2022-2025 Alfa Romeo / Dodge Front Brake Pulsation TSB

Symptoms

Owners of certain 2022-2025 Alfa Romeo and Dodge vehicles may notice a "Front Brake Pulsation and/or Clunk Noise" when braking. This often manifests as a clunk noise or a pulsating sensation felt through the brake pedal or steering wheel during deceleration.

Diagnosis

The primary diagnostic indicator for this issue is the customer's experience of a clunk noise and/or pulsation during braking. This can occur in models such as the Alfa Romeo Tonale, Alfa Romeo Stelvio, and Dodge Hornet. The manufacturer communication S1705000002 Rev. A specifically addresses this "Front Brake Pulsation and/or Clunk Noise" symptom.

Repair Procedure Summary

Manufacturer Communication S1705000002 Rev. A outlines a multi-step repair process to resolve the front brake pulsation or clunk complaint. The initial step involves a brake bedding (burnish) procedure to stabilize the interface between the brake pads and rotors. Two equivalent procedures are provided, allowing technicians to choose the one best suited for their test drive location:

Bedding (Burnish) Procedures

• Procedure A: Perform 20 consecutive brake cycles from 75 MPH (120 km/h) down to 50 MPH (80 km/h) with a deceleration of 0.4g. This deceleration rate is available in the g-meter cluster when in Dynamic mode. After each cycle, accelerate to 75 MPH (120 km/h) and maintain speed for 80 seconds without braking.
• Procedure B: Perform 30 consecutive brake cycles from 45 MPH (70 km/h) down to 0 MPH (0 km/h) at 0.4g. Accelerate to 45 MPH (70 km/h) and maintain speed for 45 seconds without braking.

After either bedding procedure, the brake system must return to ambient temperature before reevaluating the vehicle for the pulsation or clunk complaint. If the issue is resolved, the vehicle can be returned to the customer.

Further Steps if Complaint Persists

If the "Front Brake Pulsation and/or Clunk Noise" continues after the bedding procedure, the next steps involve component replacement:

1. Replace Brake Pads & Retention Springs: Order and replace the front brake pads and retention springs. Following this replacement, the bedding procedure (Step 1) must be performed again. After the brake system cools, reevaluate the complaint. If resolved, return the vehicle to the customer.
2. Replace Rotors: If the issue still persists, the final step is to replace the front rotors. Before replacement, measure the runout of the original rotors on the vehicle at a specified diameter, marking the rotor and hub for reinstallation at the original orientation. When installing new rotors, measure their runout on the vehicle. If the runout is not within the specification of .001” / .02mm MAX, remove the rotor attachment bolts and rotate the rotor relative to the hub. Reinstall the bolts and remeasure, repeating until the runout is within specifications. After rotor replacement, the bedding procedure (Step 1) must be performed once more. Once the brake system returns to ambient temperature, reevaluate the vehicle for the pulsation or clunk complaint.

Finally, several brake cycle tests should be performed at low speeds to verify that the condition has been eliminated before returning the vehicle to the customer.

Important Warnings

It is important for owners to understand that this manufacturer communication, identified as S1705000002 Rev. A, does not authorize warranty repairs. This document serves as a record of past experiences and does not provide conclusions about the root cause of the vehicle's issue. Technicians are considered the experts responsible for determining the appropriate course of action based on the symptom and condition.

Owner Action

If your 2022-2025 Alfa Romeo Tonale, Dodge Hornet, or Alfa Romeo Stelvio is experiencing "Front Brake Pulsation and/or Clunk Noise" during braking, it is recommended to contact your authorized dealership. Describe the symptoms clearly to the service advisor. The dealership technicians will follow the diagnostic and repair procedures outlined in Manufacturer Communication S1705000002 Rev. A to address the issue.

NHTSA Source Citation

NHTSA ID: 11013151