Bad Welds in the Automotive & Truck Industry

Bad Weld section 1.

Bad Welds Section 2.

Come on boys, all together,

2006: The big three continue to reduce USA manufacturing jobs and invest in China, Mexico and Canada and still the apathetic republicans do not react. Pehaps some one should explain to Washinton that for the goverment to recieve taxes, one has to create and maintain a society that recieves reasonable taxable income.

Manufacturing Ethics & Honesty Reflect
on a Companies Recall Statistics:

When one looks at the annual auto / truck recall numbers game, and find that the recall costs are measured in the billions, remember the recall statistics you read are the few defects that have come to the recall stage. For every defect that is recalled the consumer should remember the numerous defects that we are simply not made aware of.

With the different auto companies, product recall integrity and concern for human safety comes in different corporate packages. Before investing $20k - $35k in a truck or car, the consumer should give consideration to vehicle manufacturers past ethics and recall history, and be aware of those vehicle manufacturers who are aware of serious defects yet offer no recall or extended warranty. Today if you purchase a new vehicle and don't read the Consumer Report on that vehicle, you definately have more money than brain cells.

Daimler Chrysler: Manufacturing "Management" Issues?
From the BBC: March 2007: Chrysler is to recall almost half a million vehicles - the second recall by the company in two weeks. A total of 489,000 vehicles are being recalled including its new Dodge Avenger saloon, the US arm of German carmaker DaimlerChrysler said. Chrysler said it would notify owners of the affected vehicles which are suffering air conditioning, electrical and door lock problems. It is the latest problem to hit the troubled carmaker, which may be sold. Last month, parent company DaimlerChrysler said it would sell or spin off the unit which made a loss of 124m euros ($162m; £83m) in 2006. In an effort to cut costs at the US arm it also axed 13,000 jobs at Chrysler and closed down one of its plants. Two weeks ago the firm recalled more than 50,000 vehicles to resolve a problem with anti-lock brakes. The latest recall involves more 328,424 Durango sports utility vehicles - made between 2004 and 2006 - amid concerns that internal electrical circuits may overheat a potential for a fire. A further 149,605 Jeep Liberty vehicles, made between 2006 and 2007, are being recalled for air-conditioning glitches, while 10,994 of its latest Dodge Avenger saloon models need to have door locking problems fixed.

Daimler Chrysler: Manufacturing "Management" Issue

Aug, 2006

Chrysler recalls over 830,000 Jeeps for steering issue

Chrysler Group said it would recall an estimated 832,500 Jeep Liberty vehicles because of a potential steering problem. (2002 - 2006 vehicles) Daimler Chrysler AG said that in some of the vehicles, a ball joint in the the front suspension was prone to excessive wear and coming loose. The automaker said that, in some cases, that joint could separate entirely causing drivers to lose steering control.

Daimler Chrysler: Manufacturing Management Issue

[] 2006 Chrysler 300 Select Different Vehicle

Component: Power Train: Automatic Transmission

Defect Summary: ON CERTAIN PICKUP TRUCKS, SPORT UTILITY AND PASSENGER VEHICLES EQUIPPED WITH 42RLE AUTOMATIC TRANSMISSIONS, THE CUP PLUG THAT RETAINS THE PARK PAWL ANCHOR SHAFT MAY BE IMPROPERLY INSTALLED. IF THE SHAFT MOVES OUT OF POSITION, THE VEHICLE MAY NOT BE ABLE TO ACHIEVE 'PARK' POSITION.

Consequence Summary: IF THIS OCCURS AND THE PARKING BRAKE IS NOT APPLIED, THE VEHICLE MAY ROLL AWAY AND CAUSE A CRASH WITHOUT WARNING.

Daimler Chrysler: Manufacturing Management Issue.

2006.Chrysler group is recalling nearly 150,000 Jeep Grand Cherokees because cooling-fan blades may break, Automotive News reported. A broken fan could hurt people near the vehicle if the hood is open. The recall involves some 2000 and 2002 Grand Cherokees equipped
with 4.0-liter, 6-cylinder engines.

DaimlerChrysler is recalling 5,800 Jeep grand Cherokees to repair seat heaters that do their job too well. Transport Canada says the heating element in the front seats of the 2003-2004 models is defective and can heat to the point that it starts a fire. DaimlerChrysler mechanics will replace the element with one that is better at regulating temperature.

No problems associated with the heaters have been reported in Canada, but in the United States, more than 30 fires and 15 injuries have been reported. Its reported that at least six lawsuits have been filed against Chrysler.

Daimler Chrysler: Manufacturing Management Issue

Dec 05: Consumers hear rattle and may have problems passing a vehicle emission test:Daimler Chrysler agreed to pay $94 million for repairs on 1.5 million Dodge and Jeep vehicles which may be subject to deteriorating catalytic converters. Chrysler will also settle Justice departments charges that it failed to disclose the defects. The settlement is the largest ever involving the failure to report an emission related defect to the Environmental Protection Agency. Talk to Chrysler about your catalytic converter and catalytic diagnostic system. Products: 96 to 2001 Jeep Cherokees, Wranglers, Dodge Dakota trucks, Dodge Ram vans wagons and pickups.

Chrysler: Manufacturing Management Issues

2000 or 2015 does nothing change?

They could not get it right in the year 2000, and as I write this, in 2015, its another AXLE recall for the RAM trucks..

CHRYSLER: AXLE SAFTEY RECALL N26 / NHTSA 13V-239 This notice applies to vehicles (VIN: xxxxxxxxxxxxxxxxx). This notice is sent in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Chrysler has decided that defective welds, which relates to motor vehicle safety, exists in some 2012 model year RAM Truck Cab Chassis (4500/5500 series) trucks equipped with four wheel drive.

The problem is the front axle tube welds on the trucks may not have been welded correctly during the manufacturing process. Improperly welded front axle tubes could allow the differential housing to rotate under high torque operating conditions while in four wheel drive. Should the front axle tube welds break, the differential could rotate and cause the front propeller shaft universal joint to break. This can result in a loss of motive power or damage to surrounding components if the propeller shaft continues to spin after separation. This could cause a crash without warning.

2000: Models: 2000 DODGE RAM PICKUP

The welds at the right side lower control arm (LCA) bracket-to-axle-tube attachment may have inadequate fatigue life due to poor weld quality. Inadequate fatigue life may lead to separation of the LCA bracket from the axle tube. If the bracket separates, the vehicle may experience reduced directional stability, braking degradation and/or vehicle pull under braking.

Correction: Front axle will be replaced with a properly welded front axle.

2015: CHRYSLER FIAT: AXLE WELD ISSUES, DODGE RAM SAFETY RECALL N26 / NHTSA 13V-239..

From Chrysler: This notice applies to vehicles (VIN: xxxxxxxxxxxxxxxxx). This notice is sent in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Chrysler has decided that a defect, which relates to motor vehicle safety, exists in some 2012 model year RAM Truck Cab Chassis (4500/5500 series) trucks equipped with four wheel drive. The problem is the front axle tube welds on the trucks may not have been welded correctly during the manufacturing process. Improperly welded front axle tubes could allow the differential housing to rotate under high torque operating conditions while in four wheel drive. Should the front axle tube welds break, the differential could rotate and cause the front propeller shaft universal joint to break. This can result in a loss of motive power or damage to surrounding components if the propeller shaft continues to spin after separation. This could cause a crash without warning.

Daimler Chrysler: Manufacturing Management Issue.

Canadian Press posted August 6, 2004
WINDSOR, Ont. (CP) - Daimler Chrysler says there have been 17 "incidents" in Canada, but no injuries, that could be related to a potentially faulty part in the power steering units of hundreds of thousands of minivans being recalled by the automaker.

The automaker is recalling 681,000 minivans, including 150,000 in Canada, to replace the upper cooler hose on the power steering units of minivans equipped with V6 engines. The Dodge and Chrysler minivans - many of them made in Windsor, Ont, as well as at an assembly plant in St. Louis - are 2002 to 2004 model units that were made prior to August 2003.DaimlerChrysler said the hose could become damaged during use, particularly in cold climates."This damage could eventually cause a fluid leak, potentially resulting in an under-hood fire," the company said.While no injuries have been reported, there have been 23 "incidents" that "could be related to this issue," the company said. Seventeen of the incidents took place in Canada. In each incident, there was fluid leakage but not all of the incidents resulted in fires, said DaimlerChrysler Canada spokeswoman Kerrey Kerr."It was something that was identified in the field and as soon as we found out about it, we started to work on a fix to address the issue," she said.Kerr said the automaker successfully came up with a solution before winter, when the problem can occur due to cold temperatures.She said there would be no impact on the company's Windsor operations as a result of the recall.The recall is being voluntarily offered by Daimler Chrysler The upper power steering hose will be replaced at no charge to the customer.The company also is recalling immediately 2,000 Dodge Rams from 2004 with 4.7-litre engines. The company said an alternator wire can hit a valve, causing a short circuit and possibly a fire.

Daimler Chrysler: Manufacturing Management Issue.

CHRYSLER NEWS
Federal safety regulators asked Daimler Chrysler to recalled 600,000 vehicles
December 10, 2004
Federal safety regulators have asked Daimler Chrysler AG to recall 600,000 Dodge Durango and Dakota trucks because their wheels could fall off. The investigation includes vehicles from the 2000 to 2003 model years.

NOTE FROM ED: WHY DO FEDERAL REGULATORS HAVE TO ASK?

To Buckle Up or Not to Buckle Up. 2005: Class Action Status Granted to Seat Belt Lawsuit: A judge has granted nationwide class-action status to a lawsuit against Daimler Chrysler AG on behalf of owners of Chrysler, Dodge and Jeep vehicles that have a certain type of seat belt buckle. The so-called Gen 3 buckle is alleged to be prone to unlatching during accidents or from around child or infant car seats in sharp turns or sudden stops. At least three deaths have been blamed on the buckle, and four others are under investigation. The lawsuit seeks replacement of Gen 3 belt buckles on about 14 million Chrysler, Dodge and Jeep vehicles made since 1993. It also seeks reimbursement for inconveniences that may be caused during the replacements, up to $500 per owner. Daimler Chrysler still uses the Gen 3 belts in the middle and rear seats of their minivans.

Daimler Chrysler: Manufacturing Management Issue.

Chrysler recalls nearly 1 million minivans. Automaker says minivans with model years between '98-00 subject to recall due to electrical problem.October 12, 2004: 12:08 PM EDT NEW YORK (CNN/Money) - Daimler Chrysler said Tuesday it may recall up to 955,000 minivans due to potential electrical problems with the steering wheel column that may affect the driver's side airbag. The company's Chrysler Group said its Dodge Caravan and Grand Caravan, Plymouth Voyager and Grand Voyager, and Chrysler Town & Country minivans with model years between 1998 and 2000 are subject to the recall.

Daimler Chrysler: Manufacturing Management Issue.

Car and Mini Van Recalls 11/2/04. Over a quarter million domestic mini vans and sedans are being recalled over safety concerns. The vans affected are Dodge Caravan and Chrysler Town and Country mini vans from the 2001-2002 model years. The auto maker says water seeping into the radio may create a short circuit and fire. But the defect is most likely in vehicles driven in hot, humid areas. The National Highway Traffic Safety Administration began investigating the defect in July - after reports of three fires and one injury. Chrysler is also recalling more than eleven thousand Sebring and Dodge Stratus sedans from the 2005 model year. An internal audit revealed improper installation of bolts in some rear seat belt retractors. Chrysler will perform repairs for free in both cases. Be sure to contact your dealer for more information.

Daimler Chrysler: Manufacturing Management Issue.

Minivan Recall
November 30, 2000
Daimler Chrysler recalled 1993-1994 Dodge Caravan and Grand Caravan, Plymouth Caravan and Grand Caravan, and Chrysler town and Country minivans because of a defective steering wheel. Chrysler had reports of 70 steering wheel failures.

Daimler Chrysler: Manufacturing Management Issue.

Daimler Chrysler recalls 216,000 U.S. pickups.
August 21, 2001
Dodge pickup trucks were recalled by Daimler Chrysler due to problems with the driver's side airbag. Some of the vehicles had sound muffling material inside the steering wheel that could become detached and wind up disabling the driver's side air bag system according to the NHTSA.

IT'S AMUSING TO READ ABOUT BIG THREE MANAGEMENT
AMBITIONS TO ESTABLISH GLOBAL BEST MANUFACTURING PRACTICES.

Joe why are you going on about Global Weld Best Practices / Process Controls when you have not been able to get the robots outside your office door under control? Lets face Joe the global weld reality is this. We have many manufacturing plants in North America and Mexico and at these facilities we robot weld similar carbon steel parts, yet for more than a decade each plant has;

* used different weld consumables,
* used different size weld consumables,
* used different weld gas mixes,
* used different MIG weld equipment,
* used different weld data,
* used different robots.

Joe, the lack of weld process, consumable and equipment conformity in our plants has created vast differences in the weld production weld quality attained at each plant. All of the plants have excess weld reject and rework rates. Joe before we can implement best practices, our management and engineers need to understand the process fundamentals, in your case Joe for gods sake learn to walk before you try to run.

JOE HAD A DIFFICULT TIME COMPREHENDING THE TWO CONTROL MIG PROCESS, SO HE TOOK HIS INEXPERIENCED PROCESS CONTROL PERSONNEL WHO WERE RESPONSIBLE FOR WELDING AT EACH PLANT AND CREATED THE "INEXPERIENCED PROCESS CONTROL WELD TEAM"

Daimler Chrysler: Manufacturing Management Issue.

Daimler Chrysler recalls 161,682 light trucks.
June 29, 2001
Daimler Chrysler recalled 161,682 light trucks because they do not comply with federal seat belt standards. The vehicles front seat belt retractor does not comply with federal standards and vehicle occupants could be injured if it doesn't properly work in a crash according to the NHTSA.

Daimler Chrysler: Manufacturing Management Issue.

Chrysler recalls 515,000 vehicles.
May 25, 2001
Daimler Chrysler recalled 2000 and 2001 model Neons in order to replace a brake booster vacuum hose. According to Chrysler, over time contact with oil can cause the vacuum's hose to swell and loosen from the intake manifold and result in a loss of power-brake assist and an increased idle speed. This Chrysler recall affects 515,000 Dodge and Plymouth Neons.

Daimler Chrysler: Manufacturing Management Issue.
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Chrysler 11,000 minivans recalled.
April 25, 2001..
Chrysler announced a voluntary recall of their new minivans because of a possible front suspension problem. There have been 11,000 customers affected by the Chrysler recall and owners have been urged not to drive the minivans because a bolt on the lower control arm of the front suspension can break and the driver can lose control of the vehicle.

Daimler Chrysler: Manufacturing Management Issue.

Chrysler recalls 701,000 Dodge Ram pickups.
April 11, 2001
A spring problem with the hood latch, according to the NHTSA prompted a Chrysler recall of Dodge Ram pickups. This Chrysler recalls is more focused on Northeast or Midwest located pickups due to higher levels of metal corrosion rates due to road salt. This causes the mechanism to stick in the release position and allow the hood to unexpectedly open.

Daimler Chrysler: Manufacturing Management Issue.
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Chrysler recalls 1.4 million Minivans
October 28, 2000
Chrysler recalled 1.4 million minivans that were built between 1996 and 2000 to fix the problems with a fuel rail seal that could leak. The Chrysler defect fix will not be available until March. The seal on the small pipe that carries fuel to the engine can fail in vehicles repeatedly operated at elevated temperature over many years. There were 43 reports of leaking fuel rail seals according to a Chrysler spokesman. Fires near the engine have caused a few minor injuries.

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At Chrysler, it's always
time for weld reality.

An e-mail question to this site...
Mr. Craig.

The tier one automotive parts company I work for, has been told by the corporate Chrysler weld engineer that they have to use "self shielding flux cored wires" when welding their galvaneald parts. These self shielded flux cored welding wires cause us many welding issues. What is the logical, weld justification for using these wires?

Ed's Answer: I have seen more weld process knowledge in a Midas muffler shop than I have seen by the key weld decision makers at the Chrysler Corporation office.The bottom line, there is no justification for the use of these products on cars or truck parts. I believe the selection of these welding wires is based simply on " Chrylser Corporate Weld Enginnering ignorance" and that process ignorance was is fed by " weld consumable salesmanship"..

One of the biggest problems with arc welding in the auto/truck industry, is the selection of weld wire consumables poorly suited to the application. In many instances the weld wires selected are "too large" requiring weld current levels which are typically are too high for thin gage parts. The choice of the large consumables is typically derived from the "bigger the weld consumable the faster the weld" mentality that many managers and engineers have in this industry . The Self Shielding wires typically are available only in large diameters.

From a weld mechanical, weld chemistry, weld quality and weld productivity perspective, in contrast to MIG wires, the selection of the Self Shielded flux cored wires will always do more harm than good.

[a] In contrast to MIG, on thin gage applications the self shielded wires which do not offer short circuit weld characteristics, they provide a higher energy globular, open arc mode of weld transfer, and irrespective of polarity utilized this mode with the high current required can dramatically increase the weld burn-through potential on gage welds.

[b] In contrast to MIG, the weld fumes and grinding dust produced from the self shielded wires are much more hazardous and typically contain carcegenic components. When using these wires weld shops will have to invest in costly ventilation equipment that would not be required with MIG. Of special concern will be the health of manual welders that have to use these wire to do the weld repairs which will be necessary on robot welded gage parts.

[c] With MIG, weld spatter is controllable. These self shielded products produce erratic globular transfer and additional man power is typically required for extensive weld clean up. Also the robot weld cell equipment and fixtures will typically be contaminated with unnecessary excessive weld spatter.

[d] With the clean surface MIG welds, effective weld repairs should be simple to carry out. In contrast with the self shielded flux cored wires the resulting weld slag can be both excessive and difficult to remove. When repairing the self shielded welds with the slag in place, both the weld fusion and quality potential will suffer greatly. It's a common practice in automotive / truck plants to place a self shielded repair weld on top of a robot weld with the slag still in place, this practice is an invitation to product liability implicaions.

[e] The fact that the part welded are galvanealed or galvanized is irrelevant. I have had mechanical SS weld tests performed on these wires and also with MIG wires, the test results indicate that MIG provides the best weld quality reference weld / part mechanical needs than the SS wires.

TO FIND OUT HOW THE POOR MANAGEMENT - ENGINEERING DECISION TO USE THE SELF SHIELDED FLUX CORED WIRES HAS COST CHRYSLER AND IT'S SUPPLIERS MILLIONS OF DOLLARS EACH YEAR VISIT HERE;

WHEN A CORPORATE ENGINEERS AND MANAGERS LACK WELD PROCESS CONTROL - BEST PRACTICE EXPERTISE, THIS LEADS TO POOR OR INNEFECTIVE WELD DECISIONS THAT WILL BE MADE IN THE FACTORIES AND AT THE SUPPLIERS OF THEIR PARTS. THE ANNUAL COSTS CONSEQUENCES TO A CORPORATION AND TO THE SUPPLIERS WILL TYPICALLY BE IN THE MILLIONS OF DOLLARS.

IN THE CASE OF CHRYSLER, THE ENGINEERING MANAGEMENT AND THEIR WELD ENGINEERING PROCESS APATHY HAS HAD TREMENDOUS COST CONSEQUENCES IN LOST PRODUCTIVITY AND UNNECESSARY REWORK AND RECALLS . THIS PROCESS IGNORANCE WHICH IS STILL EVIDENT IN 2015 HELPS SUSTAIN THE GLASS WALLS THAT TOO OFTEN ISOLATE FRONT OFFICE PERSONNEL FROM PROVIDING THE PROCESS CONTROL TOOLS AND THE BEST WELD PRACTICES THAT HAVE ALWAYS BEEN NECESSARY FOR BOTH ROBOT AND MANUAL WELD QUALITY - PRODUCTIVITY OPTIMIZATION..

All they need is this resource and approx. 15 hours.

Daimler Chrysler: Manufacturing Management Issue.
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Lawsuit against Chrysler for a 1995 airbag death
June 1, 2000
Chrysler has settled airbag lawsuits in the past but one man is insisting on taking Chrysler to trial because he has made safer airbags his mission. His daughter was killed in a Dodge Caravan minivan when their vehicle was hit by another car. Since then he has been organizing Chrysler airbag victim families to lobby against finding a safer device to save lives.

Daimler Chrysler: Manufacturing Management Issue.

Chrysler appeals a $262.5 million verdict.
March 8, 2000
Chrysler was told to write a $262.5 million check to the parents of a six year old killed as a result of a defective latch in the family's Chrysler minivan. A judge reduced the verdict by $3.5 million but left the rest of the damages to discourage Chrysler from using the same behavior that has led to the death of more than 50 people due to Chrysler minivan latch failures.

Daimler Chrysler: Manufacturing Management Issue.

Chrysler Recalls 652,000 SUVs.
January 24, 2000
Chrysler has recalled their SUVs because of wear issues to the fuel tank straps and expanded an earlier recall to replace brake rotors that corrode and crack in 15 rust belt states and Canada.

Daimler Chrysler: Manufacturing Management Issue.
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Chrysler recalls 4.400 Mercedes.
December 2, 1999
Chrysler has recalled the 1997 Mercedes SL coupe / roadsters in 4,400 vehicles to replace the driver's side airbag modules. High humidity exposure can cause corrosion that causes the driver's front airbag to unintentionally deploy. Chrysler is recalling all of the 136,500 1998-1999 Mercedes M-Class SUV to inspect the front seat belt buckles and replace those that have been improperly manufactured.

Daimler Chrysler: Manufacturing Management Issue.
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July 99: The European Union dubs Chrysler minivans the sorriest in Europe.

The European Union and European motoring organizations tested eights Chrysler Voyager minivans and found that the steering wheel and air bag was forced upwards into the driver's face hitting the head hard and putting strain on the neck. The Europeans believe it is the car manufacturer's responsibility to provide proper restraint for all the occupants of the vehicle. The Chrysler ratings were based on performance in frontal and side crashes, as well as simulated pedestrian impact. Of all the minivans that were tested Chrysler fared the worst.

THE GLOBAL WELD QUALITY MANAGEMENT FIASCO:

Today, manual MIG weld repairs on top of robot MIG welds has become so common that many suppliers of auto / truck parts don't even class this added labor cost as a weld rejects or "weld rework".

The robot weld reality is the manual MIG weld repairs are rarely done correctly and adding weld metal on top of a robot weld with poor weld fusion still leaves that weld with poor weld fusion and the additional weld also weakens the high strength steels.

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Daimler Chrysler: Manufacturing Management Issue.

Chrysler sues lawyers, or the wolves attack the wolves.
November 19, 1999
Chrysler is suing for the third time for punitive damages because they feel lawyers have made claims against the safety of Chrysler auto seats that has harmed the company's reputation.

Note: I wonder how you can have the data as indicated at this web site and stil have a reputation worth protecting?

Daimler Chrysler: Manufacturing Management Issue.

Model 2005 Chrysler Dodge. Jeep SUVs pick up and passenger cars
Vehicles affected 256,409.

Problem Vehicle could roll unexpectantly even when its in park, good luck if you live in San Francisco.

Note from frustrated: I own a 2000 Chrysler Concord: Like so many others, I've found out the hard way that Chrysler makes a substandard product. My well-maintained 2000 Concorde now needs a new engine to the tune of $5K. This follows a varied repair job from just weeks ago that cost in excess of $800. The engine has less than 75K miles on it! Meanwhile, our GMC and Nissan, both with almost 200K on the engines, just keep chugging along. It makes NO sense that a 15-year-old car and a 17-year-old car are BOTH more reliable than my barely 4-year-old Concorde. Chrysler shame on you.
Posted By: goingnowherefast on 7/31/2004 (TX)

Daimler Chrysler: Manufacturing Management Issue.
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Model: 2000 Dodge Ram Truck Year: 2000

Defect: Due to a lack of management manufacturing expertise, the welds at the right side lower control arm bracket to axle tube attachment may have inadequate fatigue life due to poor weld quality. This can lead to separation of the control arm bracket from the axle tube. If the bracket separates the vehicle could experience reduced directional stability, braking degradation and / or the vehicle pull under braking.

THE AUTO / TRUCK INDUSTRY
& DOUBLE MFG. STANDARDS: