Cowl Cracks

[GeneH]

Dodge came out with tsb 23-63-94 dealing with cowl cracks. Here are a few photos showing the cracks and what needs to be removed to do the repair. #ad



[This message has been edited by GeneH (edited 05-06-2001). ]

 

[GeneH]

#ad

 

[GeneH]

#ad

 

[GeneH]

#ad

Here is the repair with the reinforcement plate installed.
The right side pn is 4797019
The left side pn is 4797018
Gene
92 350 4x4

 

[Gary - K7GLD]

WELL JEEZE - nothin' to it, all ya gotta DO is rip off the entire front half of yer danged truck... #ad
#ad
#ad


How do you find this problem to begin with, when you start seeing yer fenders laying alongside the road?

Stuff like THAT starts reminding me of what I didn't like Dodges for... #ad


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http://community. webshots.com/user/davison71 Early '91 250, 727 AT, 307 rear... Banks Stinger exhaust, intercooler... US Gear OD... Tweaked pump, upgraded radiator... MORE than a match for every new PS Ford encountered so far...

"Dura" WHAT? NOW I know where all those recycled beer cans go...

 

[AlK]

GeneH, excellent pictures. What are the symptoms of this problem? Or maybe I don't want to know!!

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92-LE,4x4,5spd,3. 54,Borgeson steering shaft, Tach,Isspro Pyro & Boost, 16cm2, PW injectors

 

[GeneH]

I think this problem occurs more on the 4x4's because of the stiffer front suspension.
I had noises coming from around the base of the A pillars. I thought the noise was comming from under the dash but could never find the source of the noise. One of the early TDR Mags. had a listing of the TSB's for the 1st Gen trucks. Sure enough my truck had cowl cracks on both sides.
The crack has to be drilled on each end to stop the crack from getting any larger. Then holes need to be drilled for the reenforcement plate rivets, apply an adhesive to the underside of the plate and than rivet it in place.
I did this in Jan of 97 and it stopped a lot of the noises that I thought were coming from under the dash.
Gene
92 350 4x4

[This message has been edited by GeneH (edited 05-07-2001). ]

[This message has been edited by GeneH (edited 05-07-2001). ]

 

[M'staedt]

I think ALL '72 - '93 trucks will eventually have this problem. I just pulled the fenders off of an '81 crew-cab 2wd, 360 4-spd truck and a '74 club-cab 2wd, 318 auto, both with their cowls badly cracked. I suspect my '78 Li'l Red Express suffers the same. Those reinforcement plates look trick, I may have to pick up a couple of sets.

 

[Gary - K7GLD]

The photos above are NICE, but don't really clearly show the cracks - are the usually at ALL visible WITHOUT dismanteling the front end of the truck?

------------------
http://community. webshots.com/user/davison71 Early '91 250, 727 AT, 307 rear... Banks Stinger exhaust, intercooler... US Gear OD... Tweaked pump, upgraded radiator... MORE than a match for every new PS Ford encountered so far...

"Dura" WHAT? NOW I know where all those recycled beer cans go...

 

[Matt S]

If I open my door and look through the door jam from the outside I can see the cracks. I've welded mine but they seem to break in other places. I guess I need to get one of those kits for both sides.

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90 W250, 5-speed, isspro gauges, 16 cm2, K&N, Borgeson shaft, JRE 3" exhaust, Banks Intercooler, Lucas injectors

 

[Gary - K7GLD]

Matt sez:

"If I open my door and look through the door jam from the outside I can see the cracks. "


YUP - I've tried to peek thru the edge of the open door myself, but haven't been able to spot any cracks - I have one of those dentist mirrors for looking into tight spots, so will check some more. I would think that welding the existing cracks in addition to the available "patches" would be better than merely drilling the cracks too...

ANYWAY, is fender removal and the vent piece across the yop of the cowl all that has to come off, how difficult and how much time involved?

------------------
http://community. webshots.com/user/davison71 Early '91 250, 727 AT, 307 rear... Banks Stinger exhaust, intercooler... US Gear OD... Tweaked pump, upgraded radiator... MORE than a match for every new PS Ford encountered so far...

"Dura" WHAT? NOW I know where all those recycled beer cans go...

 

[Matt S]

When I took the fender off I also had to remove the cowl, hood, front bumper, and the front 'valance pan', and grill. On the passenger side, don't for get the antenna. Everything is a one man job except the hood. Try to pick a day with very little wind.

 

[GeneH]

Just about evrything has to come off to get to the area. To be able to remove the outside fender the hood has to come off. Taking the hood off is about the most difficult part of the whole process.
The inner fender can probably stay on, I took mine off because I repainted the inside.
The reenforcement plates are stamped and seem to work very well at fixing the problem.
Gene
92 350 4x4

 

[Matt S]

Part Numbers?

I ordered these parts from my local friendly Dodge dealer and sent my wife to pick them up. They gave her one part, which she thought might be right, but they also tried to give her a huge part, which she quessed was a rocker panel? Needless to say she did not bring this part home in her car. Could you double check the part numbers for me?

Thanks!

Matt

 

[KEENO]

P/N's are correct...

Hey Matt S!



The part numbers listed are correct:



You would doubt the fastest P/N slinger ("Gene H") East of the Mississippi!?!?



TSB# 26-63-94



P/N (RT): 4797018 (qty 1)

P/N (LT): 4797019 (qty 1)

3/16 Rivets: 4746924 (qty 3)

3M P/N 08456 3M Panel Adhesive Compound 30



That said, understand that when I did mine last September that D/C was having a P/N mix up at the warehouse. I couldn't get the correct left side (D/S) part to match the Left P/N. The part was ordered 3 different times and the Pass. Side was always received. We eventually order one of each (rt. & lt. ) and (2) right side parts were delivered.



I think the warehouse finally got the bins straightened around... . Let us know your experience.



Good luck Matt!



KEENO

 

[Matt S]

Keeno,

Are they the same part numbers for the left and right side or is that a typo?

 

[KEENO]

Oops!

Thanks Matt!



Yeah, I "Fat-Fingered" the P/N... . It has been edited and is now ABSOLUTELY correct. This will conclude the TEST!



Now, I bet your wondering, "No Wonder he got the Right Side Reinforcement everytime"!



LOL!... .



Korrected Keeno