In document from NHTSA, the problem is traced from the start at the plant. The problem was spotted by the people putting the vehicle together and inspecting it, no reports of this condition were reported by owners.
Vehicles:
Chrysler/Sebring/2010
Dodge/Avenger/2010
Dodge/Nitro/2010
Dodge/Ram/2009-2010
Jeep/Commander/2010
Jeep/Grand Cherokee/2010
Jeep/Liberty/2010
Action
Chrysler will conduct a voluntary safety recall to replace the brake booster input rod retaining clip on all of the vehicles listed above and will inspect for the presence of the brake booster input rod retaining clip on all of the Dodge Ram vehicles and repair any Dodge Ram vehicles found with a missing clip. To be proactive, Chrysler issued a Rapid Response Transmittal on December 22,2009 to inspect the Dodge Ram vehicles for the presence of the clip and repair any vehicles with a missing clip.
Description of Defect: The following chronology of principal events led to the determination of a defect:
A small percentage of the affected Chrysler Sebring, Dodge Avenger, Nitro and Jeep Commander, Grand Cherokee and Liberty vehicles may have been built with an improperly formed brake booster input rod retaining clip and a small percentage of the affected Dodge Ram vehicles may have been built without a brake booster input rod retaining clip. The defect could result in the loss of service brakes.
• On November 16, 2009 an operator at Toledo North Assembly Plant (TNAP) noticed an issue with the clip which is installed to retain the brake booster input rod to the brake pedal arm.
• The clip retention tab on the brake pedal pin was improperly formed during the clip manufacturing process, resulting in reduced retention force.
• TNAP contained their shipping yard and notified the remaining Chrysler Assembly Plants that utilize the same clip.
• Toluca, Graz and Jefferson North Assembly Plants (JNAP) also contained their shipping yards, while the investigation continued.
• The initial clip found at TNAP was from A WT Metal Specialties (A WT) production lot# 09321, which was shipped on October 29,2009 to TNAP and November 5, 2009 to JNAP. This production lot of clips was only shipped to TNAP and JNAP.
• Inspection of loose clips and vehicles from lot# 09321 confirmed that only a small percentage of the clips were improperly manufactured.
• Production lot# 090107 was shipped from A WT without being 100% inspected to Sterling Heights Assembly Plant (SHAP), they contained their shipping yard on November 20,2009.
• One improperly formed clip from lot# 090107 was identified during SHAP loose clip inspection.
• On December 9, 2009 Saltillo Truck Assembly Plant (STAP) was validating vehicles after assembly, when the driver experienced a complete loss of service brakes.
• ST AP contained their shipping yard on December 10, 2009.
• Investigation determined the brake booster input rod retention clip was not installed during
the vehicle manufacturing process.
• There was a revision in the operator assignments at STAP beginning on August 17, 2009.
• STAP vehicle inspection identified two additional vehicles with missing clips.
• To be proactive, Chrysler issued a Rapid Response Transmittal on December 22, 2009 to
inspect the Dodge Ram vehicles for the presence ofthe clip and repair any vehicles with a
missing clip.
• Chrysler Group, LLC is not aware of any accidents or injuries related to these issues.
Chrysler will conduct a voluntary safety recall to replace the brake booster input rod retaining clip on all of the Chrysler Sebring, Dodge Avenger, Nitro and Jeep Commander, Grand Cherokee and Liberty vehicles and will inspect for the presence of the brake booster input rod retaining clip on all of the Dodge Ram vehicles and repair any vehicles with a missing clip. Chrysler expects to initiate national notification to both dealers and owners in January, 2010.
