S80

June 2017
Dealer Service Instructions for:
Customer Satisfaction Notification S80
Aftermarket Dana 60 Front Axle
Models
2007 - 2016
(JK) Jeep Wrangler
NOTE: This campaign applies only to the above vehicles equipped with an
Aftermarket Dana 60 Front Axle with 8 lug wheels.
IMPORTANT: Some of the involved vehicles may be in dealer used vehicle
inventory. Dealers should complete this campaign service on these vehicles
before retail delivery. Dealers should also perform this campaign on vehicles in for
service. Involved vehicles can be determined by using the VIP inquiry process.
Subject
The aftermarket front axle steering knuckles have been machined with an incorrect
taper during the manufacturing process on about 250 of the above vehicles, with
approximately 80 of the axles sold by Mopar aftermarket. This condition can result
in premature axle knuckle wear.
Repair
The aftermarket front axle knuckles must be replaced with new axle knuckles for the
left side and right side.
 Copyright 2017, FCA US LLC, All Rights Reserved (kka)
Customer Satisfaction Notification S80 –Aftermarket Dana 60 Front Axle
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Parts Information
Part Number
Description
CCAGS801AA Axle Knuckle Service Kit
Each package contains the following components:
Quantity
1
1
2
2
2
3
12
2
2
04874469
Description
Knuckle, Right Side
Knuckle, Left Side
Nut, Upper Ball Joint
Pin, Cotter
Lock Nut, Lower Ball Joint
Nylock Nut, Tie Rod/Steering Link
Nut, Lock Hub
Bolt, Steering limit
Nut, Steering limit jam
Gear & Axle Lubricant (SAE 75W-140) (API GL-5) MOPAR
Due to the unique list of affected axles (by serial
number), the following steps will be needed to
determine if the steering knuckle service kit will
be required.
1. Dealership should obtain serial number
from customer’s vehicles. The serial
Figure 1 – Front Axle Tag
number tag can be found on the top of the
front axle (Figure 1).
2. The dealership should contact DANA via email ([email protected])
with the following information:
a. Dealer name, address, and dealer code
b. Contact name and phone number
c. VIN and axle serial number
3. Dana will validate the axle serial number supplied and respond within
approximately 24 hours with the disposition on the axle repair.
4. If required, the dealership must then place the order for the specified
part through normal means using an “E” order type. If an “S” order type
is placed, it will count against your special handling allowance. Shipment
will arrive directly from the supplier (SSD), there will be no shipping or
special handling charges to the dealership.
Customer Satisfaction Notification S80 –Aftermarket Dana 60 Front Axle
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5. Dealers should confirm part has arrived before customer comes in for
their service visit.
NOTE: Dealer should include the last 6 digits of the VIN in the “Order
Number” field when placing the order.
Parts Return
This campaign part will be subject to parts return. Please make sure to return parts
in the original shipping box and attach the provided prepaid return label to box.
Special Tools
The following special tools are required to perform this repair:
 C4150A
Puller, Ball Joint
 9360
Seperator, Ball Joint
Service Procedure
1. Raise and support the vehicle.
BRAKE
CALIPER
2. Remove both front tire and
wheel assemblies.
3. Remove the caliper adapter
bolts on both sides and save
(Figure 2).
NOTE: Support the disc
brake caliper; do not let it
hang by the brake hose.
4. Remove the disc brake rotor.
CALIPER
ADAPTER
BOLTS
Figure 2 - Caliper
NOTE: May have to use a rubber mallet to loosen rotor from hub.
Customer Satisfaction Notification S80 –Aftermarket Dana 60 Front Axle
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Service Procedure (Continued)
5. Remove the three splash shield bolts and save.
6. Remove the six hub nuts and washers and discard (Figure 3).
HUB NUTS
Figure 3 – Hub Nuts
CAUTION: Use care when removing the hub nuts and washers, damaged
may occur to the ABS tone wheel during the nut removing procedure.
7. Remove the wheel speed sensor mounting bolt and save.
8. Remove the wheel speed sensor; make sure “O” ring is still attached to the sensor
(Figure 4).
“O” RING
Figure 4 – Wheel Speed Sensor
Figure 4 – Wheel Speed Sensor
Customer Satisfaction Notification S80 –Aftermarket Dana 60 Front Axle
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Service Procedure (Continued)
9. Remove Axle shaft assembly, using moderate force; pry in location shown
(Figure 5, and 6).
PRY LOCATION
PRY
LOCATION
PRY LOCATION
Figure 7 - AXEL SHAFT
Figure 5 – Axle Shaft
AXLE SHAFT ASSEMBLY
Figure 6 – Axle Shaft Right Side
NOTE: Spray rust penetrant on back of hub and near the front hub studs to
assist axle shaft removal.
NOTE: Place drain pan under the front axle to contain axle lube draining
from axle.
Customer Satisfaction Notification S80 –Aftermarket Dana 60 Front Axle
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Service Procedure (Continued)
10. Remove the tie rod end nuts and discard.
11. Disconnect the tie rod end from the steering knuckle using Miller Tool 9360 or
equivalent (Figure 7).
12. Remove the steering link nut and discard right side only (Figure 8).
TIE ROD
DISC BRAKE ROTOR
Miller Tool 9360
TIE ROD
Figure 7 – Miller Tool 9360
STEERING LINK NUT
Figure 8 – Right Side
13. Disconnect the steering link end from the steering knuckle using Miller Tool
9360 or equivalent (Figure 8).
14. Remove the upper ball joint cotter pin and partially loosen the nut to hold knuckle
in place.
15. Remove the lower ball joint nut and discard.
Customer Satisfaction Notification S80 –Aftermarket Dana 60 Front Axle
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Service Procedure (Continued)
16. Separate the upper ball joint from
the knuckle using special tool
C4150A Puller, once separated
remove the upper ball joint nut
and discard (Figure 9).
UPPER BALL JOINT
C4150A PULLER
NOTE: The lower ball joint will
typically separate at the same
time as the upper.
Figure 9 – Upper Ball Joint
17. Remove the knuckle from the
vehicle, and measure the steering
stop limit bolt height (Figure 10).
18. Install the NEW supplied steering
stop limit bolt and jam nut, and
adjust to the same height as
measured on the removed
knuckle, then tighten the jam nut.
STEERING STOP LIMIT BOLT
JAM NUT
Figure 10 - Steering Stop Bolt
Customer Satisfaction Notification S80 –Aftermarket Dana 60 Front Axle
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Service Procedure (Continued)
19. Install the NEW knuckle on to the lower and upper ball joint studs and hand start
both upper and lower ball joint with the NEW supplied nuts (Figure 11, and 12).
Note: The lower ball joint
nut has triangle marks that
MUST face up when
installed.
CASTLE NUT
NEW KNUCKLE
TRIANGLE MARKS
Figure 12 - Knuckle
Figure 11 – Lower Ball Joint Nut
20. Complete the following tightening sequence below;
a. Tighten the lower ball joint nut to 60 ft. lbs. (81 N·m) to insure proper
taper lock.
b. Tighten the upper ball joint nut to 70 ft. lbs. (94 N·m); then advance to
the next castle nut opening to line up with hole on ball joint, then install
the cotter pin.
c. Tighten the lower ball joint nut to 160 ft. lbs. (217 N·m).
21. Install the tie rod end into the NEW axle knuckle and hand start the NEW nut.
NOTE: The kit includes nuts for the stock tie rods; if the vehicle no longer
has stock tie rods, and the nuts provided are not appropriate, other action
may be required.
22. Tighten the NEW tie rod nut to 55 ft. lbs. (75 N·m).
Customer Satisfaction Notification S80 –Aftermarket Dana 60 Front Axle
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Service Procedure (Continued)
23. Install the steering link into the NEW axle knuckle and hand start the NEW nut
Right Side Only.
24. Tighten the NEW steering link nut to 55ft. lbs. (75 N·m).
25. Insert the axle shaft through the
NEW axle knuckle into the axle
assembly ensuring the spindle is
fully seated onto the NEW
knuckle studs, and the hub flange
flat is facing the rear of vehicle;
wipe any lube residue off from
the axle housing (Figure 13).
KNUCKLE
STUDS
HUB FLANGE FLAT
Figure 13 – Hub Flange
26. Install the six NEW nuts and
washers onto the hub studs
(Figure 14).
HUB NUTS AND WASHERS
ABS TONE
WHEEL
27. Tighten the axle stud nuts to
63ft. lbs. (85 N·m).
CAUTION: Use care when
tightening the hub nuts and
washers, damaged may occur to
the ABS tone wheel during the
nut tightening procedure.
Figure 14 – Knuckle Assembly
28. Install the wheel speed sensor apply appropriate lube to assist installation, verify
the “O” ring is in place and no debris is on the sensor.
29. Install and tighten the wheel speed sensor bolt to 79 in. lbs. (9 N·m).
Customer Satisfaction Notification S80 –Aftermarket Dana 60 Front Axle
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Service Procedure (Continued)
30. Install the splash shield using the three original screws.
31. Tighten the three splash shield screws to 89 in. lbs (10 N·m).
32. Install the disc brake rotor onto the hub.
AXLE FILL PLUG
33. Install the disc brake caliper and
tighten
the
caliper
adaptor
mounting bolts
to 295 ft. lbs.
(400 N·m).
34. Remove the front axle lube fill
plug, and check lube level, add if
necessary (Figure 15).
35. Install fill plug and tighten to
20 ft. lbs. (27 N·m).
FRONT AXLE COVER
36. Install the tire and the wheel
assemblies.
FILL LEVEL
Figure 15 – Front Axle
37. Lower the vehicle and depress brake pedal several times to adjust caliper brake
pads.
38. Road test vehicle.
39. Return the vehicle to the customer.
Customer Satisfaction Notification S80 –Aftermarket Dana 60 Front Axle
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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
submitted will be used by FCA to record Customer Satisfaction Notification service
completions and provide dealer payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation
Number
Time
Allowance
Inspect Axle Serial Number
02-S8-01-81
0.2 hours
Replace Front Axle Knuckles
02-S8-01-82
1.9 hours
Add the cost of the parts plus applicable dealer allowance to your claim.
NOTE: See the Warranty Administration Manual, Recall Claim Processing Section,
for complete 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 mail. They are requested to schedule appointments for this service
with their dealers. A generic copy of the owner letter is attached.
Enclosed with each owner letter is an Owner Notification postcard to allow owners
to update our records if applicable.
Customer Satisfaction Notification S80 –Aftermarket Dana 60 Front Axle
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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 campaign launch, those with a phone number, city, zip
code, or VIN sequence.
Dealers should 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.
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 notification 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 Service / Field Operations
FCA US LLC
This notice applies to your vehicle,
CUSTOMER SATISFACTION NOTIFICATION
[Model Year and Model]
Aftermarket DANA 60 Front Axle
VIN XXXXXXXXXXXXXXXXX
S80
LOGO
VEHICLE PICTURE
Dear [Name],
At FCA US LLC, we recognize that the success of our business depends on the satisfaction of
our customers. We are constantly monitoring the quality of our products and looking for
opportunities to improve our vehicles even after they are sold. Because your long-term
satisfaction is important to us, we are contacting you on important improvements we would
like to make to your vehicle [1]. This will be done at no charge to you.
We are recommending the following improvements be performed on certain [2007-2016 Jeep®
Wrangler] vehicles equipped with an DANA 60 aftermarket front axle with 8 lug wheels.
WHY DOES MY VEHICLE NEED REPAIRS?
The aftermarket front axle knuckles on your vehicle were machined with an incorrect taper.
This condition can result in premature axle knuckle wear.
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 our Recall Website,
recalls.mopar.com or scan below.
QR Code
HOW DO I RESOLVE THIS CUSTOMER SATISFACTION NOTIFICATION
FCA will repair your vehicle [2] free of charge (parts and labor). To do this, your dealer will
replace both front aftermarket axle knuckles. In addition, your dealer will require your vehicle
for proper check-in, preparation, and check-out during your visit. Your time is important to us;
please be aware that these steps may require more time. The estimated repair time is 2 hours.
We recommend that you schedule a service appointment to minimize your inconvenience.
Please bring this letter with you to your dealership.
TO SCHEDULE YOUR FREE REPAIR CALL 1-800-853-1403
OR 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.
You can find your nearest dealer and
review all your scheduling options
from this website. You will be asked
to provide your Vehicle Identification
Number (VIN) to protect and verify
your identity. The last eight characters
of your VIN are provided above.
DEALERSHIP INSTRUCTIONS
Please reference CSN S80
Customer Assistance/Field Operations
Fiat Chrysler Automobiles US LLC
Mr. Mrs. Customer
1234 Main Street
Hometown, MI 48371
[1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information.
[2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National
Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236
(TTY 1-800-424-9153), or go to safercar.gov.
[3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 218004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.
Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days.