Warrany Extension for Vacuum Components on 1995-1996 Diesel Rams
From: J&L Warranty Newsletter May 1999
Regarding: Warranty Bulletin D-97-10 May 1997
Extension of affected vacuum operated components on 1995 & 1996 Ram Trucks with 5. 9L diesel engine.
The warranty extension on these vehicles applies to quite a long list of LOP'S. The coverage was extended to 7 years and no mileage limitaion.
Recall # 720
. Vacuum Check Valve Revised June, 1997
IMPORTANT DEALER SERVICE INSTRUCTIONS
See also NHTSA Recall Notice 98V068
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DEALER SERVICE INSTRUCTIONS Safety Recall #720
Vacuum Check Valve Revised June, 1997 , Please remove and. discard all prior recall notifications (mailed to dealers in May, 1997) from your files and replace it with this revised procedure.
models:
This service requirement applies only to 1995 and 1996 model year Dodge Ram (BR) trucks equipped with a 5. 9L diesel engine ("C" in the 8th VIN position) built from July 40, 1995 (MDH 071014) through July 1, 1996 (MDH 070114).
problem:
The power brake booster vacuum hose on the above listed vehicles, may deteriorate due to oil contamination from the vacuum pump. If this occurs, the vacuum supply to the power brake booster may be restricted and could cause a loss of power assist during repeated quick brake applications. in addition, the oil contamination may cause other vacuum operated components to malfunction, such as the speed control servo, the heater/air conditioning vacuum controls and the 4X4 front axle and transfer case vacuum controls. To prevent this condition, a check valve must be installed on the engine vacuum pump and the brake booster vacuum hose must be replaced.
If the vacuum pump on an involved vehicle has been replaced previously, the replacement pump may have an internal check valve. The threaded vacuum hose nipple on pumps with an internal check valve have a larger hex head and a larger thread size. Therefore, the recall external check valve will not fit, and is no required on these vehicles. However, the vacuum hose assembly must be replaced.
The torque specification for the new check valve has been reduced to 200 in-lbs (23 N-m). Disregard the reference to 38 ft-lbs listed in the parts package instruction sheet.
Service Procedure:
A. Inspect for Vacuum Check Valve:
1. Inspect the engine vacuum pump for the existence of an internal vacuum check valve (Figure 1) or an external vacuum check valve (Figure 2).
NOTE: If the vacuum pump on an involved vehicle has been replaced previously, the replacement pump mav have an internal check valve. The threaded vacuum hose nipple on pumps with an internal check valve have a larger hex head and a larger thread size. Therefore, the recall external check valve will not fit, and is not required, on these vehicles. However, the vacuum hose assembly must be replaced.
2. If an external vacuum check valve is already installed (Figure 2), return the vehicle to the owner. No further action is necessary.
If the vacuum check valve is not present and the nipple hex head size is 14 mrn (Figure 1), continue with Section B.
If the vacuum check valve is not present and the nipple hex head size is 22 mm (Figure 1), the pump has an internal check valve. Replace only the vacuum hose assembly per the instructions in Section B.
B. Install Vacuum Check Valve and/or Vacuum Hose Assembly:
1. Disconnect the 1/8" HVAC vacuum line from the tee in the vacuum hose that runs between the vacuum pump and the brake booster (Figure 2).
2. Remove and discard the vacuum hose that runs between the vacuum pump and the brake booster (Figure 2).
3. For vehicles with a 14 mm pump nipple hex head size: Remove and discard the vacuum hose nipple from the vacuum pump.
CAUTION: DO NOT remove the 22 mm nipple (if equipped). The internal check valve components will become dislodged.
4. For vehicles with a 14 mm pump nipple hex head size: Install the provided check valve on to the vacuum pump. Tighten the check valve to 200 in-lbs (23 N-m) (Figure 2).
5. Install the supplied hose clamps on the ends of the provided vacuum hose assembly.
6. Install the hose assembly on to the vacuum pump nipple and the brake booster nipple such that the vacuum tee in the center of the assembly points upward (Figure 2). Secure the hose assembly to the vacuum pump and brake booster nipples with the hose clamps installed previously.
NOTE: The vacuum hose assembly must be routed above the power steering hoses.
7. Secure the vacuum hose assembly to the engine wiring harness near the rear of the fuel injection pump with the provided tie strap (Figure 2).
8. Connect the 1/8' HVAC vacuum line to the hose assembly tee.
Completion Report and Reimbursment:
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments.
Use one of the following labor operation numbers and time allowances:
Labor Op # Time Allowamce
Inspect vacuum check valve 09720181 0. 2 Hr
Inspect and install vacuum check valve
and/or replace vacuum hose assembly 09720182 0. 3 Hr
Add the cost of the recall parts package plus applicable dealer allowance to your claim.
NOTE: Any other vacuum operated components must be diagnosed and repaired according to the appropriate service procedures and a separate warranty claim must be filed for reimbursement.
Note: See the Warranty Administration Manual, Recall Claim Processing Section for complete recall claim processing instructions.
Additional notes:
Effective immediately all repairs on involved vehicles are to be performed according to this Recall Notification. The Labor Operation Number for TSB 24-16-96 is being canceled. Vehicles that have already had this repair performed, as determined from our warranty records, have been excluded from this notification.
7 Year/Unlimited Mileage Vacuum Operated Component Warranty:
Vehicles involved in this recall also have a 7 year warranty (with Unlimited mileage) on all affected vacuum operated components such as the power brake booster, the speed control servo, the heater and air conditioning vacuum controls, and on 4X4 vehicles, the front axle and transfer case vacuum controls. If any conditions covered by the extended warranty are found, now or in the future, dealers are to correct these conditions free of charge. Refer to Warranty Bulletin D-97-10 to be issued in late May, 1 997 for specific details of coverage. Parts for any of the covered components should be ordered through the normal means. Parts Packages: Each involved dealer, to whom vehicles in the recall were invoiced, will receive enough Check Valve Packages to service about 50% of those vehicles.
Attention: TDR Forum Junkies 
