A604 EATX - Wiring Repair Package
90chrysler12 NO.: 08-16-90GROUP: ELECTRICAL
DATE: Sept. 24, 1990
SUBJECT: A604 EATX Wiring Harness/ Electronic Connector Repair Package
MODEL YEARS/BODY CODES:
1989-90 AC - DYNASTY/NEW YORKER/NEW YORKER LANDAU
AS - CARAVAN/GRAND CARAVAN/CARAVAN C/V VOYAGER/GRAND VOYAGER/TOWN & COUNTRY
1990 AA - ACCLAIM/SPIRIT
AG - DAYTONA AJ - LEBARON COUPE/LEBARON CONVERTIBLE AY - IMPERIAL/FIFTH AVENUE
DISCUSSION
When inspecting wiring and connectors, look for cut wiring or worn through insulation, terminal push-out, and spreading of terminals. These problems have led to intermittent setting of fault codes 12, 39, and 41 among others. Wiring must be properly routed and secure to avoid sharp or moving parts. Connector seals, covers, and shields must be present and in good shape. Terminals must be clean and fully engaged with a tight fit. The 60-way, 8-way and other sealer connectors for the A604 EATX should contain Mopar Lubriplate grease PN 4549615 in the female terminals.
When wiring, connectors or terminals need repair on an A604 EATX the following service parts are now available.
REQUIRED PARTS FOR REPAIRS
Repair Package - 8-Way Solenoid Connector 4419476
(Connector Assembly on Wire w/Heat Shrink)
Repair Package - 2-Way Connector (For 4419478
Output and Turbine Speed Sensors)
Repair Package - 60-Way Connector 4419479
(14 Two Terminal Leads)
Repair Package - 60-Way Insulator 4419491
60-Way Connector Outer Shield 4400980
REQUIRED PARTS FOR MAKING A GAUGE
0.045 in. Male Pin Terminal - 2-Way 4400110
0.090 in. Male Pin Terminal - 8-Way 4368163
Heat Shrink Tubing - 0.25 in. Diameter 4419644
PROCEDURE FOR MAKING A GAUGE
To properly check a terminal for spreading, a gauge is required. To make a gauge, select the correct male pins from the parts list above (pins for gauging the 60-way connector are included in Repair Package PN 4419479). Two pins are required to make each gauge. Insert the base of a pin into each end of a single piece of heat shrink tubing PN 4419644. Heat evenly until the tubing shrinks tightly onto the base of both pins. The shrink tubing will now serve as a handle while gauging terminals.
INSPECTING CONNECTORS
Inspect connectors for pushed out terminals by removing from the A604 EATX and looking at the face of the connectors. If terminals are pushed out, carefully remove the locking wedge and push in the terminals until they snap into position. Carefully install the wedge until it is flush with the outer surface. Make sure that all of the terminals remain fully seated. If the wedge does not go in all of the way, clear the wedge cavity and reinstall the wedge.
To inspect the connector for spread terminals, take the appropriate size gauge and insert it into each of the female connector pins. The terminals should mate snugly with the gauge.
Verify proper transaxle operation after service.
NOTE: WHEN REPLACING EITHER THE SPEED SENSOR OR SOLENOID PACK, MAKE SURE THAT ALL TERMINALS HAVE AN INTERFERENCE FIT.
60-WAY CONNECTOR REPAIRS
If the 60-way insulator is damaged or the locking fingers are broken, replace the insulator using repair package PN 4419491. If terminals are damaged or spread, replace them using Repair Package 4419479 and the following procedure.
1. Remove the shield, wedge, and tape as needed. Remove the bad terminal while flexing the plastic locking finger.
2. Cut the wire with the bad terminal from the wiring harness. Strip one half inch of insulation from the remaining wire and slide on a piece of heat shrink tubing included in the Repair Package.
3. Select from the Repair Package a wire of the same base color as the wire just cut from the harness. Cut the wire to the proper length and remove one half inch of insulation from the wire and twist the two bare ends around each other.
4. Solder the joint together using a ROSIN CORE SOLDER. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of heat shrink tubing.
5. Insert the new terminal and fully seat. Install the wedge, retape the harness and snap on the shield. If the shield is damaged, replace with PN 4400980.
6. Connect the 60-way connector and torque to 40 in.lbs. (4.5 N-m). DO NOT OVER TORQUE.
8-WAY CONNECTOR
If the 8-way insulator is damaged, the locking fingers are broken or terminals are spread replace the connector using Repair Package PN 4419476 and the following procedure.
1. With the vehicle raised disconnect the wiring from the solenoid pack and transmission switches and drop the wiring for access.
2. Remove the wire covering, cut the leads to the damaged 8-way at staggered even lengths and place a piece of heat shrink tubing on each wire.
3. Cut the matching wires on the new 8-way to staggered even lengths (allowing extra lengths for solder connections) so that the length of the new wiring is the same as the original wiring.
4. Strip one half inch of insulation from each wire and twist each pair of matching wires together. Solder each joint using a ROSIN CORE SOLDER. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of heat shrink tubing.
5. Install the covering and connect the wiring to the solenoid and switches following the original routing.
6. Torque the 8-way connector bolt to 40 in.lbs. (4.5 N-m). DO NOT OVER TORQUE.
2-WAY CONNECTOR REPAIRS
If the 2-way insulator is damaged, the locking fingers are broken or terminals are spread replace the connector using Repair Package PN 4419478 and the following procedure.
1. With the vehicle raised, disconnect the wiring from the solenoid pack and transmission switches and drop the wiring for access.
2. Cut the leads to the damaged 2-way at staggered even lengths and place a piece of heat shrink tubing on each wire.
3. Cut the matching wires on the new 2-way to staggered even lengths (allowing extra length for solder connections) so that the length of the new wiring is the same as the original wiring.
4. Strip one half inch of insulation from each wire and twist each pair of matching wires together. Solder each joint using a ROSIN CORE SOLDER. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tube.
5. Install the wiring in its original routing.
6. Torque the 8-way connector bolt to 40 in.lbs. (4.5 N-m). DO NOT OVER TORQUE.
POLICY: Information only