Active Hood Hinge Shear Rivet Replacement

Fig 1: Hinge Hood Bracket, Hinge Mid-Straps, Rivets, Reset Hole, Reset Button & Reset Cap

Courtesy of CHRYSLER GROUP, LLC

In order to guarantee continued Electronic Pedestrian Protection (EPP) system integrity the active hood hinge shear rivet and the reset button in each active hood hinge must  be replaced following any non-pedestrian deployment using only  replacement parts specified in the Chrysler Mopar® Parts Catalog and the following procedure.

1. Open and prop the hood up in the open position.
2. Remove the remnants of the used shear rivets (3) from both the right and left hinge mid-straps (2) using one of the following methods:
   1. Firmly grasp the end of the shear rivet with side cutters and pull it out of the mid-strap using care not to damage or enlarge the hole from which the rivet is removed.
   2. Use a punch no larger than 4.76 millimeters (0.187 inch) to drive the remnant of the used shear rivet out of the mid-strap using care not to damage or enlarge the hole from which the rivet is removed.
3. Disengage the reset cap (6) from the mid-strap by pushing inward on the cap through the reset hole (4) and pulling lightly upward on the rear corner of the hood panel.
4. Place the concave surface of the new reset button (5) against the convex surface of the reset cap protruding from the hinge hood bracket (1).
5. While holding the reset button against the reset cap, push the rear corner of the hood panel downward far enough to capture the button between the hood bracket and the mid-strap, preventing the spring-actuated reset cap from engaging in the reset hole.
6. Move the rear corner of the hood panel up or down as needed to align the shear rivet holes in the hinge hood bracket and the mid-strap.
7. Insert the new shear rivet through the outboard side of the mid-strap, then through the hood bracket.
   WARNING:

   Be certain to hold the blind rivet installation tool so that the head of the shear rivet remains flush against the hinge mid-strap during rivet expansion. Do not twist the installation tool or rock it from side-to-side to break the rivet mandrel. The rivet mandrel must be broken in tension to ensure the mandrel does not extend through the shear joint, which will prevent the hood from lifting as designed during a subsequent deployment. Failure to comply with these instructions could result in improper or incomplete active hood deployment and increased or fatal pedestrian injuries.

8. Expand the shear rivet using a blind rivet installation tool and nose piece with adequate capacity to break the rivet mandrel in tension.
9. Following shear rivet installation, verify that the rivet mandrel is at least 5.5 millimeters (0.22 inch) below the head of the rivet by measuring the depth that a pin or drill bit less that 2.5 millimeters (0.10 inch) in diameter can be inserted into the mandrel hole in the head of the rivet.