1. TAG Transmittal #13380 – KA 17” Chrome Clad Wheel Noise
Issue:
Customer field reports for 17” chrome clad wheels making a clicking or creaking noise
while driving. Noise generated at lower vehicle speeds. Clean point broken from previous
TAG #12489 – 1/12/07. TSB completed at dealership to address noise issue. Part number
1BK49TRMAA affected.
eCIMS 246977 created to track issue. McKechnie & Prime added as Issue Solvers.
Actions:
Inspection & Initial Clean Point:
• Initiated 3CPR at TNAP / Oakley on 8/29/07. Rejection of 314 wheels out
of 364 at Oakley.
• 100% certification initiated at McKechnie. 100% failure rate of product
tested in-house. Tested initial 150 wheels out of ~1500 wheels. Sorting to
continue.
• Utilized previously identified sort criteria – hand pressure in vent windows
at rim. Test Procedure created/documented and uploaded into eCIMS.
• Clean point at Oakley established on 8/30/07. Clean point at sequence #
6122650, VIN # 130246. Product Action has been thru 30 of the 55
wheels in the latest shipment. All have passed.
• Additional 100 pc expedited shipment at 5pm on 8/30/07. Passed
McKechnie hand pressure sort. Product Action to be on-site to complete
hand pressure sort at Oakley.
• Freddy Burgess (McKechnie) to provide shipment/production schedule to
ensure clean point at Oakley maintained. Plan to include required parts for
retrofit operation. Oakley assembled 32 vehicles on 8/30 with non-
certified material. Due by COB - 8/30/07.
• Mopar stock to be identified. Deb Ziegenfelder to contact Dennis Splitt on
available stock. Due on 8/31/07.
Root Cause:
• Initial review of process parameter data shows assembly process out of
specification for RTV volume. Specification calls out 165 +/- 15 cc of
RTV. Volumes ranged from mid 80’s to upper 180’s for the timeframe of
Jan 12 – Aug 23.
• McKechnie produced 200 clad assemblies on 8/29 with process
parameters in the required specification for RTV volume. 180 parts passed
the pressure test. (Anticipate the other 20 passing the pressure test after the
proper cure time of 24hrs.)
• McKechnie confirmed the RTV pattern matches the approved clear clad
samples from Jan 07. Digital photos uploaded into eCIMS.
• 3 Legged 5 Why being developed. Due by Tues 10am – 9/3.
• McKechnie investigating how the RTV volume was adjusted and why.
Press pressure also showed deviations from 15, 30 and 50%.

2. Corrective Action:
• Production of clad wheel assemblies to the proper process parameters
established on 8/29/07.
• PCA still to be determined.
• Discuss addition of RTV Volume to the part print.
• Control Plan not updated for actions implemented in January. Open issue.
• Discuss utilization of dock audit with pressure test after 24 hour cure time.
LPA needs to review process parameters at the clad assembly process.
• Error proofing needs to be implemented at the clad cell. Parts outside of
the process tolerance should not have clad applied. Process parameters
need to be ‘locked out’.