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Safety Recall W48/NHTSA 20E-037 PTU Input Spline - Equipment (W48)

WARNING: This page is about the Charger GT, which is a different variant/trim than selected.
Publication date: 2020-07-08
Reference number: W48
Supersedes refnos: RC-W48-20

SAFETY RECALL W48/NHTSA 20E-037 PTU INPUT SPLINE - EQUIPMENT

SAFETY RECALL W48/NHTSA 20E-037 PTU INPUT SPLINE - EQUIPMENT

SERVICE CAMPAIGN BULLETIN

Reference Number(s): RC-W48-20, Date of Issue:  July 08, 2020
CHRYSLER: All Models

SUBJECT

About 2650 Power Transfer Units (part numbers 68090605AJ, 68090605AK, 68090605AL 68282447AA, 68282447AB, 68282447AC, 68307403AA, and 68307403AB) may have been built to allow movement in the PTU between the differential input splines and the transmission output shaft. This condition may result in the teeth of the input splines wearing off, which may eventually cause a loss of engagement between the transmission and the differential inside the PTU. If this occurs, torque cannot be transferred between the front wheels and the transmission, which will result in a loss of motive power while the vehicle is in motion and a loss of the PARK function while stationary. A loss of motive power or PARK function can cause a vehicle crash without prior warning and/or injury to others outside the vehicle.

REPAIR

If the PTU the owner purchased has not been installed, exchange it for a new one.

If the PTU has been installed, reprogram the affected vehicle with software for the Drive Train Control Module (DTCM) and the Electric Park Brake (EPB) that will maintain vehicle propulsion by engaging rear wheel drive function and prevent rolling in the PARK selection by activating the electric park brake if a failed input spline occurs.

ALTERNATE TRANSPORTATION

Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that reprogramming is required and the vehicle must be held overnight.

PARTS INFORMATION

If exchanging the part over the counter, use the following part number.

PARTS INFORMATION

Part Number Description
68307403AG  Power Transfer Unit 

Recalled parts: part numbers 68090605AJ, 68090605AK, 68090605AL 68282447AA, 68282447AB, 68282447AC, 68307403AA, and 68307403AB.

PARTS RETURN

Core return is required for this campaign. Return the PTU to the MOPAR Core Return Center for core credit.

SPECIAL TOOLS

The following special tools are required to perform this repair: 

SERVICE PROCEDURE

NOTE: This flash procedure is for vehicles that have had a recalled PTU installed. The flash is designed for 2014-2017 (KL) Jeep® Cherokee.
NOTE: This recall applies only to the above vehicles equipped with a Power Transfer Unit (PTU) (sales code DK4).
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 VIP inquiry process.

A. Drive Train Control Module (DTCM)

NOTE: The wiTECH scan tool must be used to perform this recall. If the reprogramming flash for the DTCM or EPB is aborted or interrupted, repeat the procedure.
  1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge.
    NOTE: Use an accurate stand-alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage.
  2. Connect the wiTECH micro pod II to the vehicle data link connector.
  3. Place the ignition in the "RUN"  position.
  4. Open the wiTECH 2.0 website.
  5. Enter your "User id"  and "Password"  and your "Dealer Code",  then select "Sign In"  at the bottom of the screen. Click "Accept". 
  6. From the "Vehicle Selection"  screen, select the vehicle to be updated.
  7. From the "Action Items"  screen, select the "Topology"  tab.
    NOTE: The DTCM must be at the latest software calibration level after completing this recall.
  8. From the "Topology"  tab, select the "DTCM"  module icon.
  9. From the "Flash"  tab, compare the "Current Electronic Control Unit (ECU) Part Number"  with the "New ECU Part Number"  listed.
    • If the "Current ECU part Number"  is the same as the "New Part Number",  proceed to Step B. Electric Park Brake. 
    • If the "Current ECU part Number"  is NOT the same as the "New Part Number",  continue with Step 10. 
  10. From the DTCM tab, select the DTCM flash part number. Read the flash special instructions page. Select "OK"  to continue.
  11. From the flash ECU agreement page, agree to terms by checking the box.
  12. Select "Flash ECU"  and then follow the wiTECH screen instructions to complete the flash.
  13. Confirm the software is at the latest available calibration level.
  14. Click "View DTCs",  select "Clear All DTCs",  click "Continue"  and then click "Close". 

B. Electric Park Brake (EPB)

  1. Go back one page to the Topology screen.
    NOTE: The EPB must be at the latest software calibration level after completing this recall.
  2. From the "Topology"  tab, select the "EPB"  module icon.
  3. From the "Flash"  tab, compare the "Current Electronic Control Unit (ECU) Part Number"  with the "New ECU Part Number"  listed.
    • If the "Current ECU part Number"  is the same as the "New Part Number",  proceed to Step   9 . 
    • If the "Current ECU part Number"  is NOT the same as the "New Part Number",  continue with Step 4. 
  4. From the EPB tab, select the EPB flash part number. Read the flash special instructions page. Select "OK"  to continue.
  5. From the flash ECU agreement page, agree to terms by checking the box.
  6. Select "Flash ECU"  and then follow the wiTECH screen instructions to complete the flash.
  7. Confirm the software is at the latest available calibration level.
  8. Click "View DTCs",  select "Clear All DTCs",  click "Continue"  and then click "Close". 
  9. Place the ignition in the "OFF"  position and then remove the wiTECH micro pod II device from the vehicle.
  10. Remove the battery charger from the vehicle.
  11. Close the vehicle hood.

COMPLETION REPORTING AND REIMBURSEMENT

Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims paid will be used by FCA to record recall service completions and provide dealer payments.

Use the following labor operation numbers and time allowances:

LABOR OPERATION NUMBER AND TIME ALLOWANCE

  Labor Operation Number Time Allowance
Inspect DTCM/EPB Software Levels 18-W4-81-81 0.2 hours
Inspect DTCM/EPB Software Level and Reprogram DTCM and EPB with New Software 18-W4-81-82 0.3 hours
Exchange PTU Unit 18-W4-81-50 0.0 hours
Related     
Handling Charge for PTU Exchange 95-21-41-50 $5
NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

DEALER NOTIFICATION

To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification.

OWNER NOTIFICATION AND SERVICE SCHEDULING

All involved vehicle owners known to FCA are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is attached.

VEHICLE LISTS, GLOBAL RECALL SYSTEM, VIP AND DEALER FOLLOW UP

All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed.

GRS provides involved dealers with an updated  VIN list of their incomplete  vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission.

To use this system, click on the "Service"  tab and then click on "Global Recall System."  Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence.

Dealers must perform this repair on all unsold vehicles before retail delivery. 

Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair.

Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. 

ADDITIONAL INFORMATION

If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager.

Customer Services/Field Operations

FCA US LLC

IMPORTANT SAFETY RECALL

PTU Input Spline 

Dear [Name],

W48/NHTSA 20E-037 

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.

FCA has decided that a defect, which relates to motor vehicle safety, exists in certain Power Transfer Units (PTUs).

It is extremely important to take steps now to repair your vehicle to ensure the safety of you and your passengers.

WHY DOES MY VEHICLE NEED REPAIRS? 

FCA records indicate that you may have purchased a Power Transfer Unit (PTU) for your vehicle Some PTUs (part numbers 68090605AJ, 68090605AK, 68090605AL 68282447AA, 68282447AB, 68282447AC, 68307403AA, and 68307403AB) may have been built to allow movement in the PTU between the differential input splines and the transmission output shaft. This condition may result in the teeth of the input splines wearing off, which may eventually cause a loss of engagement between the transmission and the differential inside the PTU. If this occurs, torque cannot be transferred between the front wheels and the transmission, which will result in a loss of motive power while the vehicle is in motion and a loss of the PARK function while stationary. A loss of motive power or PARK function can cause a vehicle crash without prior warning and/or injury to others outside the vehicle. 

HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE? 

FCA US will exchange your PTU, or repair your vehicle with new PTU installed [2] free of charge (parts and labor). To do this, your dealer will reprogram the Drive Train Control Module and the Electric Park Brake if the PTU has been installed. If the subject part is not installed in a vehicle, it will be exchanged with a new part. We recommend that you schedule a service appointment to minimize your inconvenience. Please bring the uninstalled PTU that you purchased, or the vehicle with new PTU installed, and this letter with you to your dealership.

TO SCHEDULE YOUR FREE REPAIR, CALL YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY 

WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED? 

If you have already experienced this specific condition and have paid to have it repaired, you may visit www.fcarecallreimbursement.com  to submit your reimbursement request online. [3] Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. If you have had previous repairs performed and/or already received reimbursement, you may still need to have the recall repair performed.

We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you for your attention to this important matter.

Customer Assistance/Field Operations

FCA US LLC

YOUR SCHEDULING OPTIONS 

  1. RECOMMENDED OPTION Call your authorized Chrysler/Dodge/Jeep®/RAM Dealership 
  2. Call the FCA Recall Assistance Center at 1-800-853-1403. An agent can confirm part availability and help schedule an appointment 
  3. Visit recalls.mopar.com or download the Mopar Owner's Companion App. 

Get access to recall notifications, locate your nearest dealer, and more through this website or Mopar Owner's Companion App. You will be asked to provide your Vehicle Identification Number (VIN) to protect and verify your identity.

DEALERSHIP INSTRUCTIONS 

Please reference Safety Recall W48. 

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