I bought my 2008 Caravan 9/07. After about 2-3 weeks I discovered the rear bumper skuff plate was coming up in 3 places and had rattles under 30mph over bumps, not metal to metal but more like squishing and vibration. First trip to the dealer I was told door weatherstipping came unlubricated on some of the early models, so they siliconed it and the rattles disappeared for the most part and they replaced the rear scuff plate.
Now, in 9/08, the car has about 14k miles and the rattles were back and the skuff plate was warping up again. This time they put on a new, yet again, scuff plate (supposedly re-designed) and they replaced the door seals on the sliding doors and rear doors. The rattles are about 90% gone, but was told that was all they could do, it was inherent in the vehicle design! As for the skuff plate, as outside temperature goes up, it seems to warp a bit in the center. On closer inspection, the plate seems well attached, but the bumper underneath looks a little warped! Temperature is definitely a factor, so it seems expansion is happening. Poor design!

 

i saw a Technical Service Bulletin on the rear bumper facia warping, and the scuff plate peeling off. Some models from Canada before Mar or May of 2008. The TSB said that the entire facia should be replaced

 

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 LLC.
SUBJECT:
Rear Fascia Bow at Top
OVERVIEW:
This bulletin describes procedures to address a Rear Fascia bulge condition along the top
surface
MODELS:
2008 - 2009 (RT) Town & Country/Grand Caravan
NOTE: This bulletin applies to vehicles built before August 11, 2008 (MDH0811XX).
SYMPTOM/CONDITION:
Some vehicles may have a rear fascia that may exhibit a bulge, bow or bending along the
top surface. The scuff pad and/or support on the fascia may separate due to this bowing.
The technician should inspect the scuff pad and fascia support on the rear fascia and
based on findings, follow the appropriate repair procedure in this Service Bulletin.
DIAGNOSIS:
If the vehicle exhibits the Symptom/Condition, perform the Repair Procedure.
PARTS REQUIRED:
Qty. Part No. Description
1 (AR) 05113110AB Scuff Pad, Rear Fascia
1 (AR) NPN Tape, Black double-coated acrylic adhesive -
925 mm (36.4 in.) length x 8 mm (.31 in.)
wide x 1.52 mm (.060 in.) thick strip (such as
3M PT 1500)
1 (AR) NPN Adhesive Promoter or Equivalent (such as:
3M - 4298 Adhesive Promoter)
1 06501916 Retainer
1 (AR) 68048162AA Fascia, Rear - Dodge Without Parksense
[XAA]
1 (AR) 68041471AA Fascia, Rear - Chrysler With Sales Codes
[ML3] and Parksense [XAA]
NUMBER: 23-026-08
GROUP: Body
DATE: August 28, 2008
Qty. Part No. Description
1 (AR) 68041478AA Fascia, Rear - Chrysler, With Bright Insert
[MCZ] and Parksense [XAA]
1 (AR) 68041480AA Fascia, Rear - Dodge, With Parksense [XAA]
1 (AR) 68048158AA Fascia, Rear - Chrysler, With Sales Code
[ML3] Without Parksense [XAA]
REPAIR PROCEDURE:
1. Open the liftgate.
2. Inspect the scuff pad on the top of the rear fascia. Is scuff pad lifting off fascia?
a. Yes >>> Using a Trim Stick C-4755, remove scuff pad and discard. Scuff pad will
be replaced later in this procedure. Proceed to Step #3.
b. No >>> Proceed to Step #3.
3. Loosen 4 rear fascia retaining screws (Fig. 1)
Fig. 1 REAR FASCIA
1 - 4 RETAINING SCREWS
2 - REAR FASCIA
3 - SCUFF PAD
4. Hold the fascia at the proper level to obtain proper fascia top edge mating lines at tail
light and snug upper bolts only.
23-026-08 -2-
5. Use a protected wooden or plastic handle to apply outward pressure in lower corners
of fascia liftgate opening to reduce bow in top of fascia and tighten lower screw on
both sides with fascia in new position(Fig. 2).
Fig. 2 APPLY OUTWARD PRESSURE AS LOWER BOLTS ARE TIGHTENED
1 - OUTWARD PRESSURE AT LOWER CORNER OF FASCIA LIFTGATE OPENING
2 - SCREW
6. Tighten the 4 screws to 5.5 N·m (49 in.lbs).
7. Does top surface of fascia stay flat or have a gap between fascia and liftgate of 4 mm
or greater?
a. Yes >>> Proceed to Step #9.
b. No >>> Proceed to Step #8.
8. Replace and refinish rear fascia per manufacturers instructions. Refer to the detailed
removal procedures available in DealerCONNECT > TechCONNECT under: Service
Info > 13 - Frame And Bumpers > Rear Fascia > Removal.
NOTE: When installing the new fascia, pull the fascia outboard by applying pressure
at outside corners to reduce bow in top of fascia.
9. Was scuff pad removed from fascia for lifting off fascia in Step #2 or for fascia
replacement?
a. Yes >>> Proceed to Step #10.
b. No >>> Proceed to Step #14.
10. Clean the fascia and underside of the new scuff pad where the strip of tape will be
applied. The strip of tape should be located between the forward row of carrots and
the forward edge of the scuff pad (Fig. 3).
-3- 23-026-08
Fig. 3 TAPE LOCATION ON SCUFF PAD
1 - STRIP OF TAPE
2 - FORWARD ROW OF CARROTS
3 - FORWARD EDGE OF SCUFF
11. Wipe cleaned fascia and scuff pad surface with adhesion promoter and allow to dry.
12. Apply a 925 mm (36.4 in.) strip of tape to underside of scuff pad.
13. Install scuff pad to fascia starting at the center and working to the ends. Press firmly
along taped area to ensure wetout.
14. Drill a 6.35 mm (.25 in.) hole thru fascia and plastic fascia support 15 mm forward of
scuff pad at centerline of fascia.
15. Install push pin p/n 06501916 into hole.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation
No:
Description Amount
13-20-05-94 Fascia, Adjust and Install Retainer (C) 0.2 Hrs.
13-20-05-95 Fascia, Adjust and Install Retainer and Replace
Scuff Pad(C)
0.4 Hrs.
13-20-05-96 Fascia, Adjust and Replace Rear Fascia 1.0 Hrs.
23-70-45-90 Fascia Refinish Material Allowance $197.08 2.7 Hrs.
FAILURE CODE:
ZZ Service Action
23-026-08 -4-