soft-Scrub®, etc). Cleansers with abrasives will scratch the glass surface and cause irreparable damage.

PARTS REQUIRED:

Qty. Part No. Description AR NPN Calcium Carbonate (Bon Ami®) or a glass polish containing Cerium Oxide

CLEANING PROCEDURE: 1. Moisten a clean cloth with water. 2. Wipe the glass surface leaving a very fine film of water on the glass. 3. Observe the location of the marks on the glass. 4. If the marks are on the inside of the glass surface, take precautions to cover any of the interior components the cleanser could come in contact with. 5. Rinse the cloth with clean water. 6. Apply cleanser to the moist cloth. 7. Rub the surface of the glass with the cleanser in a circular pattern being sure to cover the entire area that the mark involves. 8. Wash off any residual cleanser material with a moist cloth. 9. Dry the glass surface. 10. Check that the removal has been successful by rubbing a moistened, clean cloth back over the cleaned surface and inspect for suction cup marks. 11. Repeat as necessary to remove all of the mark(s) from the glass surface(s). POLICY: Information Only NUMBER: 23-038-05

GROUP: Body

DATE: August 19, 2005

SUBJECT: Sunroof Squeaks While Opening Or Closing

OVERVIEW: This bulletin involves lubricating the slide surfaces of the sunroof mechanism.

MODELS:

2005 (LX) 300/Magnum

NOTE: This bulletin applies to vehicles built prior to January 1, 2005 (MDH 0101XX)

SYMPTOM/CONDITION: Squeak sound may be heard when the sunroof is operated. This mechanism squeak can be distinguished from a glass seal squeak because the squeak occurs when the glass seal is not in contact with roof flange. The squeak sound is most likely to occur in higher ambient temperatures. The mechanism squeak sound occurs even when the sunroof glass is removed.

DIAGNOSIS: Operate the sunroof, if a squeak sound is heard while the glass seal is not in contact with roof flange, perform the Repair Procedure.

REPAIR PROCEDURE: 1. Remove the sunroof glass using the procedures outlined in the service information on TechCONNECT 23-Body/Sunroof/Glass Panel/Glass/Removal. 2. Gather excess grease from accessible areas the mechanism or guides with a small brush or other suitable device, (Fig. 1). 23-038-05 -2-

Fig. 1 EXCESS GREASE AREAS

1 - OBTAIN GREASE FROM THESE AREAS

3. Apply the grease to the left slide surfaces on all sides of the part, in the areas identified, (Fig. 2). There are 4 slide surfaces on each side of the sunroof. -3- 23-038-05

Fig. 2 GREASE APPLICATION

1 - APPLY GREASE TO THESE 4 SURFACES

4. Repeat steps 2 and 3 for the right side sunroof slide. 5. Install the sunroof glass using the procedures outlined in the service information on TechCONNECT 23-Body/Sunroof/Glass Panel/Glass/Installation. 6. Cycle the sunroof to verify that squeak is eliminated. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation Description Amount No: 23-30-56-92 Grease Sunroof Assembly Mechanisms 0.3 Hrs.

FAILURE CODE:

68 Noisy NUMBER: 21-014-05

GROUP: Transmission

DATE: August 23, 2005

THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.

THE FLASH FILE WILL BE AVAILABLE ON THE NEXT StarSCAN® UPDATE CD RECEIVED AFTER CD 6.02.

SUBJECT: FLASH: Clicking Sound From Rear of Vehicle After Accelerating From A Stop

OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software.

MODELS:

2005 - 2006 (LX) 300/Magnum

NOTE: This bulletin applies to 2006 vehicles equipped with a 3.5L engine (sales code EGG) and a 42RLE transmission (sales code DG6) built on or before July 29, 2005 (MDH 0729XX) and 2005 vehicles equipped with a 2.7L or 3.5L engine (sales code EER or EGG) and a 42RLE transmission (sales code DG6).

SYMPTOM/CONDITION: The new PCM software corrects a customer complaint of a click sound, coming from the rear of the vehicle, immediately after accelerating the vehicle from a stop. This sound may be verified by driving the vehicle and allowing the transmission to shift into 4th gear then allowing the vehicle to coastdown to a stop, without tipping into the accelerator pedal before the complete stop. The sound will be heard immediately after launching the vehicle and will seem to be coming from the rear of the vehicle.

DIAGNOSIS: Using a Scan Tool (StarSCAN) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine and transmission systems are functioning as designed. If DTCs are present, record them on the repair order and repair as necessary before proceeding further with this service bulletin.

If the vehicle operator experiences the Symptom/Condition perform the Repair Procedure. 21-014-05 -2-

NOTE: There are two methods to download flash files to StarSCAN. The first method (preferred) is to download the flash files to the StarSCAN from the internet. The second method is to download the flash files from the StarSCAN Software Update CD.

PARTS REQUIRED:

Qty. Part No. Description 1 04275086AB Label, Authorized Modification

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NPN Battery Charger CH9401 StarSCAN® Tool CH9404 StarSCAN® Vehicle Cable CH9409 StarSCAN® Documentation Kit CH9410 StarSCAN® Ethernet Cable, 12 ft. CH9412 StarSCAN® Software Update Device Kit TechCONNECT PC or equivalent Latest StarSCAN® Software Update CD

REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN® must be at version 5.02 or higher before the "Using The Internet To Retrieve The Flash File" repair procedure can be performed.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 2. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN® and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle. 4. Power ON the StarSCAN®. 5. Retrieve the old ECU part number. Using the StarSCAN® at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the appropriate ECU in the list of modules. -3- 21-014-05

c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference. 6. Download the flash file from the internet to the StarSCAN®. Using the StarSCAN® at the “ECU Overview” screen: a. Select “More Options” b. Select “ECU Flash”. c. Select “Browse for New File”. Follow the on screen instructions. d. Select “Download to Scantool”. e. Select “Close” after the download is complete, then select “Back”. f. Highlight the listed calibration. g. Select “Update Controller”. h. When the update is complete, select “OK”. NOTE: Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the “Home” screen select “System View”. Then select “All DTCs”. Press “Clear All Stored DTCs” if there are any DTCs shown on the list.

NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 7. Type the necessary information on the “Authorized Modification Label” p/n 04275086AB and attach near the VECI label (Fig. 1).

Fig. 1 AUTHORIZED MODIFICATION LABEL

1 - POWERTRAIN CONTROL MODULE P/N (INSERT P/N) USED 2 - CHANGE AUTHORITY: TSB XX-XXX-XX 3 - DEALER CODE: XXXXX 4 - DATE: XX-XX-XX

REPAIR PROCEDURE - USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: Before flashing this module, make sure the StarSCAN® is operating at 5.02 or later.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 21-014-05 -4-

NOTE: For detailed information on the operation of the StarSCAN®, refer to the Quick Reference documentation provided in the StarSCAN® documentation kit. In addition, more recent information may also be available at the www.dcctools.com website. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help. 1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 2. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle. 3. Power ON the StarSCAN®. 4. Retrieve the old ECU part number. Using the StarSCAN® at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the appropriate ECU in the list of modules. c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference. 5. Insert the StarSCAN® Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN® Software Update CD will start automatically. a. Select “Download Controller Flash”. b. Follow the on screen instructions. 6. At the “Select the method for looking up controller flash updates.” screen: a. If the old “Part Number” was recorded in Step #4, proceed to Step #7. b. If the old “Part Number” is not known, proceed to Step #8. 7. Select “Enter part number”. a. Follow the on screen instructions. Enter the “Part Number” recorded in Step #4 when prompted to do so. b. When completed, proceed to Step #9. 8. Select “Enter YME Information”. a. Follow the on screen instructions. Select “Next” after each step. Select “Finish” after completing the last step. b. When completed, proceed to Step #9. 9. Using the mouse highlight the appropriate “Calibration”. a. Follow the on screen instructions. 10. With the StarSCAN® powered OFF, connect the USB Key and Gender Changer to the StarSCAN® USB port (Fig. 2). -5- 21-014-05

Fig. 2 USB KEY, GENDER CHANGER, AND StarSCAN TOOL

1 - StarSCAN™ TOOL 2 - GENDER CHANGER 3 - USB KEY

11. Connect the StarSCAN® to the vehicle (if not already connected). 12. Power ON the StarSCAN®. 13. Reprogram the ECU by downloading the file from the USB key to the StarSCAN®. Using the StarSCAN® at the “Home” screen: a. Select “Flash Download”. b. Select "Use USB device” and follow the on screen instructions. c. At the “Flash File List” screen, highlight the appropriate ECU “Calibration”. d. Select “Download to Scantool”. e. Select “Close” after the download is complete, then select “Back”. f. Highlight the listed calibration. g. Select “Update Controller”. h. When the update is complete, select “OK”. NOTE: Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the “Home” screen select “System View”. Then select “All DTCs”. Press “Clear All Stored DTCs” if there are any DTCs shown on the list.

NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 21-014-05 -6-

14. Type the necessary information on the “Authorized Modification Label” p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-19-62-92 Reprogram Powertrain Control Module 0.8 Hrs.

FAILURE CODE:

15 Calibration NUMBER: 23-028-05 REV. A

GROUP: Body

DATE: August 27, 2005

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-05, DATED MAY 5, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISIONS TO THE DIAGNOSIS.

THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.

THE FLASH FILE WILL BE AVAILABLE ON THE NEXT StarSCAN® UPDATE CD RECEIVED AFTER CD 6.02.

SUBJECT: Rear Of Sunroof Glass Is Not Flush To Roof

OVERVIEW: This bulletin involves flash reprogramming the sunroof motor and possibly replacing the sunroof drain channel.

MODELS:

2005 (LX) 300/Magnum

NOTE: This bulletin applies to vehicles built prior to September 1, 2004 (MDH 0901XX) and equipped with a Sunroof (sales code GWA).

SYMPTOM/CONDITION: Sunroof does not fully close (fit flush to roof) and/or fully vent and/or is noisy at the end of full open travel.

DIAGNOSIS: 1. Verify the rear of the sunroof glass to roof flushness concern. 2. **UNCALIBRATE THE SUNROOF. a. Insure the battery is at least 12 Volts. b. Place the ignition switch in RUN position. c. Locate the sunroof fuse (Fuse 44 in the Power Distribution Center located in the trunk). d. While the sunroof is still in motion, have an assistant remove the sunroof fuse. e. Reinstall the sunroof fuse. 23-028-05 REV. A -2-

3. RECALIBRATE THE SUNROOF a. Press and hold the sunroof vent switch until it stops at the full vent position. b. Verify sunroof operation by opening, closing, and venting the sunroof. c. If the uncalibrate/recalibrate procedure corrected the sunroof glass to roof fit, perform the Repair Procedure. 4. If the uncalibrate/recalibrate procedure did not eliminate the sunroof glass to roof fit, use the procedures outlined in TechCONNECT® BODY/SUNROOF/GLASS PANEL/ADJUSTMENTS to adjust the glass panel. If the sunroof glass is now flush, perform the Repair Procedure.** PARTS REQUIRED:

Qty. Part No. Description AR (1) 05137559AD Drain Channel

NOTE: There are two methods to download flash files to StarSCAN®. The first method (preferred) is to download the flash files to the StarSCAN® from the internet. The second method is to download the flash files from the latest StarSCAN® Software Update CD.

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NOTE: Make sure the StarSCAN® is configured to the dealership's network before proceeding. -3- 23-028-05 REV. A

NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN® and the dealer's network drop (optional). 2. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle. 3. Power ON the StarSCAN®. 4. Retrieve the old Sunroof Motor (SUNR) part number. Using the StarSCAN® at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight SUNR in the list of modules. c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference. 5. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN® and the dealer's network drop (if not already connected). 6. Download the flash file from the internet to the StarSCAN®. Using the StarSCAN® at the “Home” screen: a. Select “Flash Download” b. Select “Use connected vehicle” (StarSCAN® must be connected to the vehicle) or “Enter information manually” (connection to the vehicle is not necessary). Press the “Next” button and follow the on screen instructions. c. Select the appropriate calibration. d. Select “Download to Scantool”. e. Select “Close” after the download is complete. 7. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle (if not already connected). 8. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 9. Download the file from StarSCAN® to the vehicle. Using StarSCAN® at the “Home” screen: a. Select “ECU View”. b. Browse the list of ECUs using the scroll arrows. Highlight the SUNR. c. Select “More Options”. d. Select “ECU Flash”. e. Highlight the appropriate SUNR “Calibration” from the list. f. Select “Update Controller”. g. When update is completed, select “OK”. NOTE: Due to the SUNR programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the “Home” screen select “System View”. Then select “All DTCs”. Press “Clear All Stored DTCs” if there are any DTCs shown on the list. 10. With the sunroof in the full open vent position, inspect the outboard attachments of the sunroof drain channel for breakage. If the drain channel is broken use the procedures outlined in TechCONNECT® BODY/SUNROOF/WATER CHANNEL to replace the drain channel, p/n 05137559AC. 11. Insure the battery is at least 12 Volts. 12. Place the ignition switch in RUN position. 13. Close all of the doors. 14. Press and release the vent switch (sunroof should move to vent position). 23-028-05 REV. A -4-

15. Once the sunroof has stopped motion at the vent position, press and hold the vent switch for at least 5 seconds to recalibrate the sunroof position. 16. If the sunroof did not reach the full vent open position, press and hold the vent switch until that position is reach then release the vent switch and repeat step 5. 17. Cycle the sunroof from the full vent open position to the full slide open position and back to the full vent open position at least 7 complete times. The sunroof is now in customer mode with the obstacle detection thresholds updated. REPAIR PROCEDURE - USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: Before flashing this module, make sure the StarSCAN® is operating at 5.02 or later. The flash file will be available on the NEXT StarSCAN® update CD received AFTER CD 5.04.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

Fig. 1 USB KEY AND TechCONNECT PC 5. Insert the StarSCAN® Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN® Software Update CD will start automatically. a. Select “Controller Flash”. b. Follow the on screen instructions. 6. At the “Select the type of information you wish to enter.” screen: a. If the old “Part Number” was recorded in Step #3, proceed to Step #7. b. If the old “Part Number” is not known, proceed to Step #8. 7. Select “Enter part number”. a. Follow the on screen instructions. Enter the “Part Number” (use capital letters) recorded in Step #3 when prompted to do so. Follow the on screen instructions. Select “Next” after each step . Select “Finish” after completing the last step. b. Proceed to Step #9. 8. Select “Enter YME Information”. a. Follow the on screen instructions. Select “Next” after each step. Select “Finish” after completing the last step. b. Proceed to Step #9. 9. Using the mouse highlight the appropriate “Calibration”. a. Select “Save to USB”. b. Follow the on screen instructions. Select “Next” after each step . Select “Finish” after completing the last step. 10. With the StarSCAN® powered OFF, connect the USB Key and Gender Changer to the StarSCAN® USB port, (Fig. 2). 23-028-05 REV. A -6-

Fig. 2 USB KEY, GENDER CHANGER, AND StarSCAN® TOOL 11. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 12. Connect the StarSCAN® to the vehicle (if not already connected). 13. Power ON the StarSCAN®. 14. Download the file from the USB key to the StarSCAN®. Using the StarSCAN® at the “Home” screen: a. Select “Flash Download”. b. Select “Use USB device”. c. Follow the on screen instructions. Select “Next” after each step . Select “Finish” after completing the last step. d. At the “Flash File List” screen, highlight the SUNR “Calibration”. e. Select “Download to Scantool”. f. When the download is complete, select “Close”. 15. Download the file from the StarSCAN® to the vehicle. Using the StarSCAN® at the “Home” screen: a. Select “ECU View”. b. Browse the list of ECUs using the scroll arrows. Highlight the SUNR. c. Select “More Options”. d. Select “ECU Flash”. e. Highlight the SUNR “Calibration” from the list. f. Select “Update Controller”. g. When update is completed, select “OK”. NOTE: Due to the SUNR programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the “Home” screen select “System View”. Then select “All DTCs”. Press “Clear All Stored DTCs” if there are any DTCs shown on the list. -7- 23-028-05 REV. A

16. With the sunroof in the full open vent position, inspect the outboard attachments of the sunroof drain channel for breakage. If the drain channel is broken use the procedures outlined in TechCONNECT® BODY/SUNROOF/WATER CHANNEL to replace the drain channel, p/n 05137559AC. 17. Insure the battery is at least 12 Volts. 18. Place the ignition switch in RUN position. 19. Close all of the doors. 20. Press and release the vent switch (sunroof should move to vent position). 21. Once the sunroof has stopped motion at the vent position, press and hold the vent switch for at least 5 seconds to recalibrate the sunroof position. 22. If the sunroof did not reach the full vent open position, press and hold the vent switch until that position is reach then release the vent switch and repeat step 5. 23. Cycle the sunroof from the full vent open position to the full slide open position and back to the full vent open position at least 7 complete times. The sunroof is now in customer mode with the obstacle detection thresholds updated. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-52-46-92 Flash Sunroof Motor 0.4 Hrs. 23-30-62-90 Replace Sunroof Drain Channel 0.3 Hrs.

FAILURE CODE:

FM Flash Module 11 Broken or Cracked NUMBER: 23-040-05

GROUP: Body

DATE: August 30, 2005

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-021-04, DATED JUNE 8, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL YEAR MODEL REVISION TO THE REPAIR PROCEDURE.

SUBJECT: Gap Between Carpet And Front Door Scuff Plate

OVERVIEW: This bulletin involves drilling holes and installing push pins.

MODELS:

2005 - **2006 (LX) 300/Charger/Magnum**

SYMPTOM/CONDITION: The carpet is ripped or torn at the attaching push pin. The carpet is no longer held in place by the push pin.

DIAGNOSIS: If the edge of the floor carpet is exposed below the front door scuff plate, perform the Repair Procedure

PARTS REQUIRED:

Qty. Part No. Description AR (4) 06505411AA Pin, Push **AR (1) 82300508 Inhibitor, Corrosion (will service numerous vehicles)**

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NPN Drill Motor NPN 6 mm (15/64 in.) Drill Bit

REPAIR PROCEDURE: 1. Remove the front cowl side trim extension. 2. Remove the front cowl side trim and scuff plate assembly. 3. Position the weatherstrip out of the way. 4. Remove the affected push pin. 23-040-05 -2-

5. Mark two locations for drilling, one at least 12 mm (1/2 in.) forward of and one at least 12 mm (1/2 in.) rearward of the original push pin. Ensure the drilled holes are also at least 12 mm (1/2 in.) from any carpet edge and the push pin heads will be still hidden by the scuff plate, (Fig. 1).

Fig. 1 PUSH PIN LOCATIONS

1 - ORIGINAL PUSH PIN LOCATION 2 - NEW PUSH PIN LOCATIONS

6. Drill two 6 mm (15/64 in.) holes through the carpet and the sheet metal at the marked locations. 7. **Apply MOPAR Corrosion Inhibitor, p/n 82300508, or equivalent to the holes drilled in the sheet metal.** 8. Install push pins, p/n 06505411AA, through the drilled holes in the carpet and sheet metal to hold the carpet in place. 9. Install the front cowl side trim and scuff plate assembly. 10. Install the front cowl side trim extension. 11. Vacuum/remove any residue created during drilling. 12. Return the weatherstrip to its original position. 13. If necessary, repeat steps 1 through 11 for the other side of the vehicle. -3- 23-040-05

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-21-15-90 Relocate Carpet Push Pins 0.2 Hrs.

FAILURE CODE:

X2 Split, Cut or Torn NUMBER: 23-042-05

GROUP: Body

DATE: September 9, 2005

THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL OCTOBER 17, 2005.

SUBJECT: Liftgate Spoiler Outer Seal Delamination

OVERVIEW: This bulletin involves removing the old seal and installing revised seals.

MODELS:

2005 - 2006 (LX) Magnum

SYMPTOM/CONDITION: The surround seal on the liftgate spoiler is loose and over flush to the body and spoiler.

DIAGNOSIS: Visually inspect the liftgate spoiler seal for adhesion to the spoiler, if the seal is loose perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description 1 05191042AA Kit, Liftgate Spoiler Seal Kit includes: 2 - Foam Blocks 3 - Square Seals for ‘T’ Studs 4 - White ‘W’ Based Clips AR (1) 82300234 Sealer, RTV Silicone AR NPN Isopropyl Alcohol

REPAIR PROCEDURE: 1. Use the procedures outlined on TechCONNECT 23-Body/Exterior/Spoiler to remove the liftgate spoiler from the vehicle. 2. Set spoiler upside down on a surface that will not scratch or mar the painted surface. 3. Remove the surround seal from the part, (Fig. 1). 23-042-05 -2-

Fig. 1 LIFTGATE SPOILER SEALS (DRIVERS SIDE SHOWN)

1 - REMOVE SURROUND SEAL 2 - INSTALL SEAL AT STUD (3) 3 - REPLACE WHITE CLIP(S) AS NECESSARY AND INSTALL SEALS (4) 4 - INSTALL FOAM BLOCK (2)

4. Use adhesive remover (Isopropyl Alcohol) to remove excessive residue on the spoiler, concentrate on the corners where the foam blocks are installed, (Fig. 1) 5. Remove all fastener seals from part (remove any white clips that may have broken during removal. 6. Install new white clips, as required, and/or replace all fastener seals 7. Seal wire harness into the wiring grommet using RTV sealer, p/n 82300234, (Fig. 2) -3- 23-042-05

Fig. 2 SEAL HARNESS GROMMET

1 - SEAL WIRING TO GROMMET WITH RTV

8. Use the procedures outlined on TechCONNECT 23-Body/Exterior/Spoiler to install the liftgate spoiler to the vehicle. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-02-06-93 Install Liftgate Spoiler Seal Kit 0.4 Hrs.

FAILURE CODE:

81 Poor Fit NUMBER: 23-043-05

GROUP: Body

DATE: September 21, 2005

THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL OCTOBER 05, 2005.

SUBJECT: Headliner Fit At Backlight

OVERVIEW: This bulletin involves replacing hook and loop fasteners and if necessary a magnet at the rear of the headliner.

MODELS:

2005 - 2006 (LX) 300/Charger

SYMPTOM/CONDITION: Headliner sags at rear adjacent to backlight.

DIAGNOSIS: If a vehicle operator has a concern with the headliner sagging or hanging down in rear, or if visual inspection shows obvious sag, inspect the rear headliner attachments. Fit/finish attachments are located near the rear edge of the headliner, approximately 5 inches forward of headliner rear edge. The Charger rear edge is secured with 2 hook & loop patches and one center magnet. The magnet housing may crack at the snap-tab fingers to magnet due to embrittlement of the base polycarbonate resin. The 300 rear edge is secured with a plastic cross-car locator/attachment above the left rear passenger and with a hook & loop fastener above the right rear passenger. If any one of these attachments fail, the headliner rear trim edge may sag and become flimsy to the touch. Gently grab and lower the rear trim edge and feel with your fingers for the respective left, center or right attachments for obvious issues. If any headliner attachment failure is discovered, Perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description AR (2) 05189934AA Package, Fastener, Hook & Loop and Adhesion Promoter AR (1) 05191198AA Package, Magnet & Mylar, Charger 23-043-05 -2-

REPAIR PROCEDURE: 1. Fold the rear seat backs down if the vehicle is so equipped. NOTE: Do not pull the headliner down more than necessary to maintain separated attachments. Doing so may crease, crack, or otherwise damage headliner.

Fig. 1 300 HEADLINER ATTACHMENTS

1 - ORIGINAL HOOK & LOOP LOCATION 2 - PARK ASSIST DISPLAY (IF EQUIPPED) 3 - CROSS-CAR LOCATOR 4 - REPAIR HOOK & LOOP LOCATION IF CROSS-CAR LOCATOR IS BROKEN -3- 23-043-05

Fig. 2 CHARGER HEADLINER ATTACHMENTS

1 - MAGNET LOCATION 2 - ORIGINAL HOOK & LOOP LOCATIONS

2. Carefully separate the headliner from roof at both the left rear and right rear areas - 300's are equipped with plastic snap-tab at left rear and hook & loop patch at right rear, (Fig. 1); Charger's are equipped with 2 hook & loop fasteners and a magnet in the center, (Fig. 2). 3. If the vehicle is a 300 inspect the top side of the headliner for a broken 2 way clip. Remove and discard any loose or broken portions of the clip. If the 2 way clip is broken, it will be replaced by a hook and loop fastener placed on the black foam next to the clip location. 4. Remove all white square patch(es) of hook and loop fastener, located on black foam on the backside of the headliner, and their mating halves from the roof. 5. Using a putty knife or similar tool, gently scrape any hardened adhesive residue from black foam and from roof of vehicle at outboard attachment points as needed. 6. Apply 3M Automotive Adhesion Promoter 4298 to the areas where the new hook & loop fasteners will be placed on the black foam to prepare surface for hook and loop fastener(s). 7. Remove film covering the pressure sensitive adhesive from one side of the new hook and loop, p/n 05189934AA, and apply the hook & loop fastener(s) directly to areas of the black foam as shown in (Fig. 1) and (Fig. 3) and apply 15 pounds of pressure for 5 seconds to ensure good adhesion. 23-043-05 -4-

Fig. 3 REPLACEMENT HOOK AND LOOP POSITION

1 - REPLACEMENT HOOK & LOOP

8. If the vehicle is a 300 skip to step 14. If the vehicle is a Charger, inspect the magnet, a small round metal disc in the middle of the white foam, on the headliner. If the magnet is missing from white foam, it should still be attached to roof steel. 9. Leave the magnet/base assembly in place if it is still firmly attached to the headliner and skip to step 14. If the magnet has separated from its base, remove and discard it. 10. If the magnet/base assembly was broken, remove all plastic that remains in the hole of the white foam by cutting a 45mm x 45mm (1 3/4 in. x 1 3/4 in.) square (centered about the magnet) through the full thickness of the foam as shown in (Fig. 4). Removing the foam square may require breaking a glue bond between it and headliner. Save the foam square for installation later. -5- 23-043-05

Fig. 4 WHITE FOAM REMOVAL

1 - CUT OUT 45MM X 45MM (1 3/4 IN. X 1 3/4 IN.) SQUARE IN WHITE FOAM 2 - CENTER OF MAGNET AND RETAINING FINGERS

11. Shift magnet base to one edge of opening as shown in (Fig. 5) so magnet base can be removed. Shifting magnet to one side may require breaking a glue bond between magnet base, white foam, and headliner, or some combination thereof.

Fig. 5 MAGNET BASE REMOVAL/INSTALLATION

1 - MAGNET/BASE ASSEMBLY SHIFTED TO ONE SIDE OF CUTOUT

12. Before installing new magnet/base assembly, p/n 05191198AA, remove the backing from mylar patch to expose the adhesive and center the mylar on magnet disc. Press all four corners of the mylar down to the black plastic post of the base. 13. Install the new magnet/base assembly and replace the square section of white foam. No glue is required. 23-043-05 -6-

14. Remove the remaining film covering the pressure sensitive adhesive from the hook & loop fasteners. 15. Cover the palm of your hand with a clean lint free cloth or glove then push the headliner up to contact the roof. Apply 15 pounds pressure for 5 seconds at each fastener location. 16. Return the rear seat backs to their upright and latched position. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-20-45-94 Secure Rear of Headliner 0.2 Hrs.

FAILURE CODE:

ZZ Service Action NUMBER: 08-013-05 REV. A

GROUP: Electrical

DATE: October 1, 2005

THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-013-05, DATED FEBRUARY 16, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED DISCUSSION.

SUBJECT: UConnect Hands Free Phone Inoperative

OVERVIEW: This bulletin directs the technician to the appropriate diagnostic path by vehicle line.

MODELS:

2005 - 2006 (CS) Pacifica 2005 - 2006 (DR/DH) Ram Truck/Ram Truck HD 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2005 - 2006 (LX) 300/Magnum/Charger 2005 - 2006 (ND) Dakota 2005 - 2006 (PT) PT Cruiser 2005 - 2006 (RS) Town & Country/Caravan 2005 - 2006 (WK) Grand Cherokee

NOTE: This bulletin applies to vehicles equipped with UConnect™ Hands Free Communications (sales code RSP).

**DISCUSSION: NOTE: Verify that service bulletin 08-049-05 has been performed (where applicable) before proceeding further with this bulletin.

NOTE: On CS vehicles with a 05091004AL UConnect Hands Free Module, the scan tool may display a $21 - Bus Busy DTC. This DTC is erroneous and should be ignored. If the UConnect Hands Free Phone is inoperative and if there are no DTC's, perform the existing diagnostic procedure available in TechCONNECT as described in the table below. 08-013-05 REV. A -2-

Model Path to Diagnostic Information in TechCONNECT 2005 - 2006 CS Diagnostics, Telecommunication, Voice Recognition/Phone Switch Circuit Short to Voltage 2005 - 2006 DR/DH Service Info, 8 - Electrical, Navigation/Telecommunication, Diagnosis & Testing, Voice Recognition/Phone Switch Circuit Short to Voltage 2005 - 2006 HB Service Info, 8 - Electrical, Navigation/Telecommunication, Diagnosis & Testing, Voice Recognition/Phone Switch Input Circuit High 2005 KJ Diagnostics, Telecommunication, Voice Recognition/Phone Switch Circuit Short to Voltage 2006 KJ Service Info, 8 - Electrical, Navigation/Telecommunication, Diagnosis & Testing, Voice Recognition/Phone Switch Circuit Short to Voltage 2005 - 2006 LX Service Info, 8 - Electrical, Navigation/Telecommunication, Diagnosis & Testing, Voice Recognition/Phone Switch Input Circuit High 2005 - 2006 ND Service Info, 8 - Electrical, Navigation/Telecommunication, Diagnosis & Testing, Voice Recognition/Phone Switch Input Circuit High 2005 PT Diagnostics, Telecommunication, Voice Recognition/Phone Switch Circuit Short to Voltage 2006 PT Service Info, 8 - Electrical, Navigation/Telecommunication, Diagnosis & Testing, Voice Recognition/Phone Switch Input Circuit High 2005 - 2006 RS Diagnostics, Telecommunication, Voice Recognition/Phone Switch Circuit Short to Voltage 2005 - 2006 WK Service Info, 8 - Electrical, Navigation/Telecommunication, Diagnosis & Testing, Voice Recognition/Phone Switch Input Circuit High

POLICY: Information Only. NUMBER: 08-055-05

GROUP: Electrical

DATE: October 19, 2005

THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER CONNECTOR PARTS OR PERFORM ANY ACTIONS RELATED TO CS, KJ, LH , PT, RS, WK and XK VEHICLES UNTIL NOVEMBER 28, 2005.

SUBJECT: Satellite Radio Intermittent Static

OVERVIEW: This bulletin involves replacing the Satellite Digital Audio Receiver (SDAR).

MODELS:

2005 (CS) Pacifica 2005 (DR) Ram Truck 2004 - 2005 (HB) Durango 2005 (JR) Sebring Sedan/Stratus Sedan 2005 (KJ) Liberty 2004 (LH) 300M 2005 (LX) 300/Magnum 2005 (ND) Dakota 2003 - 2005 (PT) Chrysler PT Cruiser 2005 (RS) Town & Country/Caravan 2005 (WK) Grand Cherokee

NOTE: This bulletin applies to vehicles equipped with a satellite radio receiver (sales code RSA or RSB) or dealer installed MOPAR satellite radio receiver part numbers 05064002A* and 05064020A*.

SYMPTOM/CONDITION: The vehicle operator describes extreme static over the satellite radio audio (only when in the satellite mode) to the point of almost completely covering the intended audio. The static occurs at vehicle start-up, or the first time the radio is put into the satellite mode on a key cycle. The static will last the entire key cycle. This issue is completely intermittent, and in the next key cycle, operation may go back to normal. 08-055-05 -2-

DIAGNOSIS: Due to the intermittent nature of the condition, demonstration of the issue is difficult. If the vehicle operator description is similar to the Symptom/Condition explained above, perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description AR (1) 05064074AC SDAR Module (Sales Code RSB and KJ) AR (1) 05064075AC SDAR Module (Sales Code RSA except KJ) AR (1) 05189968AA Connector Housing, CS, KJ, LH , PT, RS, WK and XK AR (1) 05189969AA Connector Lock, CS, KJ, LH , PT, RS, WK and XK AR NPN Tape, Electrical

REPAIR PROCEDURE: 1. Use the procedures outlined in TechCONNECT 8-Electrical/Audio/Antenna Module/Removal/Receiver-Satellite to remove the SDAR and separate it from it mounting bracket. NOTE: In the near future, the TechCONNECT path to the SDAR procedures will change. Receiver-Satellite will have its own heading under Audio. 2. CS, KJ, LH , PT, RS, WK and XK vehicles go to step 4. DR, HB, JR and ND go step 3. LX vehicles require the SDAR mounting bracket to be modified as follows: a. Place a drop of paint or correction fluid (white out) on the top of each of the (3) SDAR mounting studs of the replacement SDAR. b. Position the SDAR mounting studs against the SDAR mounting bracket so the wiring connectors of the SDAR are facing toward the front of the vehicle when the SDAR/bracket assembly is mounted in the vehicle and the mounting stud opposite the SDAR wiring connectors is 3/16 in. inboard of the crease in the SDAR mounting bracket, (Fig. 1) c. Drill 5/16 in. (8mm) holes in the SDAR mounting bracket at the three locations marked by the paint. -3- 08-055-05

Fig. 1 REVISED SDAR MOUNTING HOLE LOCATIONS

1 - DRILL 5/16 IN. (8MM) HOLES AT THE LOCATIONS MARKED BY THE SDAR STUDS 2 - FRONT OF VEHICLE WHEN INSTALLED

3. For DR, HB, JR, LX and ND vehicles, remove the left locating key (when viewed with the SDAR mounting studs facing you) on the tan connector of the SDAR. The key can be shaved off using a utility knife or similar device, (Fig. 2). Continue with step 8.

Fig. 2 TAN SDAR CONNECTOR

1 - REMOVE THE LEFT LOCATING KEY 2 - SDAR MOUNTING STUD

4. Slide the red lock on the blue connector housing of the antenna harness to its unlock position. 5. Use a small screwdriver to pull up on the tab uncovered by the lock. 6. Slide the housing off the connector terminal. 08-055-05 -4-

7. Replace the removed blue connector housing and red lock with the “tan” colored housing, p/n 05189968AA and white lock p/n 05189969AA. 8. Record the Electronic Serial Number (ESN) of the removed and replacement SDAR's, (Fig. 3).

Fig. 3 SDAR ESN LOCATION

1 - ESN

9. Install the appropriate replacement SDAR to the mounting bracket, tighten the fasteners to 5-7 Nm (18-25 in. lbs.). 10. Tape back the original white connector to the antenna harness to prevent rattling. This white connector will NOT be used with the new SDAR. 11. Connect the antenna connector to the tan connector on the new SDAR. Insert the 12-way connector to the module. NOTE: Be sure to route the SDAR wiring so that is has no bends with a radius of less than 1 in. and is free of contact with the mounting bracket, tape, foam or convolute may be used to isolate the wiring if necessary. 12. Install the SDAR/bracket assembly into the vehicle, tighten the fasteners to 5-7 Nm (18-25 in. lbs.). NOTE: When activating the new SDAR, the vehicle must be in open sky with no obstructions over the antenna. 13. The new SDAR MUST be activated to be able to receive satellite programs. The customer’s Sirrus account number or phone number, customer's complete address, and the ESN of the original and new SDAR are required. The ESN is on the SDAR itself, (Fig. 3), or can be retrieved through the radio. With both ESN's, the customer’s Sirrus account number or phone number, customer's complete address in hand, call Sirrus at 888-539-7474, (to skip the recordings, press 1 then 3 and 3 again). Explain the transfer that needs to take place when the Sirrus agent answers. -5- 08-055-05

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation Description Amount No: 08-20-04-90 Replace Satellite Radio Receiver 2004-2005 (CS) 0.3 Hrs. 2005 (DR) 0.3 Hrs. 2004-2005 (HB) 0.5 Hrs. 2005 (JR41) A/T 2004-2005 (KJ) 0.6 Hrs. 2003-2004 (LH) 300M A/T 2005 (LX) 300 0.5 Hrs. 2005 (ND) 0.4 Hrs. 2003-2005 (PT44) 0.5 Hrs. 2004-2005 (RS) 0.5 Hrs. 2005 (WK) 0.6 Hrs. 08-20-04-91 2005 (LX) Magnum 0.8 Hrs.

FAILURE CODE:

ZZ Service Action NUMBER: 19-008-05 REV. A

GROUP: Steering

DATE: November 2, 2005

SUBJECT: Revised Power Steering System Bleeding Procedures

MODELS:

NOTE: This bulletin does NOT apply to DR SRT10 vehicles. 19-008-05 REV. A -2-

PARTS REQUIRED:

SPECIAL TOOLS/EQUIPMENT REQUIRED:

9688 Adapter, P/S Cap C-4207-A Vacuum Pump, Hand (or equivalent)

POWER STEERING SYSTEM BLEEDING PROCEDURE: WARNING:The fluid level should be checked with engine off to prevent injury from moving components.

CAUTION: If the air is not purged from the power steering system correctly, pump failure could result.

NOTE: If the power steering reservoir cap does not have a dipstick, there will be a sight window on the side of the reservoir for checking fluid level.

Fig. 1 VACUUM PUMP

1 - HAND VACUUM PUMP C-4207-A 2 - CLEAR HOSE FROM ADAPTER TO RESERVOIR 3 - SPECIAL TOOL - 9688 4 - VACUUM PUMP RESERVOIR

CAUTION: Failure to properly connect the vacuum pump reservoir may allow power steering fluid to be sucked into the vacuum pump.

CAUTION: Do not run the engine while vacuum is applied to the power steering system.

GROUP: Body

DATE: November 4, 2005

THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL NOVEMBER 21, 2005.

SUBJECT: Rear Fascia To Body Side/Tail Lamp Fit

OVERVIEW: This bulletin involves adding two nut and bolt attachments to the rear fascia.

MODELS:

2005 - 2006 (LX/LE) 300/Charger

SYMPTOM/CONDITION: The gap between rear fascia and body side/tail lamp is more than 2mm (5/64 in).

DIAGNOSIS: If gap between rear fascia and body side/tail lamp measures more than 2mm (5/64 in), (Fig. 1), perform the Repair Procedure. 23-052-05 -2-

Fig. 1 FASCIA TO BODE SIDE/TAIL LAMP GAP

1 - GAP SHOWN GRATER THAN 2MM (5/64 IN.)

PARTS REQUIRED:

Qty. Part No. Description 2 06505546AA Bolt 2 06104726AB Nut AR 04318031 Adhesive, MOPAR Lock & Seal Adhesive (One tube will service 100's of vehicles.

REPAIR PROCEDURE: 1. Open the trunk lid. 2. Pull the trunk carpet away from one side of the trunk. 3. Remove the push pin (located above and rearward of the body exhauster) attaching the fascia to the body side, by pushing out the center (white) pin with a punch, then push (black) body through hole, (Fig. 2). Pin and body will fall to the ground under the rear fascia. -3- 23-052-05

Fig. 2 PUSH PIN LOCATION

1 - PUSH PIN 2 - EXHAUSTER RETAINER TABS

4. Apply a drop of MOPAR Lock & Seal Adhesive, p/n 04318031, to the threads of bolt, p/n 06505546AA. 5. Insert bolt, p/n 06505546AA, downward through the push pin hole. 6. Remove the body air exhauster by pushing down on the retaining tabs, and pushing the exhauster through opening. 7. Hand start nut, p/n 06104726AB, onto the bolt through the exhauster opening. 8. Tighten the nut and bolt to 11 Nm (100 in. lbs.). 9. Install the body air exhauster. 10. Return the trunk side carpet to its original position. 11. Repeat steps 2-10 for the other side repair. 12. Close the trunk lid. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 13-20-05-90 Refit Rear Fascia 0.3 Hrs.

FAILURE CODE:

ZZ Service Action NUMBER: 23-001-06

GROUP: Body

DATE: January 12, 2006

THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL JANUARY 30, 2006.

SUBJECT: Sill Cladding Replacement

OVERVIEW: This bulletin involves replacing right and left sill claddings.

MODELS:

2005 - 2006 (LX) 300/Magnum 2006 (LE) 300/300 Touring (International Markets)

NOTE: This bulletin applies to vehicles built on or prior to November 06, 2005 (MDH 1106XX).

SYMPTOM/CONDITION: Body sill cladding (right or left) has come loose from body.

DIAGNOSIS: Inspect the body sill claddings, if either sill cladding is not secure to the body, perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description AR (1) 68001659AA Package, Sill Cladding, 300 AR (1) 68001911AA Package, Sill Cladding, Magnum AR (1) 68001660AA Package, 8 - 1BA41AP1AA Clips, AP4 - Satin Jade AR (1) 68001661AA Package, 8 - 1BA41AX1AA Clips, AXR - Brilliant Black or ZMQ Deep Lava Red AR (1) 68001662AA Package, 8 - 1BA41BB1AA Clips, BB8 - Midnight Blue AR (1) 68001663AA Package, 8 - 1BA41BP1AA Clips, BPK - Magnesium AR (1) 68001664AA Package, 8 - 1BA41CY1AA Clips, CYG - Linen Gold AR (1) 68001665AA Package, 8 - 1BA41DA1AA Clips, DA4 - Silver Steel 23-001-06 -2-

Qty. Part No. Description AR (1) 68001666AA Package, 8 - 1BA41SW1AA Clips, SW1 - Stone White AR (1) 68001667AA Package, 8 - 1BA41WE1AA Clips, ARH - Inferno Red AR (1) 68001668AA Package, 8 - 1BA41WS1AA Clips, WS2 - Bright Silver AR (1) 68001669AA Package, 8 - 1BA41XWGAA Clips, XWG - Cool Vanilla AR (1) 68001725AA Package, 8 - 1BA41CD1AA CDM - Mineral Gray Metallic 4 NPN Rivet, M6.26 X 25

REPAIR PROCEDURE: 1. Use the procedures outlined in TechCONNECT 23-Body/Exterior/Body Side Cladding to remove the right and left claddings. 2. Apply the appropriate color base coat/clear coat paint to both sill claddings. Use the paint manufacturer's recommendations on application procedures. NOTE: The revised sill claddings mount up AGAINST the weld flange, they DO NOT mount under and wrap around the weld flange. 3. Install the right and left sill claddings using the appropriate color clip package from the Parts Required section above and four M6.26 X 25 rivets. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-70-57-90 Cladding, Side Sill - Replace & Refinish - Both 3.2 Hrs. Sides Material Allowance $62.49

FAILURE CODE:

ZZ Service Action NUMBER: 23-002-06

GROUP: Body

DATE: January 18, 2006

SUBJECT: Sunroof Rattle Sound

OVERVIEW: This bulletin involves applying MOPAR Stud and Bearing Mount Adhesive to and torquing the sunroof fasteners.

MODELS:

2005 - 2006 (LX) 300/Charger/Magnum 2006 (LE) 300/300 Touring (International Markets)

SYMPTOM/CONDITION: Metallic rattle sound in the area of the sunroof.

DIAGNOSIS: Rattle occurs when driving on rough roads, is a metallic sound, can be moderate to severe and typically occurs after 6000 miles are on the vehicle. The rattle can be duplicated by tapping/pounding up on the sunroof glass panel.

PARTS REQUIRED:

Qty. Part No. Description 1 04318032 Adhesive, MOPAR Stud and Bearing Mount

REPAIR PROCEDURE: 1. Inspect the four glass adjusting fasteners under the side mechanism covers. If the glass adjusting fasteners are loose, torque them to 5.5 Nm (49 in. lbs.) and retest for the rattle sound. 2. If the fasteners are secure and rattle sound is still present remove the left side A-pillar, B-pillar and C-pillar trim, grab handle assembly, sun visor and sun visor retainer. 3. Pull the left side of the headliner down to gain access to the left side sunroof module fasteners. 4. Remove one (1) of six (6) left side sunroof module fasteners. 5. Apply MOPAR Stud and Bearing Mount Adhesive, p/n 04318032, to the fastener threads. 6. Install the fastener and torque it to 8-10 Nm (70-88 in. lbs.). 7. Repeat step 4-6 for the remaining five (5) left side sunroof module fasteners. 8. Install the left side A-pillar, B-pillar and C-pillar trim, grab handle assemblies, sun visors and sun visor retainers. 23-002-06 -2-

9. Repeat steps 2-8 for the right side sunroof fasteners. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-30-56-93 Apply Adhesive and Torque Sunroof Fasteners 1.4 Hrs.

FAILURE CODE:

ZZ Service Action NUMBER: 08-014-06

GROUP: Electrical

DATE: March 16, 2006

THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-049-05 DATED SEPTEMBER 01, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED REPAIR PROCEDURES.

SUBJECT: Flash: UConnect Hands Free Module Fails To Respond Due To Module Lock Up

OVERVIEW: This bulletin involves flash reprogramming the Hands Free Module (HFM) module.

MODELS:

2006 (DR/DH/D1) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (LX) 300/Magnum/Charger 2005 - 2006 (ND) Dakota 2006 (PT) PT Cruiser 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander

NOTE: This bulletin applies to vehicles equipped with UConnect Hands Free Communications (sales code RSP) that were built prior to October 02, 2005 (MDH 1002XX).

SYMPTOM/CONDITION: The Hands Free Module (HFM) fails to operate causing the UConnect Hands Free Communications system to not respond when system activation is attempted by the customer. Further diagnosis may reveal that when the StarSCAN® scan tool is used to read Diagnostic Trouble Codes (DTC's) the tool indicates that the module is not responding. Other modules on the bus may display loss of communication with the HFM. If the Hands Free Communication system is unresponsive then the HFM may require electronic reset. 08-014-06 -2-

DIAGNOSIS: Attempt to reset (power reset) the HFM as follows: 1. With the ignition switch in the “Off” position, remove the “Ignition Off Draw” (IOD) fuse and wait 10 seconds. 2. Install the IOD fuse. 3. Turn the ignition to the “On” position (engine not running).

Fig. 1 UCONNECT HANDS FREE PHONE MIRROR SWITCHES

1 - VOICE RECOGNITION BUTTON 2 - PHONE BUTTON

4. After the module is reset, press the “Phone Button” on the rear view mirror to activate the UConnect Hands Free system and to verify proper system operation (Fig. 1). Did the UConnect Hands Free system reset and now operates properly? a. Yes >> Perform Repair Procedure. b. No >> This bulletin does not apply. Further diagnosis is required. Continue diagnosis as needed using the existing diagnostic procedures available in TechCONNECT under: Service Info, 8 - Electrical, Navigation/Telecommunication, Diagnosis & Testing. NOTE: Do NOT replace the mirror for the above condition. -3- 08-014-06

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NPN Battery Charger 9097A Special Tool, Bluetooth UConnect Flash Adapter CH9401 StarSCAN® Tool CH9404 StarSCAN® Vehicle Cable CH9409 StarSCAN® Documentation Kit CH9410 StarSCAN® Ethernet Cable, 12 ft. CH9412 StarSCAN® Software Update Device Kit TechCONNECT PC or equivalent StarSCAN® Software Update CD 6.03 or Higher

**REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: USE THE StarSCAN® TO PERFORM THIS PROCEDURE.

NOTE: The StarSCAN® diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. Make sure the StarSCAN® is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: “DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation”, or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on the www.dcctools.com website under the "Download Center".

NOTE: If this flash process is interrupted/aborted, the flash should be restarted. The HFM may take up to 20 minutes to time out of the original flash process. A power reset of the HFM, as performed above, may be required. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN® and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle data link connector (DLC). 4. Connect the 9097A, Bluetooth UConnect Flash Adapter, to the StarSCAN® . 5. Power ON the StarSCAN®. CAUTION: Be careful to select the correct file. 6. Retrieve the old HFM part number. Using the StarSCAN® at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the HFM in the list of modules. 08-014-06 -4-

c. Select “More Options” d. Select “ECU Flash”. e. Record the "Part Number", displayed on the “Flash HFM” screen, for later reference. f. Select “Browse for New File”. Follow the on screen instructions. g. Select “Download to Scantool”. h. Select “Close” after the download is complete, then select “Back”. i. Highlight the listed HFM calibration. j. Select “Update Controller”. Follow the on screen instructions. NOTE: Check your watch, “Sending Update File” may take approximately 17 minutes. Be patient. k. When the HFM update is complete, select “OK”. l. Verify that the part number changed at the top of the “Flash HFM” screen. NOTE: Due to the HFM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the “Home” screen select “System View”. Then select “All DTCs”. Press “Clear All Stored DTCs” if there are any DTCs shown on the list.

REPAIR PROCEDURE - USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: USE THE StarSCAN® TO PERFORM THIS PROCEDURE.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted. The HFM may take up to 20 minutes to time out of the original flash process. A power reset of the HFM, as performed above, may be required. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle data link connector (DLC). 3. Power ON the StarSCAN®. 4. Retrieve the old HFM part number. Using the StarSCAN® at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the HFM in the list of modules. c. Select “More Options” d. Select “ECU Flash” e. Record the "Part Number", displayed on the "HFM Flash" screen, for later reference. -5- 08-014-06

5. Insert the StarSCAN® Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN® Software Update CD will start automatically. a. Select “Download Controller Flash”. b. Follow the on screen instructions. 6. At the “Select the method for looking up controller flash updates.” screen: a. If the old HFM “Part Number” was recorded in Step #4, proceed to Step #7. b. If the old HFM “Part Number” is not known, proceed to Step #8. 7. Select “Enter part number”. a. Follow the on screen instructions. Enter the “Part Number” recorded in Step #4 when prompted to do so. b. When completed, proceed to Step #9. 8. Select “Enter YME Information”. a. Follow the on screen instructions. Select “Next” after each step. Select “Finish” after completing the last step. b. When completed, proceed to Step #9. CAUTION: Be careful to select the correct file. 9. Using the mouse highlight the appropriate HFM “Calibration”. a. Follow the on screen instructions. 10. With the StarSCAN® powered OFF, connect the USB Key and Gender Changer to the StarSCAN® USB port (Fig. 2).

Fig. 2 USB KEY, GENDER CHANGER, AND StarSCAN® TOOL

1 - StarSCAN® TOOL 2 - GENDER CHANGER 3 - USB KEY

11. Connect the StarSCAN® to the vehicle data link connector (if not already connected). 12. Power ON the StarSCAN®. 08-014-06 -6-

13. Download the new HFM calibration (file) to the StarSCAN®. a. Select “Flash Download”. b. Select "Use USB device” and follow the on screen instructions. c. At the “Flash File List” screen, highlight the appropriate ECU (HFM) “Calibration”. d. Select “Download to Scantool”. e. Select “Close” after the download is complete, then select “Back”. 14. Disconnect the USB Key and gender changer from the StarSCAN® USB port. 15. Connect the gender changer and 9097A, Bluetooth UConnect Flash Adapter, to the StarSCAN® . 16. Reprogram the vehicle HFM. Using the StarSCAN® at the “ ECU Overview” screen: a. Select “More Options” b. Select “ECU Flash”. c. Highlight the HFM calibration. d. Select “Update Controller”. Follow the on screen instructions. NOTE: Check your watch, “Sending Update File” may take approximately 17 minutes. Be patient. e. When the HFM update is complete, select “OK”. f. Verify that the part number changed at the top of the “Flash HFM” screen. NOTE: Due to the HFM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the “Home” screen select “System View”. Then select “All DTCs”. Press “Clear All Stored DTCs” if there are any DTCs shown on the list.**

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-20-34-90 Reset and Flash UConnect Hands Free Module 0.5 Hrs. (HFM)

FAILURE CODE:

FM Flash Module NUMBER: 08-015-06

GROUP: Electrical

DATE: April 1, 2006

THE StarSCAN® FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.

THE FLASH FILE WILL BE AVAILABLE ON THE NEXT StarSCAN® UPDATE CD RECEIVED AFTER CD 6.05.

SUBJECT: FLASH: Illuminated Approach, Fog Lamps and/or Rear Wiper Operation

OVERVIEW: This bulletin involves selectively erasing and reprogramming the Front Control Module (FCM) with new software.

MODELS:

2005 - 2006 (LX) 300/Charger/Magnum

SYMPTOM/CONDITION: Due to a software issue in the FCM, some vehicles may exhibit one or more of the following conditions: 1) Illuminated Approach may not function on the first Remote Keyless Entry (RKE) Unlock request. 2) Fog lamps may stay on for a period of approximately 10 minutes after exiting the vehicle if high beams were in use. 3) Rear wiper may be intermittently inoperable when Rear Defrost is also active.

DIAGNOSIS: Using a Scan Tool (StarSCAN®) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences one or more Symptom/Conditions, use the StarSCAN®, to determine the FCM part number: 1. From the Home screen, select “ECU View” 2. Touch the screen to highlight the FCM in the list of modules. 3. Select “More Options” 4. Select “ECU Flash” 5. Record the part number at the top of the screen. 08-015-06 -2-

If the FCM part number has a NIC level: AK or earlier for FCM p/n 56038742 AC or earlier for FCM p/n 05026021 and 56040698 AK or earlier for FCM p/n 04692032 and 04692028 perform the Repair Procedure. If the FCM has a later NIC this bulletin does not apply and further diagnosis is required.

NOTE: There are two methods to download flash files to StarSCAN®. The first (preferred) method is to download the flash files to the StarSCAN® from the internet. The second method is to download the flash files from the StarSCAN® Software Update CD.

SPECIAL TOOLS / EQUIPMENT REQUIRED:

REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: The StarSCAN® diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN® for your dealership's network. Make sure the StarSCAN® is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: “DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation”, or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on the www.dcctools.com website under the "Download Center".

NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN® and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle. 4. Power ON the StarSCAN®. -3- 08-015-06

5. Retrieve the old FCM part number. Using the StarSCAN® at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the FCM in the list of modules. c. Select “More Options” d. Select “ECU Flash” e. Record the part number at the top of the “Flash” screen for later reference. f. Select “Browse for New File”. Follow the on screen instructions. g. Select “Download to Scantool”. h. Select “Close” after the download is complete, then select “Back”. i. Highlight the listed calibration. j. Select “Update Controller”. Follow on screen instructions. k. When the update is complete, select “OK”. l. Verify the part number at the top of the “Flash” screen has updated to the new part number. NOTE: Due to the FCM programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the “Home” screen select “System View”. Then select “All DTCs”. Press “Clear All Stored DTCs” if there are any DTCs shown on the list.

REPAIR PROCEDURE - USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

NOTE: For detailed information on the operation of the StarSCAN® refer to either: “DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation”, or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on the www.dcctools.com website under the "Download Center". More recent information and help may also be available at the www.dcctools.com website under "Training Aids" and also under "Download Center > Frequently Asked Questions". 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle. 3. Power ON the StarSCAN®. 4. Retrieve the old FCM part number. Using the StarSCAN® at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the FCM in the list of modules. c. Select “More Options” d. Select “ECU Flash” e. Record the part number at the top of the “Flash” screen for later reference. 5. Insert the StarSCAN® Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN® Software Update CD will start automatically. Select “Download Flash Updates”. 08-015-06 -4-

6. At the “Select a method for looking up controller flash updates.” screen: a. Select “Enter part number”. Enter the “Part Number” recorded in Step #4 when prompted to do so. b. Using the mouse highlight the appropriate “Calibration”. Select “Next”. c. Follow the on screen instructions. d. When completed, proceed to Step #7. 7. With the StarSCAN® powered OFF, connect the USB Key and Gender Changer to the StarSCAN® USB port (Fig. 1).

Fig. 1 USB KEY, GENDER CHANGER, AND StarSCAN® TOOL

1 - StarSCAN® TOOL 2 - GENDER CHANGER 3 - USB KEY

8. Connect the StarSCAN® to the vehicle (if not already connected). 9. Power ON the StarSCAN®. 10. Download the flash file from the USB key to the StarSCAN®. Using the StarSCAN® at the “Home” screen: a. Select “Flash Download”, then select “Retrieve files from the USB storage device” b. Highlight the appropriate calibration. Select “Download to Scan Tool” c. When the download is complete, select “Close” and “Back”. 11. Reprogram the FCM. Using the StarSCAN® at the “Home” screen: a. Select “ECU View”. b. Select "More Options”. c. Select “ECU Flash”. d. Highlight the appropriate calibration. e. Select “Update Controller”. Follow the on screen instructions. f. When the update is complete, select “OK”. -5- 08-015-06

NOTE: Due to the FCM programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the “Home” screen select “System View”. Then select “All DTCs”. Press “Clear All Stored DTCs” if there are any DTCs shown on the list.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 18-19-08-11 Reprogram Front Control Module 0.3 Hrs.

FAILURE CODE:

ZZ Service Action NUMBER: 23-019-06

GROUP: Body

DATE: May 10, 2006

SUBJECT: Adhesive Residue From The Protective Covering On Carpeting

MODELS:

2005 - 2006 (ND) Dakota 2005 - 2006 (LX) 300/Magnum/Charger 2005 - 2006 (RS) Town & Country/Caravan/Voyager

PARTS REQUIRED:

Qty. Part No. Description AR (1) 04886330AB Super Kleen (One bottle will service 50 vehicles)

DISCUSSION: Occasionally when the protective covering is removed from the carpeting during new vehicle prep, an adhesive residue remains. Carpet replacement is not necessary as this residue is easily removed from the carpeting using Mopar® Super Kleen, p/n 04886330AB and a clean brush or cloth.

POLICY: Information Only NUMBER: 08-025-06

GROUP: Electrical

DATE: May 27, 2006

THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-032-04, DATED SEPTEMBER 22, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL YEARS, MODELS AND PARTS.

SUBJECT: Poor Radio Reception

OVERVIEW: This bulletin involves repairing the rear window defroster grid or replacing the backlight.

MODELS:

2005 - **2007** (LX) 300/Magnum/**Charger**

SYMPTOM/CONDITION: Radio reception (AM or FM) is fine until the rear window defroster is turned on.

DIAGNOSIS: 1. Start the vehicle and turn on the radio. 2. Select an FM station between 98 - 101. 3. Note the sound quality, then turn the rear window defroster on, and note the sound quality again. 4. If the sound quality degrades greatly with the defroster on, check for a broken or scratched rear window defroster grid line. NOTE: Make sure there is no aftermarket tint or treatment on the glass. 5. Pass the Remote Keyless Entry (RKE) Tester (Miller Tool No. 9001) over the individual grid lines of the backlight to determine the line or lines that are broken. A good grid line will cause little to no deflection on the tester. 6. Turn the radio and vehicle off and perform the Repair Procedure. PARTS REQUIRED:

Qty. Part No. Description AR (1) 04549275 Kit, Rear Window Defroster Repair AR (1) 04780987AI Backlight, 300 **AR (1) 05065945AD Backlight, Charger** AR (1) 05065623AE Backlight, Magnum - Sunscreen 08-025-06 -2-

Qty. Part No. Description AR (1) 05065840AE Backlight, Magnum - Solar Tint

SPECIAL TOOLS/EQUIPMENT REQUIRED:

Miller Tool No. 9001 Remote Keyless Entry Tester

REPAIR PROCEDURE: 1. If the open point of grid line is accessible, follow instructions in Defroster Repair Kit, p/n 04549275, to repair the grid. 2. If the open grid line is not accessible or the location of the break cannot be determined, replace backlight with appropriate backlight listed in the Parts Required section above using the service procedures outlined in TechCONNECT. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-91-PK-93 Repair Rear Window Defroster Grid (B) 0.3 Hrs.

FAILURE CODE:

18 Open Circuit NUMBER: 23-031-06

GROUP: Body

DATE: July 27, 2006

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-023-04, DATED JUNE 15, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES . ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL YEAR AND MODELS.

SUBJECT: Windshield Header Buzz Or Humming Sound

OVERVIEW: This bulletin involves applying sealer to the joint between windshield header molding and the roof panel.

MODELS:

2005 - **2006 (LX) 300/Charger**Magmun **2006 (LE) 300C/300C Touring (International Markets)** **2005 - 2006 (WK) Grand Cherokee** **2005 - 2006 (WH) Grand Cherokee (International Markets)**

SYMPTOM/CONDITION: In warmer weather the vehicle operator may report a buzz or humming sound from the upper front windshield area particularly at speeds above 45 mph (72 kph). Some vehicles may have been built with the upper windshield molding partially rocked forward. When air passes over top of the tail section of the molding it may vibrate creating a buzz or humming sound and is more likely to occur in warmer ambient temperatures when the molding material is more flexible.

DIAGNOSIS: If the vehicle operator describe the above Symptom/Condition, perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description 1 04467708 Sealer, Silicone Windshield and Glass 23-031-06 -2-

REPAIR PROCEDURE: 1. Use a trim stick to hold the tail section of the windshield molding away from the roof panel and use an alcohol wipe to clean all the way across the vehicle between the molding and roof panel.(Fig. 1).

Fig. 1 JOINT TO BE SEALED

1 - APPLY SEALER BETWEEN TAIL OF MOLDING AND ROOF PANEL

2. Use a trim stick to hold the tail section of the windshield molding away from the roof panel and apply MOPAR Silicone Windshield and Glass Sealer, p/n 04467708, in the joint between molding and the roof panel. 3. If sealer squeeze out occurs, immediately wipe off the excess with a clean paper towel. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-50-25-90 Seal Upper Windshield Molding 0.2 Hrs.

FAILURE CODE:

ZZ Service Action NUMBER: 24-006-06

GROUP: Heating & A/C

DATE: August 9, 2006

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE.

SUBJECT: A/C Cooling Coil Odor

OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing.

MODELS:

1995 - 2003 (AB) Ram Van/Wagon 1995 - 2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 24-006-06 -2-

2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander

SYMPTOM/CONDITION: Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the A/C cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results.

DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model.

PARTS REQUIRED:

Qty. Part No. Description AR (3) 05170022AA Cleaner, A/C Cooling Coil, 8 oz. Bottle Refer To Table For Quantity Required 1 04728942AB Coating, A/C Cooling Coil, 8 oz. Bottle AR (1) 82205905 Filter, Cabin Air (CS/RS vehicles) AR (1) 04596501AB Filter, Pollen (LX vehicles w/sales code ADB) AR (1) 05103600AA Filter, A/C and Heater Unit (VA vehicles)

A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL

Number of Bottles Models Required 2 JR, KJ, PG, PL, PT, ST, TJ, ZB 3 AB, AN, CS, DN, DR/DH/D1, HB, LH, LX, ND, RG, RS, VA, WG, WJ, WK/WH, XK**/XH**

EQUIPMENT REQUIRED:

AI-62637 **or Applicator Tool, teamPSE 534-62637** Pliers, Hose Clamp Fabricated Cap 15.9 mm (0.625 in.) Fabricated Cap 19 mm (0.75 in.) -3- 24-006-06

AB/CS/LX/RS/WK/XK VEHICLE PROCEDURE: 1. Open the hood. 2. On LX/RS/**2005 WK/ WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain.

Fig. 1 FABRICATED PLUG FOR **2005 WK/WH** VEHICLES

1 - 152.4 MM (6 in.) OF 15.9 MM (5/8 in.) I.D. HEATER HOSE, p/n HHR00058AA 2 - DEEP 12 MM, 9.8 MM (3/8 in.) DRIVE SOCKET 2 - 457.2 MM (18 in.) LONG, 9.8 MM (3/8 in.) DRIVE SOCKET EXTENSION

Fig. 2 FABRICATED PLUG IN PLACE IN **2005 WK/WH** VEHICLES

1 - RIGHT SIDE SUB-FRAME 3 - FABRICATED PLUG IN PLACE 2 - EXHAUST 4 - FORWARD HOIST ARM 24-006-06 -4-

4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step #7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step #12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor/power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles , remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the A/C housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step #18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. -5- 24-006-06

24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 24-006-06 -6-

54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step #72, CS vehicles proceed to Step #68, LX/RS/**2005 WH/WK** vehicles proceed to Step #66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ VEHICLES PROCEDURE: 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step #9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. -7- 24-006-06

13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing.

NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 24-006-06 -8-

44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST VEHICLE PROCEDURE: 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. -9- 24-006-06

5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 24-006-06 -10-

41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA VEHICLE PROCEDURE: 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to A/C OFF. 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. -11- 24-006-06

28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. 24-006-06 -12-

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 24-65-02-98 TJ 0.6 Hrs. AB,CS,DR,DH,D1,KJ,PL 0.7 Hrs. ST, VA 0.8 Hrs. JR, LX, PG, PT, RG, RS, WJ, WG, WK, WH, XK 0.9 Hrs. HB 1.0 Hrs. AN, DN, LH, ND 1.1 Hrs.

FAILURE CODE:

ZZ Service Action NUMBER: 08-030-06 REV. A

GROUP: Electrical

DATE: August 25, 2006

THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES.

SUBJECT: Powertrain Control Module Initialization

MODELS:

2001 - 2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005 - 2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX 2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 08-030-06 REV. A -2-

2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster

NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply.

DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key™ Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII® or StarSCAN™ Scan Tool to enter a PIN number.

When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute.

NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) “P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM” will be set. This DTC will not effect vehicle or system performance and cannot be erased.

SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII®), J1962 MMC Cable (Special Tool CH7010), and the BLUE ST22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. To lease the DRBIII® call 1-800-801-5420. A credit card deposit will be required.

CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII®), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREENSprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of -3- 08-030-06 REV. A time. To lease the DRBIII® call 1-800-801-5420. A credit card deposit will be required.

The DRBIII® will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII® is returned, your credit card will be charged the lease price.

2007 GRAND CHEROKEE w/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004 - 2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector “Quantity Values” must be physically read from each injector and the values written to the ECU with an appropriate scan tool.

**PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII®.

Automatic Replacement 1. **Using the DRBIII® select: "1. DRBIII® Standalone" 2. "1. 1998 - 2007 Diagnostics" 3. Make the appropriate selection: “5. 2004 - 2006 Crossfire” or “6. 2002 - 2006 Sprinter” 4. “1. System Select” 5. “1. Engine” 6. “9. Miscellaneous Functions” NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select “5. Injector Classification” then “2. Injector Modification” on the DRBIII® and record the information for all 5 cylinders. 7. “1. Module Auto Replacement” 8. Follow the DRBIII® “On Screen” prompts until “Module Replacement Successful” message is displayed.

Module Service Replacement 1. **Using the DRBIII® select: "1. DRBIII® Standalone" 2. "1. 1998 - 2007 Diagnostics" 3. Make the appropriate selection: “5. 2004 - 2006 Crossfire” or “6. 2002 - 2006 Sprinter” 4. “1. System Select” 5. “1. Engine” 6. “9. Miscellaneous Functions” 7. “7. Read PCM Coding for Crossfire” OR “6 Read ECM Coding for Sprinter” and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select “5. Injector Classification” then “2. Injector Modification” on the DRBIII® and record the information for all 5 cylinders. 08-030-06 REV. A -4-

8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII® , repeat above steps 1 through 6 and select “2. Module Service Replacement”. 10. Follow the DRBIII® “On Screen” prompts until “Module Replacement Successful” message is displayed. 11. Was the message “Module Replacement Successful” received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step #12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet, www.techauthority.com 13. At the “Home” page, open the “Powertrain Control Module Initialization” link. 14. Open the “Coding String Calculator for Sprinter & Crossfire Vehicles” link. 15. Open the “Select Module” pull down menu and select “PCM”. 16. Select the appropriate “Transmission Type” button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM p/n located on the new PCM. 19. Select the “Calculate” button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the “Coding String”, “SCN”, and “CheckSum” information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII® select: "1. DRBIII® Standalone" 22. "1. 1998 - 2007 Diagnostics" 23. Make the appropriate selection: “5. 2004 - 2006 Crossfire” or “6. 2002 - 2006 Sprinter” 24. “1. System Select” 25. “1. Engine” 26. “9. Miscellaneous Functions” 27. “2. Module Service Replacement” 28. Follow the on screen instructions and carefully enter the “Coding String”, “SCN”, “CheckSum” and VIN information into the DRBIII®** NOTE: If one or more errors were made entering the data in step 28, the DRBIII® will display an error and ask to that the data be checked and re-input as necessary. 29. Follow the DRBIII® “On Screen” prompts until “Module Replacement Successful” message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the “Registration Procedure” described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet at: www.techauthority.com under the “Powertrain Control Module Initialization” link. POLICY: Information Only NUMBER: 21-012-06 REV. B

GROUP: Transmission

DATE: October 3, 2006

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-012-06 REV. A, DATED JUNE 15, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF 3.5L MODELS FOR THE 2006 MODEL YEAR.

THE StarSCAN® FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET.

UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN®.

StarSCAN® SOFTWARE LEVEL MUST BE AT RELEASE 7.02 OR HIGHER FOR THIS BULLETIN.

StarMOBILE® STANDALONE DOES NOT SUPPORT THIS FLASH RELEASE.

SUBJECT: Flash: 1 - 2 Upshift Shudder or Rough Shift

OVERVIEW: This bulletin involves checking the 2 - 4 Clutch Volume Index (CVI) and if necessary selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software and then performing a Quicklearn to reset the CVI.

MODELS:

2005 - 2006 (LX/LE) 300/Charger/Magnum (Includes International Markets)

NOTE: This bulletin applies to all 2005 models with a 2.7L or 3.5L engine and 42RLE transmission (Sales Code EER or EGG with DG6) and 2006 LX models equipped with a 2.7L engine and 42RLE transmission (Sales Code EER and DG6) built prior to April 4, 2006 (MDH0404XX) or 2006 LE models equipped equipped with a 2.7L engine and 42RLE transmission (Sales Code EER and DG6) built prior to April 5, 2006 (MDH0405XX) ** and all 2006 models equipped with a 3.5L engine and 42RLE transmission (Sales Code EGG with DG6)**.

SYMPTOM/CONDITION: The customer may experience rough 1 - 2 upshifts or vehicle shudder. 21-012-06 REV. B -2-

DIAGNOSIS: Using a Scan Tool (StarSCAN®) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin.

Using the StarSCAN® read the transmission 2 - 4 Clutch Volume Index value. If the CVI value is low (30 or below) proceed with the Repair Procedure. If the CVI is above 30, further diagnosis may be required.

PARTS REQUIRED:

Qty. Part No. Description 1 04275086AB Label, Authorized Modification

SPECIAL TOOLS / EQUIPMENT REQUIRED:

REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN®; must be programmed with 7.02 level software or higher. The software release level is visible in the blue header at the top of the StarSCAN® screen.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted. -3- 21-012-06 REV. B

1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN® and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle. 4. Power ON the StarSCAN®. 5. Retrieve the old PCM part number. Using the StarSCAN® at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the appropriate ECU in the list of modules. c. Select “More Options” d. Select “ECU Flash” e. Record the part number at the top of the “Flash PCM” screen for later reference. f. Select “Browse for New File”. Follow the on screen instructions. g. Select “Download to Scantool”. h. Select “Close” after the download is complete, then select “Back”. i. Highlight the listed calibration. j. Select “Update Controller”. Follow on screen instructions. k. When the update is complete, select “OK”. l. Verify the part number at the top of the “Flash PCM” screen has updated to the new part number. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the “Home” screen select “System View”. Then select “All DTCs”. Press “Clear All Stored DTCs” if there are any DTCs shown on the list. 6. Using the StarSCAN® make sure all DTC's are cleared then perform a quicklearn procedure to “relearn” all the transmission parameters prior to returning the vehicle to the customer. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 7. Type the necessary information on the “Authorized Modification Label” p/n 04275086AB and attach near the VECI label (Fig. 1). 21-012-06 REV. B -4-

Fig. 1 AUTHORIZED MODIFICATION LABEL

1 - POWERTRAIN CONTROL MODULE P/N (INSERT P/N) USED 2 - CHANGE AUTHORITY: TSB XX-XXX-XX 3 - DEALER CODE: XXXXX 4 - DATE: XX-XX-XX

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 18-19-06-19 Reprogram Powertrain Control Module (B) 0.4 Hrs.

FAILURE CODE:

ZZ Service Action NUMBER: 23-040-06

GROUP: Body

DATE: September 26, 2006

THE StarSCAN® FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET.

StarSCAN® UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES.

SUBJECT: FLASH: Rear Of Sunroof Glass Is Not Flush To Roof/Sunroof Will Not Close

OVERVIEW: This bulletin involves selectively erasing and reprogramming the Sunroof Module (SUNR) with new software.

MODELS:

2006 (DR) Ram Truck 2005 - 2006 (LE) 300C/300C Touring 2005 - 2006 (LX) 300/Charger/Magnum 2005 - 2006 (WH) Grand Cherokee (International Markets) 2005 - 2006 (WK) Grand Cherokee 2006 (XH) Commander (International Markets) 2006 (XK) Commander

NOTE: This bulletin applies to vehicles equipped with a sunroof (sales code GWA or GWF).

SYMPTOM/CONDITION: DIAGNOSIS: 1. Verify the rear of the sunroof glass to roof flushness concern. 2. UNCALIBRATE THE SUNROOF. a. Insure the battery is at least 12 Volts. b. Place the ignition switch in RUN position. c. Locate the sunroof fuse (Fuse 44 in the Power Distribution Center located in the trunk). d. While the sunroof is still in motion, have an assistant remove the sunroof fuse. e. Reinstall the sunroof fuse. 23-040-06 -2-

SPECIAL TOOLS / EQUIPMENT REQUIRED:

REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN®; must be programmed with software release level 7.02 or higher. The software release level is visible in the blue header at the top of the StarSCAN® screen.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the Repair Procedure. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. -3- 23-040-06

2. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN® and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle. 4. Power ON the StarSCAN®. 5. Select “ECU View” 6. Touch the screen to highlight the SUNR in the list of modules. 7. Select “More Options” 8. Select “ECU Flash” 9. Record the part number at the top of the “Flash SUNR” screen for later reference. 10. Select “Browse for New File”. Follow the on screen instructions. 11. Highlight the appropriate calibration then select “Download to Scantool”. 12. Select “Close” after the download is complete, then select “Back”. 13. Highlight the listed calibration. 14. Select “Update Controller”. Follow on screen instructions. 15. When the update is complete, select “OK”. 16. Verify the part number at the top of the “Flash SUNR” screen has updated to the new part number. NOTE: Due to the SUNR programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the “Home” screen select “System View”. Then select “All DTCs”. Press “Clear All Stored DTCs” if there are any DTCs shown on the list. 17. Insure the battery is at least 12 Volts. 18. Place the ignition switch in RUN position. 19. Close all of the doors and windows. 20. Press and hold the vent switch until the sunroof glass moves to the full open vent position. 21. Cycle the sunroof from the full vent open position to the full slide open position and back to the full vent open position at least 7 complete times. The sunroof is now in customer mode with the obstacle detection thresholds updated. 22. Remove the charger from the battery. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 18-19-46-90 Reprogram Sunroof Control Module 0.4 Hrs.

FAILURE CODE:

ZZ Service Action NUMBER: 23-045-06

GROUP: Body

DATE: October 14, 2006

SUBJECT: Ratcheting Sound During Sunroof Operation

OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit.

MODELS:

2004 - 2007 (DR) Ram Truck 2005 - 2007 (LE) 300C/300C Touring (International Markets) 2005 - 2007 (LX) 300/Charger/Magnum 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee

SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position.

DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description AR (2) 68003812AA Conduit, Cable

REPAIR PROCEDURE: 1. Ensure the sunroof module is in the full closed position. 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig. 1). 23-045-06 -2-

Fig. 1 CONDUIT RETENTION

1 - CLIP END 2 - RETAINING FEATURES 3 - MOTOR END

4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step #3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig. 2).

Fig. 2 CONDUIT FLARE INTO NOTCH

1 - LOCATE CONDUIT FLARE INTO NOTCH

5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig. 3). -3- 23-045-06

Fig. 3 CLIP TO ALUMINUM GUIDE LOCATION

1 - ENSURE CLIP IS POSITIONED BETWEEN MARKS

6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 23-30-56-94 Replace Sunroof Drive Cable DR 1.4 Hrs. Conduit - One or Both LE/LX 1.5 HRS. WH/WK 1.2 Hrs.

FAILURE CODE:

ZZ Service Action NUMBER: 18-031-06

GROUP: Vehicle Performance

DATE: October 28, 2006

THE StarSCAN® FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET.

UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN®.

StarSCAN® SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP1 OR HIGHER FOR THIS BULLETIN.

SUBJECT: Flash: Delayed Engine Crank or MIL Illumination with DTC P0573

OVERVIEW: This bulletin involves inspecting the brake switch if DTC P0573 is found and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software.

MODELS:

2005 - 2006 (LX) 300/Charger/Magnum (Includes International Markets) 2006 (LE) 300C/300C Touring

NOTE: This bulletin applies to models equipped with a 2.7L or 3.5L engine Sales Code EER or EGG).

SYMPTOM/CONDITION: The customer may experience a 3 to 5 second delay between turning the ignition switch to “Crank” and the engine actually cranking. This may be intermittent and difficult to reproduce.

Diagnostic Trouble Code (DTC) P0573 may be set if the vehicle gets physically stuck in a slippery condition and while trying to get the vehicle unstuck is rocked back and forth (transmission shifted drive to reverse to drive) without pressing the brake pedal. 18-031-06 -2-

If delayed crank is described by the owner or MIL illumination with DTC P0573 found, Perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description 1 04275086AB Label, Authorized Modification

SPECIAL TOOLS / EQUIPMENT REQUIRED:

REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN®; must be programmed with 7.02 SP1 level software or higher. The software release level is visible in the blue header at the top of the StarSCAN® screen.

2. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN® and the dealer's network drop. 3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle. 4. Power ON the StarSCAN®. 5. Retrieve the old PCM part number. Using the StarSCAN® at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the PCM in the list of modules. c. Select “More Options” d. Select “ECU Flash” e. Record the part number at the top of the “Flash PCM” screen for later reference. f. Select “Browse for New File”. Follow the on screen instructions. g. Select “Download to Scantool”. h. Select “Close” after the download is complete, then select “Back”. i. Highlight the listed calibration. j. Select “Update Controller”. Follow on screen instructions. k. When the update is complete, select “OK”. l. Verify the part number at the top of the “Flash PCM” screen has updated to the new part number. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the “Home” screen select “System View”. Then select “All DTCs”. Press “Clear All Stored DTCs” if there are any DTCs shown on the list.

NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the “Authorized Modification Label” p/n 04275086AB and attach near the VECI label (Fig. 1).

Fig. 1 AUTHORIZED MODIFICATION LABEL

1 - POWERTRAIN CONTROL MODULE P/N (INSERT P/N) USED 2 - CHANGE AUTHORITY: TSB XX-XXX-XX 3 - DEALER CODE: XXXXX 4 - DATE: XX-XX-XX

POLICY: Reimbursable within the provisions of the warranty. 18-031-06 -4-

TIME ALLOWANCE:

Labor Operation No: Description Amount 18-19-06-31 Reprogram Powertrain Control Module (B) 0.4 Hrs.

FAILURE CODE:

ZZ Service Action NUMBER: 18-035-06

GROUP: Vehicle Performance

DATE: November 17, 2006

SUBJECT: FLASH: Malfunction Indicator Lamp (MIL) On For P0573

OVERVIEW: This bulletin involves inspecting the brake pedal switch and selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software.

MODELS:

2005 - 2006 (LX) 300/Charger/Magnum 2006 (LE) 300C/300C Touring

SYMPTOM/CONDITION: Diagnostic Trouble Code (DTC) P0573 is set if the vehicle gets physically stuck in a slippery condition and while trying to get the vehicle unstuck is rocked back and forth (transmission shifted drive to reverse to drive...) without pressing the brake pedal.

If the vehicle operator describes the Symptom/Condition above perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description 1 04275086AB Label, Authorized Modification 18-035-06 -2-

SPECIAL TOOLS / EQUIPMENT REQUIRED:

REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN®; must be programmed with 7.02 SP1 level software or higher. The software release level is visible in the blue header at the top of the StarSCAN® screen.

5. Retrieve the old PCM part number. Using the StarSCAN® at the “Home” screen: a. Select “ECU View” b. Touch the screen to highlight the PCM in the list of modules. c. Select “More Options” d. Select “ECU Flash” e. Record the part number at the top of the “Flash PCM” screen for later reference. f. Select “Browse for New File”. Follow the on screen instructions. g. Select “Download to Scantool”. h. Select “Close” after the download is complete, then select “Back”. i. Highlight the listed calibration. j. Select “Update Controller”. Follow on screen instructions. k. When the update is complete, select “OK”. l. Verify the part number at the top of the “Flash PCM” screen has updated to the new part number. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the “Home” screen select “System View”. Then select “All DTCs”. Press “Clear All Stored DTCs” if there are any DTCs shown on the list.

Fig. 1 AUTHORIZED MODIFICATION LABEL

1 - POWERTRAIN CONTROL MODULE P/N (INSERT P/N) USED 2 - CHANGE AUTHORITY: TSB XX-XXX-XX 3 - DEALER CODE: XXXXX 4 - DATE: XX-XX-XX 18-035-06 -4-

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 18-19-06-32 Flash PCM 0.4 Hrs.

FAILURE CODE:

ZZ Service Action NUMBER: 26-003-07

GROUP: Miscellaneous

DATE: March 30, 2007

SUBJECT: Fluid Flushing Requirements

MODELS:

2005 - 2007 (CS) Pacifica 2007 (D1/DC) Ram Truck 2005 - 2007 (DR/DH) Ram Truck 2005 - 2007 (HB) Durango 2007 (HG) Aspen 2007 (JK) Wrangler 2005- 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2008 (JS) Avenger/Sebring 2007 (KA) Nitro 2005 - 2007 (KJ) Liberty 2005 - 2007 (LE) 300C/300C Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2007 (MK) Compass/Patriot 2005 - 2007 (ND) Dakota 2005 (PL) Neon 2007 (PM) Caliber 2005 - 2007 (PT) Chrysler PT Cruiser 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 (VB) Sprinter 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 26-003-07 -2-

2005 - 2006 (ZB) Viper 2005 - 2007 (ZH) Crossfire

DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE® approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water.

POLICY: Information Only NUMBER: 08-001-07 REV. B

GROUP: Electrical

DATE: May 16, 2007

THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED.

THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION.

DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION.

SUBJECT: Passenger Air Bag Deactivation

MODELS:

2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakota 2006 - 2007 (DR) Ram Truck 08-001-07 REV. B -2-

2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible

NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY.

DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet.

NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States.

PARTS REQUIRED:

Qty. Part No. Description Models AR (1) 05179022AA Package, Airbag Deactivation RS/RG Wiring AR (1) 05191094AA Package, Airbag Deactivation LX/LE Wiring AR (1) 05191025AA Package, Airbag Deactivation WK/WH/XK/XH Wiring AR (1) 68025259AA Package, Airbag Deactivation KJ Wiring AR (1) 68025260AA Package, Airbag Deactivation KA Wiring AR (1) 68025261AA Package, Airbag Deactivation JK Wiring AR (1) 68025262AA Package, Airbag Deactivation PT/PG Wiring AR (1) 68028820AA Package, Airbag Deactivation HB/HG/ND/DR Wiring AR (1) 68025768AA Package, Airbag Deactivation CS Wiring -3- 08-001-07 REV. B

Qty. Part No. Description Models AR (1) 68019990AA Package, Airbag Deactivation PM Wiring AR (1) 68019991AA Package, Airbag Deactivation MK Wiring AR (1) 68025593AA Package, Airbag Deactivation JS Wiring

POLICY: Information Only NUMBER: 08-011-07

GROUP: Electrical

DATE: May 18, 2007

SUBJECT: Inoperative Power Window Express Up Feature

OVERVIEW: This bulletin involves replacing both door modules.

MODELS:

2005 - 2007 (LX) Charger, Magnum, 300

SYMPTOM/CONDITION: The express up feature in the power window system may be inoperative or intermittently inoperative.

DIAGNOSIS: If a customer indicates that the condition is present, perform the Repair Procedure.

PARTS REQUIRED:

Qty. Part No. Description 2 56038720AP Door Module (without Memory Mirror System) 2 56038722AP Door Module (with Memory Mirror System) 2 04602838AC Door Module (2007 With Sales Code LEC)

REPAIR PROCEDURE: 1. Using the procedures outlined in the Service Information on TechCONNECT, Section 8, Electronic control Modules, remove both door modules and install the new door modules listed in the “Parts Required” section. POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-52-32-90 Door Module, Replace both 0.8 Hrs. doors (B)

FAILURE CODE: 08-011-07 -2-

ZZ Service Action NUMBER: 23-028-05 REV. A

GROUP: Body

DATE: August 27, 2005

THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.

THE FLASH FILE WILL BE AVAILABLE ON THE NEXT StarSCAN® UPDATE CD RECEIVED AFTER CD 6.02.

SUBJECT: Rear Of Sunroof Glass Is Not Flush To Roof

OVERVIEW: This bulletin involves flash reprogramming the sunroof motor and possibly replacing the sunroof drain channel.

MODELS:

2005 (LX) 300/Magnum

NOTE: This bulletin applies to vehicles built prior to September 1, 2004 (MDH 0901XX) and equipped with a Sunroof (sales code GWA).

SYMPTOM/CONDITION: Sunroof does not fully close (fit flush to roof) and/or fully vent and/or is noisy at the end of full open travel.

Qty. Part No. Description AR (1) 05137559AD Drain Channel

SPECIAL TOOLS/EQUIPMENT REQUIRED:

NOTE: Make sure the StarSCAN® is configured to the dealership's network before proceeding. -3- 23-028-05 REV. A

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

TIME ALLOWANCE:

Labor Operation No: Description Amount 08-52-46-92 Flash Sunroof Motor 0.4 Hrs. 23-30-62-90 Replace Sunroof Drain Channel 0.3 Hrs.

FAILURE CODE:

FM Flash Module 11 Broken or Cracked