Cowl - Creaking/Popping Sounds
NO: 23-63-94GROUP: Body
EFFECTIVE DATE: Aug. 26, 1994
SUBJECT:
Cowl Cracks
MODELS:
1993 and Prior (AD) Ram Truck/Ramcharger
SYMPTOM/CONDITION:
Cracking or popping sounds coming from the cowl area at the lower corners of the windshield.
DIAGNOSIS:
Inspect the area underneath the fender at the cowl welds. The fenders must be removed to see the cracks. If cracks are present, perform the repair procedure (See Illustration).
PARTS REQUIRED:
AR 4797018 Cowl Reinforcement-Left
AR 4797019 Cowl Reinforcement-Right
3 4746924 3/16" Structural Rivet
1 3M P/N - 08456 3M Panel Adhesive Compound 30
1 3M P/N - 08198 Applicator Gun
1 3M P/N - 08193 Applicator Nozzle
REPAIR PROCEDURE:
This bulletin involves repairing the cracks and installing a reinforcement.
1. Remove the wiper arms.
2. Remove the cowl screen.
3. Remove the hood with the hood hinges attached.
4. Remove the front fender or fenders.
5. Drill stop the crack ends with a 1/16" drill.
6. Grind any rough edges from the area where the reinforcement will be secured. Grind the surface of the area to provide a good surface for the adhesive to adhere.
7. Grind the inside surface of the patch.
8. Grind away any paint from the vertical seam to prepare for application of adhesive (See Illustration) and clean the area with a solvent such as Mopar Super Kleen, P/N 4318015.
9. Clean the cowl and the reinforcement with a solvent such as Mopar Super Kleen, P/N 4318015.
10. Assemble the adhesive cartridge to the applicator gun following the manufacturers instructions.
11. Apply adhesive to the cowl approximately 1/16" thick and apply a bead to the vertical seam as shown.
12. Position the patch on the cowl.
13. Drill the 3/16" holes in the cowl and install the rivets, one at a time, until the patch is secure. Clean any excess adhesive from around the reinforcement.
14. Allow 4 hours for the epoxy to cure.
15. Prime the area and apply a coating of rustproofing to minimize corrosion.
16. Seal the panel joint seam at the windshield gasket with RTV to prevent leaks (See Illustration).
17. Install the fender and hood.
18. Install the cowl screen and wiper arms.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 23-00-27-90 (One Side) 3.6 Hrs.
23-00-27-91 (Both Sides 6.0 Hrs.
FAILURE CODE: XX - Service Adjustment