Repair Procedure

Figure 1:

This repair involves opening the electronic transaxle controller wire harness at the 60-way connector and splicing the bus wires.

1. Disconnect the battery negative cable.
2. Disconnect the electronic transaxle controller wire harness at the 60-way connector.
3. Remove the protective tape (friction tape) from the 60-way connector to the first harness junction, Figure 1.

NOTE: USE CARE WHEN REMOVING THE TAPE TO PREVENT NICKING OR CUTTING ANY WIRES IN THE HARNESS.

Figure 2:

4. Locate the two sets of twisted wire pairs (violet with brown tracer and white with black tracer). Gently pull the twisted pair wire sets from the wire bundle, being sure not to strain the wires, Figure 2. Do not un-twist the wires any more than is necessary to perform the repair.

5. Spot tape (3 to 5 wraps) the remaining bundle wires just behind the 60-way connector to hold them in position during the repair, Figure 2.

Figure 3:

6. Measure eight inches back from the 60-way connector on the twisted wires exiting the top row of the connector an cut both twisted wires, Figure 3.

Figure 4:

7. Strip one inch of insulation from both wires leading to the 60-way connector, Figure 4.

8. Cut one of the heat shrink tubes (PN 4419644) in half so that you have 2 one inch long heat shrink tubes.

NOTE: USE ONLY HEAT SHRINK TUBE PN 4419644 FOR THIS REPAIR BECAUSE IT IS THE CORRECT DIAMETER AND CONTAINS A SEALER TO ENSURE A WATER TIGHT CONNECTION.

9. Position the one inch long heat shrink tubes over the two wires that run back into the harness so that 1/2 inch of the shrink tube is over the wire insulation. Using an air heat gun, apply heat until the heat shrink tube contracts over the wire and sealer is showing at both ends, Figure 4.

NOTE: DO NOT USE AN OPEN FLAME, OR SOLDER GUN TO SHRINK THE TUBING.

Figure 5:

10. Measure 5-1/2 inches back from the 60-way connector on the twisted wires exiting the bottom row of the connector and cut both wires, Figure 5.

Figure 6:

11. Strip 1/2 inch of insulation from the four wire ends, Figure 6.
12. Place one of the heat shrink tubes over the white with black tracer wires running back into the harness, and the remaining tubes over the violet with brown tracer wire running back into the harness.

Figure 7:

13. Take the two white with black tracer wires coming from the connector, twist the 1/2 inch bare wire around the 1 inch bare wire. Twist the white with black tracer 1/2 inch bare wire coming from the harness around the 1 inch bare wire, Figure 7. (As an option to hold the twisted wire in place during the soldering operation, you can use the 14 gauge wire grip ends off four terminals PN 3843601, simply cut and discard the end of the terminal, position the wire grip ends over the two 1/2 inch wires clamping them to the one inch wire and crimp in place.)

NOTE: INSPECT THE TWISTED WIRES TO BE SURE THAT YOU HAVE AT LEAST ONE TWIST PER TWO INCHES ON BOTH SIDES OF THE CONNECTION.
14. Repeat the procedure in step 13 to connect the violet with brown tracer wires.

15. Solder the two connections using only a rosin core solder. Be sure the solder has flowed and contacted all the wire strands.
NOTE: FAILURE TO SOLDER THESE TWO CONNECTIONS COULD RESULT IN FAULTY TRANSMISSION OPERATION AND ERRONEOUS DIAGNOSTICS.

16. Center the heat shrink tubes over the solder joints, heat the shrink tubes using an air heat gun until the shrink tubes contracts over the wires and the sealer is showing at both ends of the tubes.

17. Work the two sets of twisted wire pairs back over the length of the bundle and spot tape in place.

18. Using a protective tape (friction tape) re-tape the wire bundle.

19. install the 60-way connector to the transmission controller, torque the attachment bolt to 40 inch pounds.

20. Install the negative battery cable.

21. Connect the DRB II and road test the vehicle as outlined in the diagnosis procedure.


POLICY: Reimbursable within the provisions of the warranty.


TIME ALLOWANCE:
Labor Operation No. 08-19-05-94 Inspect wiring for proper part no. 0.2 Hrs.
08-19-05-95 Inspect wiring for proper part no. 0.9 Hrs. and modify wiring


Failure Code: 58 - Internal Defect