Well, I now have an update on my wife's Riot and not a great one. So about 20K miles ago the ball joints were shot, along with one of the front CV joints, so I ordered up some Moog replacement axles and RK-series control arms. Installation went pretty good, no real issues other than none of the (4) tranny axle seals matched up to the car...good thing I did not pull them first. Front x-member looked pretty good, just some basic surface rust. All is good till ~4 months ago when I realized the ball joint death rattle along with a crooked steering wheel indicated the Moog units were dying already...ugghh!!
This time I ordered up the Moog CK-series control arms that have grease-able ball joints. Well, life got in the way till I got the car for a day two weekends ago to toss them in. Two weeks before that new noises entered the picture, which included clacks, snaps and plings...WTF!?! I get the car up in the air and sure enough the passenger ball joint is almost ready to separate from the cup (pic below). The bigger issue is that I scrapped out over 1lb of metal flakes from the driver's side rear arm mount flange...uh, oh! I pulled the driver's arm out and was greeted with a half lifted sway bar mount and separated clamshell. When compared to the passenger side, the difference is quite striking and now explains all the additional sound effects during suspension movement. You can also see how much the sway bar mount pulls out when comparing the loaded vs unloaded pics.
So we schedule an appt with a local CDJR dealer and drop it off for the x-member replacement and handle an outstanding air bag controller recall. Long story, but we are denied a warranty replacement on the x-member!?! They couldn't explain why other than FCA won't cover it and didn't perform the recall work due to not ordering the controller, but they could give us a quote on the x-member replacement...the service writer was lucky I didn't have a blunt object in my hands at the time, so we took our Riot and left the building. I promptly called the Jeep dealer where we purchased it and explained the situation/needs. They explained that they had to inspect the x-member due to FCA rules and that they had a controller in stock, which they reserved for our visit...that is 10x more info we got from the other dealer. That brings us to our visit to the dealer this afternoon...no go on the x-member yet again...huh?? Apparently there is a very specific method for inspecting/testing the x-member from FCA that apparently requires holes to perforate flat areas of the x-member and that the torn/separated spots I noticed don't qualify under FCA rules...are you f'ing kidding me!! Our service writer certainly seemed honestly annoyed that he couldn't help us and gave us the local service rep phone number to complain, so I have a feeling we are not the first folks who have run into this.
I will call tomorrow to see if we can get this taken care of, as I don't want to have to drive it till the x-member breaks and possibly strands us out on the road somewhere...the saga continues!
1st pic: Moog RK ball joint @ 20K miles.
2nd pic: Passenger side x-member condition.
3rd pic: Driver side x-member sway bar mount.
4th pic: Driver side x-member clamshell spread.
5th pic: Driver side x-member ~1lb metal/rust debris.