NUMBER:
GROUP:
DATE:
11-005-11 REV. A
Exhaust System
November 12, 2011
This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of Chrysler Group LLC.
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 11-005-11, DATED OCTOBER
18, 2011, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE
REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT:
Rattle Sound At Idle Or Drone/Vibration Between 60 And 65 MPH (96 And 104 KPH)
OVERVIEW:
This bulletin involves diagnosing the condition and only if necessary making adjustments
to the exhaust system or installing a right halfshaft as required.
MODELS:
2008 - 2010
RT
Dodge Grand Caravan/Chrysler Town &
Country
NOTE: This bulletin applies to vehicles equipped with the 3.3L or 3.8L engine (Sales
Code EGV or EGL).
SYMPTOM/CONDITION:
Vehicles may exhibit a drone sound on 3.3L engines that may be present when the vehicle
is driven between 60 & 65 MPH (96 & 104 KPH) (steady state driving) and is more
pronounced while driving up a slight grade.
A rattle sound may also be noticed at all RPM ranges, idle or driving.
RATTLE DIAGNOSIS:
1. Inspect for witness marks or contact between the exhaust system and the underbody.
2. Are there witness marks or contact between the exhaust system and the underbody?
a. Yes >>> Proceed to Step #1 of “ALIGN EXHAUST REPAIR PROCEDURE”.
b. No >>> Proceed to Step #3.
3. Using a rubber mallet hit the muffler and listen for rattle.
4. Is rattle sound heard?
a. Yes >>> Replace muffler. Refer To Group 11 - Exhaust > Muffler, Exhaust,
Removal and Installation procedures.
b. No >>> Proceed to Step #5.
5. Is vehicle equipped with a 3.8L engine?
a. Yes >>> Proceed to Step #6.
b. No >>> This Service Bulletin does not apply further diagnosis required.
11-005-11 REV. A
-2-
6. Locate the bottle resonator directly behind the catalytic converter. Using a rubber
mallet hit the resonator.
7. Is rattle sound heard?
a. Yes >>>Replace the catalytic converter/bottle resonator. Refer To Group 11 Exhaust > Converter, Catalytic, Removal and Installation procedures.
b. No >>> This Service Bulletin does not apply further diagnosis required.
DRONE DIAGNOSIS:
1. Is vehicle equipped with 3.3L engine?
a. Yes >>> Proceed to Step #2.
b. No >>> This Service Bulletin does not apply further diagnosis required.
2. Drive Vehicle at a constant speed between 60 MPH (96 KPH) to 65 MPH (104 KPH).
3. Is drone present between 60 & 65 MPH (96 & 104 KPH) (steady state driving)?
a. Yes >>> Replace the right halfshaft. Refer To Group 03 - Differential & Driveline >
Half Shaft, Removal and Installation procedures.
b. No >>> This Service Bulletin does not apply further diagnosis required.
PARTS REQUIRED:
Qty.
Part No.
Description
AR (1)
04877533AH
Muffler 3.3L Engine
AR (1)
04877538AI
Muffler 3.8L Engine
AR (1)
68040858AC
Converter, Catalytic 3.8L Engine
AR (1)
04880210AH
Halfshaft, Right
ALIGN EXHAUST REPAIR PROCEDURE:
1. Loosen the all exhaust mounts.
2. Adjust away from contact point.
3. Re-torque all fasteners. Refer To Group 11 - Exhaust System > Specifications and
inspect again for clearance.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation
No:
Description
Amount
11-00-01-91
Exhaust System, Inspection (C)
0.2 Hrs.
11-00-01-92
Exhaust System, Align (C)
0.2 Hrs.
11-30-01-99
Muffler, Replace (D)
0.4 Hrs.
11-50-01-95
Converter, Catalytic Replace (C)
0.9 Hrs.
02-13-05-95
Halfshaft, Replace (B)
0.8 Hrs.
FAILURE CODE:
ZZ
Service Action