August 2001 Dealer Service Instructions for: Safety Recall No. 978 -- Front Seat Belt Retractors

Models

1999 (AB) Dodge Ram Van/Wagon NOTE: This recall applies only to the above vehicles built from December 18, 1998 through January 29, 1999 (MDH 1218XX through 0129XX). 1999 (AN) Dodge Dakota NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 15, 1999 (MDH 1206XX through 0115XX). 1999 (DN) Dodge Durango NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 18, 1999 (MDH 1206XX through 0118XX). 1999 (LH) Chrysler Concorde, LHS and 300M and Dodge Intrepid NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 19, 1999 (MDH 1206XX through 0119XX). 1999 (NS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth Voyager/Grand Voyager NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 19, 1999 (MDH 1206XX through 0119XX).

1999 (WJ) Jeep? Grand Cherokee NOTE: This recall applies only to the above vehicles built from December 6, 1998 through January 19, 1999 (MDH 1206XX through 0119XX).

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 DIAL VIP System.

Subject

One or both of the front seat belt retractor assemblies on about 150,000 of the above vehicles may not comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 209. An improperly manufactured internal lever may not lock the seat belt retractor. This could allow increased risk of injury to a front seat occupant in certain accident conditions.

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Repair

The front seat belt retractor assembly(s) must be replaced.

Parts Information

No parts will be distributed initially for this recall. Dealers should determine which Seat Belt Retractor package is required for each vehicle at the time appointments are scheduled to assure that the correct parts are available when the customer arrives. Each package contains a right and a left front seat belt retractor (except as noted). The retractor package for the vehicle to be serviced may be determined by: ? Using the part code in the third column of the VIN list along with the following table (involved dealers); ? Using the VIN and part number list electronically transmitted to DIAL System Function 53 (involved dealers); or ? Entering the VIN into the DIAL VIP System (sales code information) along with the following table (all dealers):

Vehicle Interior Color Sales Code Part Part Model Code Number DN Agate or Mist Gray -AZ or -C3 1 CCB29781 Camel/Tan -K9 2 CCA29782 WJ Taupe -L5 3 CCA29783 Agate -AZ 4 CCB29784 Camel -K5 5 CCA29785 NS Mist Gray -C3 6 CCD29786 Camel -K5 7 CCA29787 Silverfern -JK 8 CCB29788 Taupe -L5 9 CCA29789 (Left side only) AN Agate or Mist Gray -AZ or -C3 10 CCB2978A (Left side only) LH Agate or Medium Quartz -AZ or -D5 11 CCC2978B Lt. Pearl Beige -FK 12 CCA2978C Camel/Tan -K9 13 CCA2978D AB Mist Gray -C3 14 CCA2978E w/ Hinged Door Camel/Tan -K9 15 CCA2978F AB Mist Gray -C3 16 CCA2978G w/ Sliding Door (Right side only) Camel/Tan -K9 17 CCA2978H (Right side only)

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Service Procedure for AB Vans/Wagons

IMPORTANT: Ram Vans/Wagons equipped with a sliding door require right (passenger side) front seat belt retractor assembly replacement only. 1. Open the passenger side doors. 2. Using a small flat blade, pry the turning loop cover open. 3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster (Figure 1). 4. Remove the retractor/seat belt lower anchor bolt from the front seat riser (Figure 1). 5. Remove and discard the retractor assembly. 6. Install the new retractor assembly. 7. Install the retractor/seat belt anchor bolt. Tighten the bolt to 30 ft-lbs (41 N?m). Figure 1 8. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 N?m). 9. Close the turning loop cover. 10. For vehicles equipped with dual hinged side doors, repeat Steps 1-9 for the driver’s side of the vehicle. Safety Recall No. 978 -- Front Seat Belt Retractors Page 4

Service Procedure for AN Trucks

IMPORTANT: Dakota trucks require left (driver side) front seat belt retractor assembly replacement only. 1. Open the driver’s side door. 2. Remove the driver’s door sill plate. 3. For Club Cab trucks, remove the cab back trim panel. 4. Using a small flat blade, pry the front seat belt turning loop cover open. 5. Remove the front seat belt turning loop attaching bolt and disconnect the turning loop from the height adjuster (Figure 2). 6. For Club Cab trucks, pry the rear seat belt turning loop cover open using a small flat blade. 7. For Club Cab trucks, remove the rear seat belt turning loop attaching bolt and disconnect the turning loop from the height adjuster (Figure 2). TURNING

LOOP 8. Remove the quarter (B-Pillar) trim ADJUSTER panel (Figure 2). TRIM PANEL 9. Remove the lower seat belt anchor bolt (Figure 2). CONNECTOR RETRACTOR 10. Remove the anchor bolt that attaches the retractor to the B-pillar (Figure 2). 11. Disconnect the retractor electrical connector (if equipped). BELT ANCHOR 12. Remove and discard the retractor Figure 2 – Club Cab Model Shown assembly. 13. Install the new retractor assembly. 14. Install the retractor anchor bolt (Figure 2). Tighten the bolt to 30 ft-lbs (41 N?m). 15. Connect the retractor electrical connector (if equipped). Safety Recall No. 978 -- Front Seat Belt Retractors Page 5

Service Procedure for AN Trucks (Continued)

16. Install the lower seat belt anchor bolt (Figure 2). Tighten the bolt to 30 ft-lbs (41 N?m). 17. Install the quarter (B-pillar) trim panel (Figure 2). 18. For Club Cab trucks, install the rear seat belt turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 N?m). 19. Install the front seat belt turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 N?m). 20. Close the turning loop cover(s). 21. For Club Cab trucks, install the cab back trim panel. 22. Install the door sill plate. Safety Recall No. 978 -- Front Seat Belt Retractors Page 6

Service Procedure for DN Vehicles

1. Open the driver’s door. 2. Using a small flat blade, pry the turning loop cover open. 3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster (Figure 3). 4. Remove the lower seat belt anchor bolt from the driver’s seat (Figure 3). 5. Remove the driver’s door sill plate. 6. Remove the upper B-Pillar trim panel (Figure 3). 7. Remove the lower B-Pillar trim panel (Figure 3). 8. Disconnect the retractor electrical connector. 9. Remove the anchor bolt that attaches the retractor to the B-pillar (Figure 3). Figure 3 10. Remove and discard the retractor assembly. 11. Remove the anti-rotation tab from the new retractor assembly and then install the new retractor assembly. 12. Install the retractor anchor bolt (Figure 3). Tighten the bolt to 30 ft-lbs (41 N?m). 13. Connect the retractor electrical connector. 14. Install the lower B-pillar trim panel (Figure 3). 15. Install the upper B-pillar trim panel (Figure 3). 16. Install the driver’s door sill plate. 17. Install the lower seat belt anchor bolt (Figure 3). Tighten the bolt to 17 ft-lbs (23 N?m). 18. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 N?m). 19. Close the turning loop cover. 20. Repeat Steps 1-19 for the passenger side of the vehicle. Safety Recall No. 978 -- Front Seat Belt Retractors Page 7

Service Procedure for LH Vehicles

1. Using a small flat blade, pry the turning loop cover open. 2. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster (Figure 4). 3. Remove the seat belt/retractor lower anchor bolt (Figure 4). 4. Remove the upper B-Pillar trim panel (Figure 4). 5. Remove the lower B-Pillar trim panel (Figure 4). 6. Remove and discard the retractor assembly (Figure 4). 7. Install the new retractor assembly. 8. Install the lower B-pillar trim panel (Figure 4). 9. Install the upper B-pillar trim panel (Figure 4). 10. Install the seat belt/retractor lower Figure 4 anchor bolt (Figure 4). Tighten the bolt to 30 ft-lbs (41 N?m).

11. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 N?m). 12. Close the turning loop cover. 13. Repeat Steps 1-12 for the other side of the vehicle. Safety Recall No. 978 -- Front Seat Belt Retractors Page 8

Service Procedure for NS Minivans

IMPORTANT: Town & Country minivans equipped with a taupe-colored leather interior require left (driver side) front seat belt retractor assembly replacement only. 1. Using a small flat blade, pry the turning loop cover open. 2. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster (Figure 5). 3. Remove the upper B-Pillar trim panel (Figure 5). 4. Remove the seat belt floor anchor bolt (Figure 5). Figure 5 5. Remove the lower B-Pillar trim panel (Figure 5). (On three door models, remove the upper bolster from the left quarter trim panel, remove the five screws across the top and three screws at the front of the trim panel and then pull the front of the quarter trim panel back far enough to access the retractor assembly.) 6. Remove the anchor bolt that attaches the retractor to the B-pillar (Figure 5). 7. Disconnect the retractor electrical connector, if equipped, and then remove and discard the retractor assembly. 8. Connect the retractor electrical connector, if equipped, and then install the new retractor assembly. 9. Install the retractor anchor bolt (Figure 5). Tighten the bolt to 30 ft-lbs (41 N?m). 10. Install the lower B-pillar trim panel (or left quarter trim panel on three door models) (Figure 5). 11. Install the seat belt floor anchor bolt (Figure 5). Tighten the bolt to 30 ft-lbs (41 N?m). Make sure that the floor anchor is properly oriented (30? outboard). 12. Install the upper B-pillar trim panel (Figure 5). 13. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 N?m). 14. Close the turning loop cover. 15. Repeat Steps 1-14 for the other side of the vehicle if necessary. Safety Recall No. 978 -- Front Seat Belt Retractors Page 9

Service Procedure for WJ Vehicles

1. Open the driver’s door. 2. Using a small flat blade, pry the turning loop cover open. 3. Remove the turning loop attaching bolt and disconnect the turning loop from the height adjuster. 4. Remove the lower seat belt anchor bolt (Figure 6). 5. Remove the driver’s door sill plate. 6. Remove the lower B-Pillar trim panel (Figure 6). 7. Remove and discard the retractor assembly (Figure 6). 8. Install the new retractor assembly. 9. Install the lower B-pillar trim panel (Figure 6). 10. Install the driver’s door sill plate. 11. Install the lower seat belt anchor bolt Figure 6 (Figure 6). Tighten the bolt to 30 ft-lbs (41 N?m).

12. Install the turning loop anchor bolt. Tighten the bolt to 30 ft-lbs (41 N?m). 13. Close the turning loop cover. 14. Repeat Steps 1-13 for the passenger side of the vehicle.

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Completion Reporting and Reimbursement

Claims for vehicles that have been serviced must be submitted on the DIAL System. 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 ? Replace ONE front seat belt retractor AB Van/Wagon – with sliding door 23-97-81-82 0.2 hours AN Trucks – All 23-97-81-82 0.4 hours

NS Minivans – with Taupe interior (Sales Code –L5) 23-97-81-82 0.4 hours ? Replace BOTH front seat belt retractors AB Van/Wagon – with Dual Hinged doors 23-97-81-83 0.3 hours DN Vehicles – All 23-97-81-83 0.7 hours LH Vehicles – All 23-97-81-83 0.7 hours WJ Vehicles – All 23-97-81-83 0.7 hours NS Minivans ? With driver side sliding door (Sales Code GKD) 23-97-81-83 0.7 hours but without Taupe interior (w/o Sales Code –L5) ? Without driver side sliding door 23-97-81-84 0.8 hours (without Sales Code GKD) 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

Not required.

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Dealer Notification and Vehicle List

All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.

DIAL System Functions 53 and VIP

All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type “53” at the “ENTER FUNCTION” prompt, then type “ORD978”.

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 copy of the owner letter is attached. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. 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.

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Vehicle Not Available

If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to:

DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757

Additional Information

If you have any questions or need assistance in completing this action, please contact your Zone Service Office. Customer Services Field Operations DaimlerChrysler Corporation

SAFETY RECALL TO REPLACE YOUR VEHICLE’S FRONT SEAT BELT RETRACTOR ASSEMBLIES Dear DaimlerChrysler Vehicle Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. DaimlerChrysler Corporation has determined that some 1999 model year Chrysler Concorde, LHS, 300M and Town & Country; Plymouth Voyager and Grand Voyager; Dodge Intrepid, Caravan, Grand Caravan, Dakota, Durango and Ram Van/Wagon and Jeep? Grand Cherokee vehicles do not comply with Federal Motor Vehicle Safety Standard (FMVSS) No. 209 – Seat Belt Assemblies. The problem is... One or both of the front seat belt retractor assemblies on your vehicle (identified on the enclosed form) may not comply with the requirements of FMVSS No. 209. An improperly manufactured internal lever may not lock the seat belt retractor. This could allow increased risk of injury to a front seat occupant in certain accident conditions. What DaimlerChrysler DaimlerChrysler will repair your vehicle free of charge (parts and your dealer will and labor). To do this, your dealer will replace one or both of the do... front seat belt retractor assemblies depending upon your vehicle model. 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 do to ? Simply contact your dealer right away to schedule a service ensure your safety... appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ? Bring the enclosed form with you to your dealer. It identifies the required service to the dealer. If you need help... If you have questions or concerns which the dealer is unable to resolve, please contact the DaimlerChrysler Customer Assistance Center at 1-800-853-1403. A representative will assist you. If you have already experienced the problem described above 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 Customer Assistance Center, P.O. Box 1040, St. Charles, MO 63302-1040, 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 Buckle up 978 for Safety