1992 Plymouth Voyager Maintenance Schedule

Issue: VEHICLE DESCRIPTION: PASSENGER MINI-VANS. THE CENTER REAR SEAT, RIGHT OUTBOARD SIDE, SAFETY BELT ANCHOR HOOK CAN BECOME UNATTACHED FROM THE BODY ANCHOR POSITION.

Risk: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.

Fix: DEALERS WILL REPLACE THE ANCHOR HOOK RETAINING CLIP WITH A REVISED PROFILE CLIP AND A COVER PLATE.

Issue: VEHICLE DESCRIPTION: PASSENGER MINI-VANS. COVERS ON THE SOLID STALK MOUNTED SEAT BELT BUCKLES CAN BECOME DISLODGED CAUSING THE RELEASE BUTTON TO STICK INSIDE THE COVER. THE BUCKLE WOULD THEN BE ONLY PARTIALLY LATCHED.

Risk: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.

Fix: DEALERS WILL INSTALL A COVER RETAINING CLIP TO THE STALK MOUNTED BUCKLE COVER TO PREVENT DISLOCATION OF THE BUCKLE COVER.

Issue: THE ABS HYDRAULIC CONTROL UNIT CAN EXPERIENCE EXCESSIVE BRAKE ACTUATOR PISTON SEAL WEAR CAUSING PUMP-MOTOR DETERIORATION.

Risk: IF THIS CONDITION OCCURS, THE ABS FUNCTION COULD BE LOST AND REDUCED POWER ASSIST WOULD BE EXPERIENCED DURING VEHICLE BRAKING INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.

Fix: DEALERS WILL TEST THE VEHICLE'S ANTI-LOCK BRAKE SYSTEM AND REPAIR THE VEHICLES IF NECESSARY. ALSO THE WARRANTY ON ALL ABS COMPONENTS WILL BE EXTENDED TO 10 YEARS OR 100,000 MILES (EXCEPT FOR THE BRAKE ACTUATOR PISTON ASSEMBLY AND THE PUMP-MOTOR ASSEMBLY WHICH WILL HAVE A LIFETIME COVERAGE). OWNERS WILL ALSO BE REIMBURSED FOR PREVIOUS ABS COMPONENT REPAIR COSTS.

Issue: VEHICLE DESCRIPTION: MINIVANS. THE LEFT HAND WINDSHIELD WIPER PIVOT DRIVE ARM WAS NOT MECHANICALLY STAKED TO THE PIVOT SHAFT.

Risk: THIS COULD ALLOW THE DRIVE ARM TO DISENGAGE FROM THE SHAFT LEADING TO A LOSS OF WIPER FUNCTION. THE DRIVER'S VISIBILITY WOULD BE IMPAIRED, INCREASING THE RISK OF A CRASH.

Fix: DEALERS WILL REPLACE THE LEFT HAND SIDE WINDSHIELD WIPER PIVOT ASSEMBLY.

Issue: THE BRAKE PEDAL PAD ATTACHMENT TO THE PEDAL ARM MAY NOT HAVE ADEQUATE STRENGTH DUE TO MISLOCATION OF WELDS, AND COULD BREAK.

Risk: FAILURE OF THE PEDAL PAD TO PEDAL ARM ATTACHMENT RESULTSIN LOSS OF BRAKING ABILITY, AND COULD RESULT IN AN ACCIDENT.

Fix: REPLACE INADEQUATE BRAKE PEDALS WITH PROPERLY MANUFACTURED PEDALS.

Issue: THE ZINC PLATING OPERATION PERFORMED ON THE UPPER STEERING COLUMN SHAFT COUPLING BOLT CAUSED HYDROGEN EMBRITTLEMENT AND BREAKAGE OF THE BOLT.

Risk: FRACTURES OF THE UPPER STEERING COLUMN SHAFT COUPLINGBOLT RESULT IN A LACK OF COUPLING LOAD ON THE SHAFT AND LOSS OF STEERINGCONTROL.

Fix: REPLACE THE ZINC PLATED BOLT WITH A PHOSPHATE PLATED BOLT.

Issue: THE STEERING WHEEL ARMATURE STAMPING CAN CRACK AND SEPARATE FROM THE CENTER HUB ATTACHMENT TO THE STEERING COLUMN.

Risk: IF THE STEERING WHEEL SEPARATES FROM THE CENTER HUB ATTACHMENT TO THE STEERING COLUMN, LOSS OF CONTROL CAN OCCUR INCREASING THE RISK OF AN ACCIDENT.

Fix: DEALERS WILL INSPECT THE STEERING WHEEL FOR ARMATURE CRACKS IN THE CENTER HUB ATTACHMENT AREA. ANY STEERING WHEELS SHOWING CRACKS WILL BE REPLACED. ALL OTHER VEHICLES WILL HAVE A REINFORCEMENT PLATE INSTALLED TO PREVENT STEERING WHEEL SEPARATION IN THE EVENT CRACKING OCCURS.

Issue: THE BOLTS USED TO ATTACH THE STRUT TO THE BODY AND THE REAR LIFTGATE CAN ACCUMULATE FATIGUE DAMAGE IF THREE FACTORS COMBINE. IF THE BOLT IS LOOSE, THE GAS STRUT IS OVER-PRESSURIZED, AND THE FREQUENCY OF OPENING AND CLOSING CYCLES IS HIGHER THAN FOR THE AVERAGE CUSTOMER, THE BOLT CAN FAIL.

Risk: PERSONAL INJURY COULD OCCUR IF THE BOLTS BREAK ALLOWING THE LIFTGATE TO FALL SUDDENLY.

Fix: DEALERS WILL INSPECT FOR LOOSE FASTENERS, IF THE FASTENERS ARE LOOSE, THE STRUT (AND INTEGRAL BOLTS) WILL BE REPLACED. IF THE BOLT SHOWS EVIDENCE OF TORQUE, THE BOLT WILL BE REMOVED, LARGER WASHERS WILL REPLACE THE EXISTING WASHER AND THE BOLT WILL BE REINSTALLED AND HAND TIGHTENED TO THE TARGET TORQUED.

Issue: VEHICLE DESCRIPTION: LIGHT DUTY PASSENGER MINIVANS WITH REMOTE RELEASE. THIS IS NOT A SAFETY RECALL. THERE HAS BEEN NO DETERMINATION THAT A SAFETY DEFECT EXISTS WITH THE MINIVAN LATCHES. CHRYSLER IS CONDUCTING A SERVICE CAMPAIGN TO REPLACE THE LIFTGATE LATCH ASSEMBLY OF THE AFFECTED MINIVANS. IN A COLLISION, THE REAR LIFTGATE LATCH ASSEMBLY COULD OPEN.

Risk: IF THE LIFTGATE LATCH OPENS, OCCUPANTS CAN BE EJECTED RESULTING IN SIGNIFICANTLY INCREASED RISK OF INJURY OR DEATH.

Fix: CHRYSLER DEALERS WILL REPLACE THE LIFTGATE LATCH WITH A NEW STRONGER LATCH ASSEMBLY WITHOUT CHARGE. CHRYSLER BEGAN NOTIFYING OWNERS OF THESE VEHICLES IN MARCH 1996.

Issue: VEHICLE DESCRIPTION: LIGHT DUTY PASSENGER MINIVANS WITHOUT REMOTE RELEASE. THIS IS NOT A SAFETY RECALL. THERE HAS BEEN NO DETERMINATION THAT A SAFETY DEFECT EXISTS WITH THE MINIVAN LATCHES. CHRYSLER IS CONDUCTING A SERVICE CAMPAIGN TO REPLACE THE LIFTGATE LATCH ASSEMBLY OF THE AFFECTED MINIVANS. IN A COLLISION, THE REAR LIFTGATE LATCH ASSEMBLY COULD OPEN.

Risk: IF THE LIFTGATE LATCH OPENS, OCCUPANTS CAN BE EJECTED RESULTING IN SIGNIFICANTLY INCREASED RISK OF INJURY OR DEATH.

Fix: CHRYSLER DEALERS WILL REPLACE THE LIFTGATE LATCH WITH A NEW STRONGER LATCH ASSEMBLY WITHOUT CHARGE. CHRYSLER BEGAN NOTIFYING OWNERS OF THESE VEHICLES IN OCTOBER 1995.

Issue: FUEL TANK FLANGES WERE NOT BENT AS REQUIRED TO ALLOW THE SPECIFIED CLEARANCE FOR THE FUEL TANK MOUNTING STRAPS AND FUEL LINES AT THE TANK.

Risk: THE UNBENT FLANGES TO THE FUEL TANK WILL DAMAGE THEMOUNTING STRAPS AND/OR FUEL LINES. THE DAMAGED MOUNTING STRAPS MAY BREAK CAUSINGTHE TANK TO DROP AND THE DAMAGED FUEL LINE WILL LEAK FUEL. IN EITHER CASE A FIRECOULD RESULT IF THE SPILLED FUEL IS EXPOSED TO AN IGNITION SOURCE.

Fix: REPAIR THE FLANGE BY BENDING TO THE CORRECT ANGLE; REPLACE DAMAGED FUEL LINES AND MOUNTING STRAPS.