Steering - Power Steering Overheats During Training (Police)
NUMBER: 19-003-12GROUP: Steering
DATE: December 08, 2012
SUBJECT:
Police Vehicle Power Steering Overheat During Closed Course Training Exercises
OVERVIEW:
This bulletin involves installing an external power steering cooler on the involved police fleet vehicles.
MODELS:
2011 - 2012 (LD) Charger
NOTE:
This bulletin applies only to vehicles equipped with Police Package (sales
code AHB) and in police fleet usage.
SYMPTOM/CONDITION:
The police fleet may experience increased steering efforts or power steering overheat during extended periods of extreme closed course handling maneuvers while conducting training exercises in ambient temperatures above 100° F (38° C). Diagnostic Trouble Code
C2210-00 - ECU over temp may be present.
DIAGNOSIS:
If the customer describes the symptom, perform the Repair Procedure.
PARTS REQUIRED:
NOTE:
One 4.2oz bottle of 3M 08681 Single Step Primer can service 25 vehicles.
NOTE:
This vehicle features an Electro Hydraulic Power Steering (EHPS) pump
which requires a different power steering fluid P/N # 68088485AA. Do not mix power steering fluid types. Damage may result to the power steering pump and system if any other fluid is used. The EHPS system uses fluid which meets material specification MS-11655 or equivalent.
SPECIAL TOOLS/EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
1. Raise and support the vehicle.
2. Remove the front and rear belly pans. Refer to the detailed procedures available in DealerConnect > TechCONNECT > under: Service Info > 13 - Frame and Bumpers > Under Body Protection > BELLY PAN> Removal.
3. Remove the passenger side front wheelhouse splash shield. Refer to the detailed procedures available in DealerConnect>TechCONNECT> under: Service Info> 23 - Body > Exterior > SHIELD, Splash, Front Wheelhouse > Removal.
4. Using a suitable jack, remove the lower radiator core support bolts (1) (Fig. 1).
5. Using care not to damage condenser or radiator fins, lower the core support from the vehicle and leave the radiator/condenser assembly suspended by the upper and lower radiator hose attachment points.
NOTE:
Do not drain radiator or disconnect the condenser as the upper and lower radiator hoses will help in suspending and supporting the assembly during the installation of the steering cooler. Do not pull down on the
radiator/condenser assembly as this may cause damage to components that
suspend the assembly. Removing the lower core support will allow the
assembly to drop down and provide access between the radiator and
condenser in order to install the cooler properly.
6. Carefully remove the lower plastic shroud that covers the bottom gap between the radiator and condenser by using a pick to pull the cover hole away from the retaining tabs (1) along the edge (Fig. 2).
7. Viewing the condenser from the front of the vehicle count 12 rows up the passenger side of the condenser from the bottom of the condenser core and mark (2) the location of the 12th row (Fig. 2).
8. Measure out from the passenger side edge (2) of the condenser core 2-1/8"(54mm) and mark the location in the 12th row of the condenser.
9. Viewing the condenser from the front of the vehicle count 8 rows up the driver side of the condenser from the bottom of the condenser core and mark (3) the location of the 8th row (Fig. 2).
10. Measure out from the passenger side edge (2) of the condenser core 21"(532mm) and mark the location in the 8th row of the condenser.
11. Locate the passenger side air deflector (1) and modify it to allow clearance for the installation of the auxiliary steering cooler (Fig. 3).
12. Using a utility/exacto knife, cut along the indicated top contour/feature line (2) and extend the cut along the side contour/feature line (3) and remove the section indicated by finishing the cut along the top of the lower rib/feature line (4) (Fig. 3).
13. Insert the holding clips (2) into the steering cooler (4) (Fig. 4).
14. From the front of the vehicle, with the outlet lines of the cooler (1) facing toward the passenger side, insert the cooler holding clips (2) into the condenser (3) at the marks indicated on the condenser (Fig. 4).
15. Using long needle nose pliers (1) attach the retaining clips (2) to the back of the cooler
holding clips (3) located between the radiator and the condenser (Fig. 5).
16. Position the lower radiator core support to the vehicle. Refer to (Fig. 1).
17. Loosely install the lower radiator core support attachment bolts. Refer to (Fig. 1).
18. Seat the radiator assembly lower rubber isolators (4) (Fig. 5) into the mounting holes in the lower radiator support and tighten the attachment bolts. Refer to (Fig. 1).
19. Locate the lower steering pump bracket (1) and measure 2-61/64"(75mm) from the inside edge of the inner bracket slot (2) and place a mark centered in the middle of the bracket stand off feature as shown in (Fig. 6).
20. Measure 1-11/64"(30mm) from the inside edge of the inner bracket slot (3) and place a mark centered with the first mark in the middle of the bracket stand off feature as shown in (Fig. 6).
21. Drill a 5/16"(8mm) hole (4) into the mark indicated on the lower steering pump bracket (Fig. 6).
NOTE:
Apply 3M 08681 Single Step Primer to the 5/16"(8mm) hole drilled into the pump bracket.
22. Remove the power steering return hose. Refer to the detailed procedures available in DealerConnect > TechCONNECT > under: Service Info > 19 - Steering > Pump > HOSE, Power Steering, Return > Removal > NON SRT.
23. Install the steering cooler (1) return hose (2) on the power steering pump reservoir (Fig. 7).
24. Install the revised steering gear to cooler return hose (3) starting with the fitting at the steering gear (4). Install the frame mounted retaining clip and connect the return hose to the cooler (Fig. 7).
25. Install the line retaining push clip (5) into the hole created in the lower steering pump bracket and connect the holding clip (6) to the cooler to pump return line (2) (Fig. 7).
26. Replace any lost power steering fluid. Refer to the detailed procedures available in DealerConnect >TechCONNECT > under: Service Info > 19 - Steering > Pump > FLUID > Standard Procedure > STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING or NON-SRT POWER STEERING FLUID LEVEL CHECKING.
NOTE:
This vehicle features an Electro Hydraulic Power Steering (EHPS) pump
which requires a different power steering fluid P/N # 68088485AA. Do not mix power steering fluid types. Damage may result to the power steering pump and system if any other fluid is used. The EHPS system uses fluid which meets material specification MS-11655 or equivalent.
27. Perform the necessary power steering bleeding procedure. Refer to the detailed procedures available in DealerConnect > TechCONNECT > under: Service Info > 19 - Steering > Standard Procedure > STANDARD PROCEDURE - POWER STEERING SYSTEM BLEEDING.
28. Reinstall the passenger side front wheelhouse splash shield. Refer to the detailed procedures available in DealerConnect > TechCONNECT > under: Service Info > 23 - Body > Exterior > SHIELD, Splash, Front Wheelhouse > Installation.
29. Reinstall the front and rear belly pan. Refer to the detailed procedures available in DealerConnect > TechCONNECT > under: Service Info > 13 - Frame and Bumpers > Under Body Protection > BELLY PAN > Installation.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.