TSBs for 2004 SRT4

SUBJECT:
WOT Acceleration Stumble/Number 4 Spark Plug Wire Appearance
OVERVIEW:
This bulletin involves inspecting spark plugs and spark plug wires then replacing as
required.
MODELS:
2003 - 2004 (PL) Neon SRT4
NOTE: This bulletin applies to vehicles equipped with a 2.4L turbo engine (sales
code EDV).
SYMPTOM/CONDITION:
During Wide Open Throttle (WOT) acceleration, the engine stumbles periodically. This
might feel like you are driving over multiple broomsticks. Some 2003 and 2004 SRT4's
were built with four straight-boot spark plug wires. In some extreme cases, the number 4
cylinder ignition wire sheathing can turn white, this appearance in itself is not an indication
of wire failure.
PARTS REQUIRED:
Qty. Part No. Description
1 05033266AA Wire, #4 Cylinder 90 Degree Boot
AR (1) 05033233AB Wire, #1, 2, or 3 Cylinder Straight Boot
AR (4) SPRE14MCC5 Plug, Spark
DIAGNOSIS/REPAIR PROCEDURE:
1. Inspect all four spark plugs for electrode condition and carbon tracking. Spark plug
insulator surface imperfections may cause carbon tracking on the surface of the spark
plug insulator and through the spark plug boot insulation. Deterioration of this
insulation can cause periodic single cylinder misfire that may not happen often enough
to set a MIL light.
2. If carbon tracking is evident on the spark plug insulation or otherwise damaged,
replace the spark plug, p/n SPRE14MCC5, and the corresponding wire.
NUMBER: 18-012-04
GROUP: Engine Performance
DATE: March 16, 2003
NOTE: Whenever replacing a spark plug for a carbon tracking related misfire issue,
always be sure to replace the ignition wire as well. If the wire is not replaced
with the spark plug, the damaged boot seal will allow contamination into the
plug contact area. The damaged boot seal may also allow continued carbon
tracking due to the reduced insulation performance of the perforated boot
seat.
3. If the number 4 spark plug wire has abnormally high resistance (greater than 8000
ohms) or the sheathing is split/cracked/discolored, replace the wire with spark plug
wire, p/n 5033266AA.
4. If the number 1, 2, or 3 spark plug wire has abnormally high resistance (greater than
7200 ohms) or the sheathing is split/cracked/discolored, replace the wire with a 90
degree boot spark plug wire, p/n 05033233AB.

SUBJECT:
Steering Column Click Sound
OVERVIEW:
This bulletin involves aligning the steering column or removing the steering column and
installing a new steering column shaft, revised wedge, **revised spring** and seating the
lower bearing.
MODELS:
2000 - 2004 (PL) Neon
NOTE: This bulletin applies to vehicles built prior to November 16, 2003 (MDH
1116XX).
SYMPTOM/CONDITION:
A click sound is heard when the steering wheel is turned.
PARTS REQUIRED:
Qty. Part No. Description
1 **05159136AB**
Kit consists of:
**05057088AA
(3) 04664130
06503985
06506112AA
05057229AA
04690570
Kit, Lower Steering Column Click Repair
Kit consists of:
Spring, Lower Preload**
Retainer
Roll Pin
Screw
Shaft With O-ring
Wedge
AR (1) 04690507AB Bearing, Upper
AR (1) 04690344AB Bearing, Lower
NUMBER: 19-002-04 REV. A
GROUP: Steering
DATE: August 27,2004
SPECIAL TOOLS/EQUIPMENT REQUIRED:
NPN Steering Wheel Puller
NPN 90° Snap Ring Pliers
6831-A Roll Pin Remover/Installer
DRBIII® Scan Tool
DIAGNOSIS/REPAIR PROCEDURE:
NOTE: Refer to the appropriate service manual or service information on
TechCONNECT for removal and installation procedures.
1. Turn the steering wheel and listen for a click sound. If the click sound is heard, remove
the steering column shrouds.
2. Turn the steering wheel, listen to hear if the click sound remains.
3. If the click sound is eliminated determine the source interference with the steering
column shrouds and correct, the repair is then complete.
WARNING:When an undeployed airbag is to be removed from the steering wheel,
disconnect and isolate the battery ground cable. Allow the system
capacitor to discharge for two minutes, then begin airbag removal.
NOTE: Be sure to center the steering wheel and have the front tires and wheels
straight ahead before removing the steering wheel and disconnecting the
lower coupling. Access to the steering column shaft coupler screw is easier
if the steering wheel is turned so the screw head is pointing straight down.
4. If a click sound is heard, remove the steering wheel and disconnect the intermediate
shaft to steering gear (lower) coupling.
NOTE: Turn the steering shaft no more than one revolution in either direction from
center. Keep track of the centered position.
5. Turn the steering shaft, listen to see if the click sound remains.
6. If the click sound is eliminated reattach the lower coupling and install the steering
wheel, being sure the clockspring/steering wheel travel is centered. Torque the
coupling pinch bolt to 29 Nm (21 ft. lbs.) and torque the steering wheel bolt to 54 Nm
(40 ft. lbs.).
7. Turn the steering wheel; listen to hear if the click sound remains.
8. If the click sound returns, loosen the lower coupling pinch bolt and the four steering
column mounting bracket nuts.
19-002-04 REV. A -2-
9. Jiggle the steering column and then tighten lower coupling pinch bolt. Torque the
coupling pinch bolt to 29 Nm (21 ft. lbs.) Tighten the 2 lower steering column assembly
mounting nuts to hold the steering column in place. Be sure both break-away capsules
are still fully seated in the slots of the upper steering column mounting bracket and the
mounting studs are centered fore-and-aft in the plastic capsules. Then equally tighten
both steering column mounting nuts, until upper steering column mounting bracket is
seated against support bracket. Tighten the 4 steering column bracket to support
bracket nuts to 17 Nm (150 in. lbs.).
10. Turn the steering wheel; listen to hear if the click sound remains. If the click sound is
eliminated, replace the lower coupling pinch bolt, p/n 06506112AA, torque the coupling
pinch bolt to 29 Nm (21 ft. lbs.), then the repair is complete.
11. If the click sound remains, remove the clock spring. To avoid damaging the clock
spring:
a. The clock spring is positioned to the lock housing by two snap latch features at
12:00 and 6:00 o'clock positions. Lift the top latch up slightly while guiding it over
the lock housing. This will prevent the latch from being broken.
b. Care should be taken regarding centering of the steering wheel and clock spring
with respect to the front wheels; follow the service manual clock spring centering
procedure. Turning the steering wheel when the column is disconnected from the
steering gear can damage the clock spring.
c. When using the steering wheel puller, hand tighten the puller bolts (no more than
five revolutions) and avoid contact between the bolts and the top of the clock spring.
d. When removing the airbag inflator connectors, squeeze the sides of the connector,
to release it, while pulling it out of the airbag.
12. Disconnect the lower coupling.
13. Turn the steering shaft; listen to hear if the click sound remains. If the sound is
eliminated determine the source interference with the clockspring and correct, the
repair is then complete.
14. If the click sound remains, remove the steering column from the vehicle.
NOTE: The ignition key must be turned to the run position to remove the
shifter/ignition interlock cable from the key lock housing.
15. Remove the two screws attaching the multifunction switch and separate the switch
from the steering column.
16. Remove the steering column intermediate shaft from the steering column shaft. Install
Remover/Installer, Special Tool 6831-A, through center of roll pin in intermediate
shaft's universal joint and install knurled nut. While holding hex on end threaded rod,
tighten the nut on threaded rod of Remover/Installer. This will pull the roll pin out of the
intermediate shaft's universal joint. Using a screwdriver inserted between the shaft's
universal joint and the steering column lower mounting bracket, gently pry intermediate
shaft off steering column shaft.
17. Remove the spring retainer by squeezing the outside diameter with pliers and sliding it
off the end of the steering column shaft, refer to (Fig. 1).
-3- 19-002-04 REV. A
Fig. 1 SPRING RETAINER REMOVAL
1 - SQUEEZE THE OUTSIDE DIAMETER OF RETAINER TO REMOVE
18. Remove the spring, wedge and steering column shaft .
19. Inspect the upper and lower steering column bearings, if damaged replace them/it as
necessary, p/n 04690507AB upper bearing, p/n 04690344AB lower bearing (with
notch).
20. Stand the steering column on end so the outer race of the upper bearing is supported
on a 1 1/16 in. socket. Using a 7/8" deep well socket or other suitable tool placed
against the lower bearing outer race tap the bearing downward several times with a
brass hammer until the bearing is fully seated. Use a 0.005" feeler gauge to make sure
no clearance exists between the lower casting and the outer race of the lower bearing.
Refer to (Fig. 2)
19-002-04 REV. A -4-
Fig. 2 CHECK THAT BEARING IS FULLY SEATED
1 - BEARING
2 - 0.005 IN. FEELER GAUGE
21. Install the revised steering column shaft p/n 05057229AA, revised wedge, p/n
04690570, and **revised preload spring, p/n 05057088AA**.
22. Thread the steering wheel bolt into the steering column shaft.
23. Stand the column assembly on the head of the steering wheel bolt, insure the surface
is flat. Refer to (Fig. 3).
-5- 19-002-04 REV. A
Fig. 3 STAND STEERING COLUMN ON END
1 - 7/8 IN. DEEP WELL SOCKET
2 - INSURE SURFACE IS FLAT
24. Install a new retainer, p/n 04664130, onto the steering column shaft by using a 7/8"
deep well socket and small hammer to tap the retainer into place so the installed
distance between the lower housing and the outside face of the retainer is 12-14 mm
(15/32-17/32 in.). If the retainer is installed to distance less than 12 mm (15/32 in.)
remove the retainer and install a new retainer, repeat as necessary until the installed
distance is 12-14 mm (15/32-17/32 in.). Refer to (Fig. 4).
NOTE: If the installed dimension is less than 12mm a binding condition may result. If
the installed dimension is greater than 14mm a loose condition may result.
19-002-04 REV. A -6-
Fig. 4 INSTALLATION DISTANCE
1 - INSTALLED DISTANCE BETWEEN THE LOWER HOUSING AND THE OUTSIDE FACE OF THE RETAINER MUST
BE 12-14 mm (15/32-17/32 in.)
25. Verify the click sound has been corrected. If a sound is still present further diagnosis is
required.
26. Using the procedures outlined in the appropriate service information, install the
steering column and intermediate shaft assembly into the vehicle.

Irregular Engine Snapping Sound
OVERVIEW:
This bulletin involves chamfering the bore radius on cam bearing caps
L2 through L5 and R2 through R5.
MODELS:
2001 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan
2002 - 2004 (KJ) Liberty
2002 - 2004 (KJ) Cherokee (International Markets)
2003 - 2004 (PL) Neon
2001 - 2004 (PT) PT Cruiser
2001 - 2004 (RG) Chrysler Voyager (International Markets)
2001 - 2004 (RS) Town & Country/ Caravan/Voyager
2003 - 2004 (TJ) Wrangler
NOTE: This bulletin applies to vehicles equipped with a 2.0L, 2.4L DOHC or 2.4L
Turbo engine (sales code ECC, EDZ, ED1, EDV, ED2 or EDT).
SYMPTOM/CONDITION:
The sound may be noticed when the engine is idling in park between idle rpm and 1400
rpm at normal operating temperature. The sound is on the upper end of the engine
(cylinder head) towards the front of the engine or passenger side (right side). The sound is
irregular, not periodic or harmonious. The frequency of the sound will increase with RPM.
The sound is more of a higher pitch snapping noise not a low metallic knock.
DIAGNOSIS:
If the vehicle operator describes the Symptom/Condition and the technician determines
that the sound is from the upper end of the engine (cylinder head) towards the front of
the engine or passenger side (right side), perform the Repair Procedure.
09-007-04 -2-
REPAIR PROCEDURE:
1. Remove the cylinder head cover (Refer to information available in TechCONNECT
9 - ENGINE/CYLINDER HEAD COVER - Removal)
2. Remove L2 cam bearing cap (Fig. 1).
NOTE: Do not remove the #L1/R1 or L6 cam bearing caps, or loosen the fasteners.
NOTE: Only remove one cam bearing cap at a time.
Fig. 1 CAMSHAFT BEARING CAP IDENTIFICATION
3. Lightly chamfer the two bore radius edges with a small hand file, creating a 45 chamfer
1.0 to 1.5 mm in width along the edge of each bore radius (Fig. 2).
CAUTION: Be careful not to scratch bore surface of cam bearing
cap. Chamfer both bore radius.
Fig. 2 CAMSHAFT BEARING CAP
1 - CAM BEARING CAP RADIUS
4. Clean part to remove any aluminum filings prior to reinstalling.
-3- 09-007-04
5. Reinstall L2 cam bearing cap by loosely assembling fasteners. Prior to and during the
torquing of each fastener, twist the cam bearing cap by hand in a clockwise direction,
as viewed from the top of the engine. Torque M6 fasteners to 12 N·m (105 in. lbs.)
while maintaining a clockwise twisting force on the cam bearing cap.
6. Repeat steps 2 through 4 for cam bearing caps L3, L4, L5, R2, R3, R4, R5 and R6.

SUBJECT:
Front Hub/Half Shaft Click/Pop Sound
OVERVIEW:
This bulletin involves installing a rubber gasket to the face of the half shaft that mounts to
the hub bearing.
MODELS:
2000 - 2005 (PL) Neon
2001 - 2004 (PT) Chrysler PT Cruiser
NOTE: This bulletin applies to PT vehicles built prior to February 18, 2004, (MDH
0218XX).
SYMPTOM/CONDITION:
Vehicle may exhibit a popping/clicking/snapping/ticking sound from the front hub/half shaft
area during acceleration after Drive to Reverse or Reverse to Drive shifts. The sound may
also be present while turning and accelerating from a stop.
DIAGNOSIS:
In order to determine if the popping/clicking/snapping/ticking sound is coming from the
front hub/half shaft interface, perform the following procedure:
1. Raise the vehicle on an appropriate hoist and remove both front wheels.
2. Remove the cotter pin, nut lock, and wave washer from the end of both front half
shafts.
3. With the vehicle's brakes applied to keep hub from turning, loosen both half shaft nuts
to zero torque.
4. With the service brake applied, shift the vehicle from Drive to Reverse and Reverse to
Drive. Once the transmission is engaged in gear, raise the engine speed to 1800 rpm.
5. If the sound is not present, perform the Repair Procedure. If the sound is still present,
the source of the sound is elsewhere. Further diagnosis is required.
PARTS REQUIRED:
Qty. Part No. Description
2 04809863AB Gasket/Washer, Axle (1 per side)
NUMBER: 03-006-04
GROUP: Axle and Propshaft
DATE: September 15, 2004
REPAIR PROCEDURE:
1. Raise the vehicle.
2. Remove the half shaft nut.
3. Remove the wheel and tire assembly from the vehicle. Refer to the service information
available in TechCONNECT Section 22.
4. Remove the two front disc brake caliper adapter to steering knuckle attaching bolts
(Fig. 1).
Fig. 1 FRONT BRAKE MOUNTING
1 - BRAKE ROTOR
2 - HUB AND BEARING
3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP
5. Remove the disc brake caliper assembly from the steering knuckle. The caliper
assembly is removed by first rotating the top of the caliper assembly away from the
steering knuckle and then removing the bottom of the assembly out from under the
machined abutment on the steering knuckle.
6. Support the disc brake caliper assembly by using a wire hook and suspending it from
the strut assembly (Fig. 2).
NOTE: Do not allow the brake caliper assembly to hang by the brake flex hose.
03-006-04 -2-
Fig. 2 PROPERLY SUPPORTED DISC BRAKE CALIPER - TYPICAL
1 - STEERING KNUCKLE
2 - BRAKE FLEX HOSE
3 - CALIPER ASSEMBLY
4 - WIRE HANGER
5 - STRUT ASSEMBLY
7. Remove the brake rotor from the hub and bearing assembly.
8. If the vehicle is equipped with eccentric bolts attaching the steering knuckle to the strut
assembly, proceed to next step. If not, proceed to step 10.
9. Mark the head of the eccentric bolt and the strut, so that the bolt can be installed in the
same position later.
10. Remove the wheel speed sensor bolt.
11. Remove the steering knuckle-to-strut attachment bolts from the steering knuckle (Fig.
3).
-3- 03-006-04
Fig. 3 STRUT TO STEERING KNUCKLE ATTACHING BOLTS
1 - STRUT CLEVIS BRACKET
2 - NUTS AND BOLTS
3 - STEERING KNUCKLE
12. Pull the steering knuckle from the strut clevis bracket.
NOTE: Care must be taken not to separate the inner C/V joint during this operation.
Do not allow half shaft to hang by inner C/V joint after removing outer C/V
joint from the hub/bearing assembly in steering knuckle, the outboard end of
the half shaft must be supported.
13. Pull the steering knuckle assembly down and away from the outer C/V joint while
pulling the C/V joint out of the hub bearing.
14. Support the outer end of the half shaft assembly.
NOTE: The rubber gasket is to be installed as is (after removing the paper backing).
The gasket should not be cut in any way.
15. Slide the gasket/washer p/n, 04809863AB, over the C/V joint splines to the C/V joint
surface, item 2, shown in (Fig. 4).
03-006-04 -4-
Fig. 4 OUTER C/V JOINT
1 - OUTER C/V JOINT
2 - APPLY GASKET TO THIS SURFACE
3 - SPLINES
4 - OIL SEAL SEALING SURFACE.
16. Grasp the inner tripod joint and interconnecting shaft. Forcefully push the tripod joint
into side gear of the transaxle, be sure the snap-ring is engaged with the transaxle
side gear.
17. Clean all debris and moisture out of steering knuckle, in the area were outer CV joint
will be installed into steering knuckle.
18. Clean the C/V joint surface.
19. Ensure that the front of the outer CV joint which fits against the face of the hub and
bearing is free of debris and moisture before installing the outer CV joint into the hub
and bearing assembly.
20. Slide the half shaft back into the front hub and bearing assembly.
21. Install the wheel speed sensor bolt and torque it to 12 Nm (105 in. lbs.).
CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and
must not be turned during installation. Install nuts while holding bolts
stationary in the steering knuckle.
CAUTION: If the vehicle being serviced is equipped with eccentric strut assembly
attaching bolts, the eccentric bolt must be installed in the bottom
(slotted) hole on the strut clevis bracket(Fig. 5).
-5- 03-006-04
Fig. 5 CORRECTLY INSTALLED ECCENTRIC ATTACHING BOLT
1 - STEERING KNUCKLE
2 - FLANGED BOLT IN TOP HOLE
3 - CAM BOLT IN BOTTOM HOLE
4 - STRUT CLEVIS BRACKET
22. Install the steering knuckle in the clevis bracket of the strut assembly. Install the strut
to steering knuckle attaching bolts. If the eccentric bolt and strut was marked in step 9,
align the marks. Tighten both bolts to a torque of 88 Nm (65 ft. lbs.) plus an additional
1/4 turn.
23. Install the brake rotor on the hub and bearing assembly.
24. Install the disc brake caliper assembly on the steering knuckle. The caliper is installed
by first sliding the bottom of the caliper assembly under the abutment on the steering
knuckle, and then rotating the top of the caliper against the top abutment.
25. Install the disc brake caliper adapter to steering knuckle attaching bolts (Fig. 1).
Tighten the disc brake caliper adapter attaching bolts to a torque of 169 Nm (125 ft.
lbs.).
26. Clean all foreign matter from the threads of the outer CV joint. Install the washer and
half shaft nut on half shaft and securely tighten the nut (the nut will be torqued later).
27. Install the front wheel and tire assembly. Install and tighten the wheel mounting stud
nuts in proper sequence until all the nuts are torqued to half the required specification.
Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft.
lbs.).
28. Repeat steps 2 through 27 on the other side of the vehicle. When steps 2 through 25
have been completed on both sides of the vehicle, lower the vehicle.
29. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a
torque of 244 Nm (180 ft. lbs.) .
30. Install the spring wave washer on the end of the half shaft.
31. Install the hub nut lock, and a new cotter pin. Wrap the cotter pin prongs tightly around
the hub nut lock as shown in (Fig. 6).
03-006-04 -6-
Fig. 6 Halfshaft Retaining Hardware
1 - COTTER KEY
2 - WASHER
3 - HUB NUT
4 - SPRING WASHER
5 - NUT LOCK
32. Repeat steps 29 through 31 on the other side of the vehicle.