June 2020
Dealer Service Instructions for:

Emissions Recall W38
Catalyst Y-Pipe
Remedy Available
2020

(DJ)

Ram 2500 Pickup

NOTE: This recall applies only to the above vehicles equipped with a 6.4L engine.
NOTE: Some vehicles above may have been identified as not involved in this
campaign and therefore have been excluded from this campaign.
IMPORTANT: Some of the involved vehicles may be in Dealer vehicle
inventory. Dealers should complete this recall service on these vehicles before
retail delivery. Involved vehicles can be determined by using the VIP inquiry
process.

Subject
The internal components of the Catalyst Y-Pipe assembly on about 30 of the above
vehicles may be incorrect for the specific vehicle application. This issue was
caused by a vehicle assembly plant error resulting in the incorrect component
being installed during vehicle assembly.

Repair
Replace the Catalyst Y-Pipe assembly on all involved vehicles.
 Copyright 2020, FCA US LLC, All Rights Reserved

(tdb)

Emissions Recall W38 -- Catalyst Y-Pipe

Page 2

Parts Information
Part Number

Qty.

Description

68357624AA

1

Catalyst Y-Pipe Assembly

06036734AA

4

Bolt - Exhaust Header to Y-Pipe

06036684AA

4

Nut - Exhaust Header to Y-Pipe

52103592AA

1

Clamp - Y-Pipe to Exhaust Pipe

Parts Return
Return the Y-Pipe Catalyst to the Mopar Core Return Center for core credit.

Special Tools
No special tools are required to perform this service procedure.

Emissions Recall W38 -- Catalyst Y-Pipe

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Service Procedure
A. Catalyst Y-Pipe Replacement
1. Disconnect
the
Intelligent
Battery Sensor (IBS) wire
harness connector (Figure 1).

NOTE: Failure to disconnect
the
IBS
wire
harness
connector can lead to damage
of the IBS wire harness
connector.

IBS CONNECTOR

GROUND TERMINAL

Figure 1 – Battery Negative Connection

2. Loosen the ground terminal nut
and remove the battery negative
cable with IBS from the battery
and isolate it (Figure 1).

3. Raise and support vehicle.

4. Saturate the bolts and nuts (1, 2)
with Mopar® Rust Inhibitor.
Allow for penetration while
removing skid plates and oxygen
sensors (Figure 2).

Figure 2 – Exhaust to Manifold Bolts

Y-PIPE

EXHAUST CLAMP

EXTENSION PIPE

5. Saturate the exhaust clamp for
Y-pipe to muffler extension pipe
with Mopar® Rust Inhibitor.
Allow for penetration while
removing skid plates and oxygen
sensors (Figure 3).
Figure 3 – Exhaust Clamp

Emissions Recall W38 -- Catalyst Y-Pipe

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Service Procedure [Continued]
6. If equipped, remove and SAVE
the skid plate bolts (2)
(Figure 4).

7. If equipped, remove and SAVE
the skid plate bolts (3) then
remove and SAVE the skid plate
(1) (Figure 4).

8. Disconnect
the
upstream
Oxygen (O2) sensor electrical
connectors (1) (Figure 5).

Figure 4 – Skid Plate

9. Remove and SAVE the upstream O2 sensors (4) from the pipes (Figure 5).

Figure 5 – Upstream O2 Sensors

Emissions Recall W38 -- Catalyst Y-Pipe

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Service Procedure [Continued]
10. Disconnect the downstream O2
sensors electrical connectors
(1, 2) (Figure 6).
11. Remove
and
SAVE
the
downstream O2 sensors (3, 5)
(Figure 6).
12. Remove and DISCARD the
exhaust clamp for Y-pipe to
muffler
extension
pipe
(Figure 7).
13. Release the hangers and ground
strap from the tail pipe and
muffler and assembly.

Figure 6 – Downstream O2 Sensors

14. Separate the catalyst Y-pipe outlet from the muffler extension pipe (Figure 7).
EXTENSION PIPE

Y-PIPE

EXHAUST CLAMP

Figure 7 – Catalyst Y-Pipe to Muffler Extension Pipe

Emissions Recall W38 -- Catalyst Y-Pipe

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Service Procedure [Continued]
15. Remove and SAVE the three nuts securing the transmission mount to the
crossmember (Figure 8).
16. Using a suitable lifting device, raise and support the transmission.
17. Remove and SAVE the nuts and bolts from the crossmember then remove and
SAVE the crossmember (Figure 8).
NOTE: Position the front suspension control arm fastener flags out of the
way of the crossmember if necessary.
SUSPENSION
CONTROL ARM

FASTENER FLAG

CROSSMEMBER

BOLTS

NUTS

TRANSMISSION
MOUNT NUTS

BOLTS

SUSPENSION
CONTROL ARM

NUTS

FASTENER FLAG

Figure 8 – Crossmember

18. Remove and DISCARD the catalyst Y-pipe to manifold bolts and nuts (1, 2)
(Figure 2).
19. Remove the catalyst Y-pipe assembly. The catalyst must be prepared for core
return per Section B of the Service Procedure.

Emissions Recall W38 -- Catalyst Y-Pipe

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Service Procedure [Continued]
20. Position the NEW catalyst Y-pipe assembly to the vehicle.

21. Install and hand tighten the NEW flange bolts and nuts (1, 2) attaching the
catalyst Y-pipe to the exhaust manifold (Figure 2).

22. Install the exhaust extension pipe, muffler and tail pipe assembly to the catalyst
Y-pipe outlet (Figure 7).

23. Attach the exhaust system hangers and ground strap.

24. Tighten the exhaust flange bolts (1, 2) to 30 N·m (22 ft. lbs.) (Figure 2).

25. Install a NEW exhaust clamp and tighten to 57 N·m (42 ft. lbs.) (Figure 7).

26. Check the exhaust system for contact with the body panels. A minimum of 25
mm (1.0 in.) is required between the exhaust system components and
body/frame parts. Make the necessary adjustments, if needed.

27. Install the upstream O2 sensors (4) to the pipes. Tighten to 50 N·m (37 ft. lbs.)
(Figure 5).

28. Connect the upstream O2 sensor electrical connectors (1) (Figure 5).
29. Install the downstream O2 sensors (3, 5) to the pipes. Tighten to 50 N·m
(37 ft. lbs.) (Figure 6).

30. Connect the downstream O2 sensor electrical connectors (1, 2) (Figure 6).

Emissions Recall W38 -- Catalyst Y-Pipe

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Service Procedure [Continued]
31. Position the crossmember to the vehicle (Figure 8).
32. Install the crossmember bolts and nuts. Tighten to 240 N·m (177 ft. lbs.)
(Figure 8).

33. Lower the transmission and install the three nuts securing the transmission
mount to the crossmember. Tighten the nuts to 61 N·m (45 ft. lbs) (Figure 8).

34. If equipped, position the skid plate (1) to the vehicle then install the skid plate
bolts (2, 3). Tighten the transmission crossmember bolts (3) to 37 N·m
(27 ft. lbs.) and the skid plate crossmember bolts (2) to 16 N·m (12 ft. lbs.)
(Figure 4).

35. lower the vehicle.

36. Install the battery negative cable with IBS to the battery negative post then
tighten the ground terminal nut to 6 N·m (53 in. lbs.) (Figure 1).

37. Connect the IBS wire harness connector.

38. Start the engine and inspect for exhaust leaks. Correct any exhaust leaks as
necessary.

39. Return the vehicle to the customer.

40. Prepare the old catalyst for core return Section B.

Emissions Recall W38 -- Catalyst Y-Pipe

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Service Procedure [Continued]
B. Prepare Catalyst for Core Return:
NOTE: Catalytic converter catalyst must be intact and all pipes must be
completely removed prior to core return. Mopar® will reimburse only 50%
of the core deposit on returns that do not comply with this requirement.
1. Cut the inlet and outlet pipes off of the catalyst as close to the pipe weld as
possible (Figure 9).
2. Return only the catalyst section for core deposit credit. Discard / recycle the
pipes cut off of the catalyst section (Figure 9).
CUT AT WELD

DISCARD / RECYCLE

DISCARD / RECYCLE
RETURN FOR CORE DEPOSIT

Figure 9 – Remove Pipes from Catalyst for Core Return

For any questions relating to Core Returns
Please call GCRS Customer Service Toll-Free at 866-254-2940
or
Submit your inquiry on Dealer Connect under Parts>Contact Global Core Returns

Emissions Recall W38 -- Catalyst Y-Pipe

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Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the
DealerCONNECT Claim Entry Screen located on the Service tab. Claims paid
will be used by FCA to record recall service completions and provide dealer
payments.
Use the following labor operation numbers and time allowances:
Labor Operation
Number
Replace the Catalyst Y-Pipe assembly

Time
Allowance

11-W3-81-82

1.9 hours

11-W3-81-60

0.3 hours

11-W3-81-50

0.3 hours

Optional Equipment
Skid Plate
Related:
Remove pipe from catalyst for core return
up to $3 reimbursement per vehicle for
cutting supplies, bill as NPN

Add the cost of the recall parts plus applicable dealer allowance to your claim.
NOTE: See the Warranty Administration Manual, Recall Claim Processing Section,
for complete recall claim processing instructions.

Dealer Notification
To view this notification on DealerCONNECT, select “Global Recall System” on
the Service tab, then click on the description of this notification.

Emissions Recall W38 -- Catalyst Y-Pipe

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Owner Notification and Service Scheduling
All involved vehicle owners known to FCA are being notified of the service
requirement by first class mail. They are requested to schedule appointments for this
service with their dealers. A generic copy of the owner letter is attached.

Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
All involved vehicles have been entered into the DealerCONNECT Global Recall
System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed.
GRS provides involved dealers with an updated VIN list of their incomplete
vehicles. The owner’s name, address and phone number are listed if known.
Completed vehicles are removed from GRS within several days of repair claim
submission.
To use this system, click on the “Service” tab and then click on “Global Recall
System.” Your dealer’s VIN list for each recall displayed can be sorted by: those
vehicles that were unsold at recall launch, those with a phone number, city, zip
code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule
appointments for this repair.
Recall VIN lists may contain confidential, restricted owner name and address
information that was obtained from the Department of Motor Vehicles of various
states. Use of this information is permitted for this recall only and is strictly
prohibited from all other use.

Additional Information
If you have any questions or need assistance in completing this action, please
contact your Service and Parts District Manager.
Customer Services / Field Operations
FCA US LLC

This notice applies to your vehicle,

[Model Year and Model]

IMPORTANT EMISSIONS RECALL

VIN XXXXXXXXXXXXXXXXX

Catalyst Y-Pipe

W38
Dear [Name],

LOGO
VEHICLE PICTURE

YOUR SCHEDULING OPTIONS
1. RECOMMENDED OPTION
Call your authorized Chrysler /
Dodge / Jeep® / RAM / Dealership
2. Call the FCA Recall Assistance
Center at 1-800-853-1403. An
agent can confirm part availability
and help schedule an appointment
3. Visit recalls.mopar.com, scan the
QR code below, or download the
Mopar Owner’s Companion App.

QR Code

FCA US LLC, has determined that certain [2020 (DJ) Ram 2500 Pickup] vehicles may not comply
with Federal and California emission regulations.

WHY DOES MY VEHICLE NEED REPAIRS?
The internal components of the Catalyst Y-Pipe assembly on your vehicle [1] may be incorrect
for your specific vehicle application. This issue was caused by a vehicle assembly plant error
resulting in the incorrect component being installed during vehicle assembly.

HOW DO I RESOLVE THIS IMPORTANT EMISSIONS ISSUE?
FCA will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace
the Catalyst Y-Pipe assembly. The estimated repair time is 2 ½ hours. In addition, your dealer
will require your vehicle for proper check-in, preparation, and check-out during your visit,
which require more time. Your time is important to us, so we recommend that you schedule a
service appointment to minimize your inconvenience. Please bring this letter with you to your
dealership.

TO SCHEDULE YOUR FREE REPAIR,
CALL YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY

WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED?
If you have already experienced this specific condition and have paid to have it repaired, you
may visit www.fcarecallreimbursement.com to submit your reimbursement request online. [2]
Once we receive and verify the required documents, reimbursement will be sent to you within
60 days. If you have had previous repairs performed and/or already received reimbursement,
you may still need to have the recall repair performed.
We apologize for any inconvenience, but are sincerely concerned about your satisfaction. Thank
you for your attention to this important matter.

Get access to recall notifications, locate
your nearest dealer, and more through
this website or Mopar Owner’s
Companion App. You will be asked to
provide your Vehicle Identification
Number (VIN) to protect and verify
your identity. The last eight characters
of your VIN are provided above.
DEALERSHIP INSTRUCTIONS
Please reference Emissions Recall
W38

Customer Assistance/Field Operations
FCA US LLC

Mr. Mrs. Customer
1234 Main Street
Hometown, MI 48371

[1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information.
[2] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-8004,
Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.