S2003000001RevE

Case Number: S2003000001 REV. E
Release Date: August 2022
Symptom/Vehicle Issue: Noise From The Front Axle Area Over Bumps
Discussion: Some customers may experience a grinding, rumbling, or whirring type
noise from the front axle. The noise can be intermittent or constant, and typically
happens at 30mph (48kph) or higher when hitting a bump or irregularity in the road. In
addition, it may also be noted that the noise is not present in 4wd.
If a technician receives a vehicle in for repair with the above condition, please perform
the following diagnosis and repair procedure.
Diagnosis:
1. Drive the vehicle with the transfer case in 2wd mode to duplicate the noise concern.
2. With the noise occurring, shift the transfer case from 2wd to 4wd. Was the noise
eliminated?
a. Yes>>> Proceed to (Step 3).
b. No>>> This document does not apply. Continue with normal diagnostics and
repair as necessary.
3. Remove the Front Axle Disconnect (FAD). Please refer to Service Library Service
Information Section 03 – Differential Driveline > Actuator/Motor > Removal and
Installation > Front Axle Disconnect (FAD).
4. Inspect both the intermediate and output shafts for excessive radial play. Excessive
radial play in the output shaft is an indication of intermediate shaft bushing wear.
5. Inspect the intermediate and output shaft’s outer splines for signs of scoring or other
damage.
This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Online
does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the
appropriate course of action.
Contact STAR Center, or your Technical Assistance Center Via TechConnect, eCONTACT or Service Library
entry if no solution is found.
Stellantis US LLC
Version 4.5 07/22/2022
6. Did the output shaft have excessive radial play and/or are there signs of
damage/scoring on the outer splines?
a. Yes>>> Please perform the repair procedure.
b. No>>> This document no longer applies. Please continue with normal
diagnostics for the concern and repair as necessary.
Repair Procedure:
1. Replace both the Intermediate Shaft assembly (Figure 1) AND the output shaft.
Refer to detailed replacement procedures in Service Library Service Information
Section 03 – Differential and Driveline > Shafts, Axle/Drive/Half > Removal and
Installation > Front Halfshafts.
1.
Intermediate shaft kit. 2. Intermediate shaft. 3. Intermediate shaft bushing. 4. Intermediate Shaft Bearing. 5. Snap ring. 6. Shift Collar
Figure 1.
This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Online
does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the
appropriate course of action.
Contact STAR Center, or your Technical Assistance Center Via TechConnect, eCONTACT or Service Library
entry if no solution is found.
Stellantis US LLC
Version 4.5 07/22/2022
NOTE: Replace the Intermediate Shaft as an entire assembly. Intermediate shaft
assemblies are available through Mopar as a complete kit.
NOTE: The output shaft must also be replaced.
2. While installing the new intermediate shaft assembly, apply a thin layer of grease to
the inner diameter of the intermediate shaft bushing using Mopar pn# 05083149AA
(MS-6560) or equivalent. Please see (Figure 2).
1.
2.
3.
Intermediate shaft bearing.
Intermediate shaft bushing.
Grease application area.
Figure 2.
This document does not authorize warranty repairs. This communication documents a record of past experiences. STAR Online
does not provide any conclusions about what is wrong with the vehicle. Rather, it captures all previous cases known that appear
to be similar or related to the vehicle symptom / condition. You are the expert, and you are responsible for deciding on the
appropriate course of action.
Contact STAR Center, or your Technical Assistance Center Via TechConnect, eCONTACT or Service Library
entry if no solution is found.
Stellantis US LLC
Version 4.5 07/22/2022