NUMBER:

23-027-17

GROUP:

23 - Body

DATE:

June 3, 2017

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 FCA US LLC.

SUBJECT:
Rusty Water Draining From Vehicle
OVERVIEW:
This bulletin involves drilling drain holes in the headlamp fastener pocket and replacing two
headlamp fasteners.
MODELS:
2016 - 2017

(ZD)

Dodge Viper

NOTE: This bulletin applies to vehicles within the following markets/countries: NAFTA.
NOTE: This bulletin applies to all vehicles built on or before February 01, 2017 (MDH
0201XX) equipped with the Extreme Hood (Sales Code MEW).
SYMPTOM/CONDITION:
Customers may describe rusty water sometimes drains down one or both sides of the vehicle after
driving. This condition is caused by a headlamp fastener rusting.
DIAGNOSIS:
If the customer describes the symptom/condition listed above, perform the Repair Procedure.
PARTS REQUIRED:
NOTE: One kit will repair both headlamps on the vehicle.
Qty.

Part No.

Description

1

68378430AA

Fastener Kit

SPECIAL TOOLS/EQUIPMENT REQUIRED:
Step Drill Bit

#1 5.93 mm (0.228 in.)

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-2-

REPAIR PROCEDURE:
NOTE: Repair procedure is to be done on both headlamps.
1. Open the hood.
2. Remove and discard the headlamp fastener (Fig. 1) .

Fig. 1
Fastener Removed

3. Using a punch or equivalent tool, indent the carbon fiber to align pilot hole on the headlamp
fastener pocket (Fig. 2) .

Fig. 2
Punch Marking Headlamp Pocket

-3-

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4.
CAUTION! Care must be used while drilling hood to not damage rubber hood seal. Failure to
do so may result in damage to hood and hood seal.
NOTE: Protect the area under headlamp fastener pocket as rusty water may drain from the
pocket while drilling the pilot hole.
Using a drill and a 2 to 3 mm (0.07 to 0.11 in.) drill bit marked to a 35 mm (1.3 in.) max depth, drill
a pilot hole into the headlamp fastener pocket (Fig. 3) .

Fig. 3
Drilled Drain Hole

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5.
CAUTION! Care must be used while drilling hood to not damage rubber hood seal. Failure to
do so may result in damage to hood and hood seal.
Using a #1 - 5.93 mm (0.228 in.) step drill bit marked to a 35 mm (1.3 in.) max depth, drill the pilot
hole in the headlamp fastener pocket (Fig. 4) .

Fig. 4
Step Drill Hole And Hood Seal
1 - Step Bit Marked
2 - Hood Seal

-5-

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6.
CAUTION! Protect all electrical and air induction areas under the hood that could be
subjected to water intrusion as a result of directing water at the over wheel hood
vents. Failure to do so may result in component failure.
NOTE: Do not use a pressure washer.
Close the hood and flush the remnants of corrosion that could remain inside the hood with a water
hose. Direct the water at the hood vents over the wheels towards the front of the vehicle (Fig. 5) .
Dry vehicle as needed.

Fig. 5
Direction To Water Flush Hood

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-6-

7. Once the corrosion has been flushed out of the hood, open hood and remove the rust residue
(Fig. 6 ) from the hood liner seam with a cleaner wax.

Fig. 6
Hood Liner Seam Corrosion

8. Install the new stainless steel headlamp fastener (Fig. 7) . Tighten fastener to 3 N·m (26 in.
lbs.).

Fig. 7
New Headlamp Fastener

9. Close the hood.

-7-

23-027-17

POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation
No:

Description

Skill Category

Amount

08-50-31-9C

Fastener, Headlamp - Replace Both
Front Outboard; Includes Fastener
Pocket Modification
(0 - Introduction)

6 - Electrical and
Body Systems

0.4 Hrs.

FAILURE CODE:
ZZ

Service Action