ABS/TCS - Temporary ABS/ESP Functionality Loss (Police)
NUMBER: 08-001-12GROUP: Electrical
DATE: January 10, 2012
THIS SERVICE BULLETIN IS ALSO BEING RELEASED AS RAPID RESPONSE TRANSMITTAL (RRT) 12-001. ALL APPLICABLE SOLD AND UN-SOLD RRT VIN's HAVE BEEN LOADED. TO VERIFY THAT THIS RRT SERVICE ACTION IS APPLICABLE TO THE VEHICLE, USE VIP OR PERFORM A VIN SEARCH IN TECHCONNECT. ALL REPAIRS ARE REIMBURSABLE WITHIN THE PROVISIONS OF WARRANTY.
SUBJECT:
Temporary Loss Of ABS/ESP Functionality
OVERVIEW:
Rerouting ABS power feed circuit in the front PDC from fuse 14 to fuse 6
MODELS:
2011-2012 (LD) Charger (Police Only)
NOTE:
This bulletin applies to vehicles built before December 21, 2011 equipped with POLICE GROUP (sales code AHB)
SYMPTOM/CONDITION:
The customer may complain of following conditions:
^ Temporary loss of ABS/ESP function.
^ ABS/ESP Lamp Illumination.
^ C2100-16: Battery Voltage Low - Circuit Voltage Below Threshold.
DIAGNOSIS:
If a customer's VIN is listed in VIP or your RRT VIN list, perform the repair.
PARTS REQUIRED:
SPECIAL TOOLS/EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
1. Obtain Mopar Service Kit Part # 68183960AA
2. Remove the Negative battery connection from the vehicle battery in the trunk.
3. Remove PDC top cover (Located in engine compartment) and lay down face up to prevent scratches.
4. Wrap PDC in protective cloth or lay down on soft mat prevent scratches.
5. Remove fuse 14 (25 Amp) with fuse puller (Fig 1).
6. Remove the PDC from metal PDC bracket - 3 Push out the Style Clips (Fig 2).
7. Rotate PDC and remove bottom cover (Total of 9 tabs) Pull out to un-clip the retainers with small pick tool or screwdriver (Fig 3).
NOTE:
Arrow head clip on wire bundle may need to be removed for easier access, if clip needs to be replaced a new clip is included in the service kit.
8. From bottom side of PDC, remove black rear terminal retainer (Fig 4) using a flat pick tool (Located between fuse location's 2 through 8), and discard.
9. From service kit insert the blade terminal pig tail into cavity 6B (fuse 6) and ensure you hear the terminal click into place (Fig. 5). Pull to verify engagement.
10. From service kit, insert new Black rear terminal retainer back into the correct position (Fig. 6).
NOTE:
Verify 4 clicks are heard for check point (Do Not Re-use original retainer).
11. Locate the A902 RD circuit from cavity 14B (fuse 14) on the bottom of the PDC.
12. Approximately 35mm from the back of the terminal crimp, cut the circuit with wire cutters (Fig 7). This circuit will no longer be used.
13. From service kit, take the black 25mm heat shrink tube and place it over the end of the wire protruding from the PDC to seal the un-used circuit (Fig. 8). Heat evenly to seal properly.
NOTE:
Use caution to avoid other wires when heating heat shrink to avoid melting surrounding wire.
NOTE:
Visible glue on both sides are an indication of a good seal.
14. Prep for splice: On the remaining portion of the cut circuit, strip approximately 10-15mm of insulation using wire strippers (Fig. 9).
15. From service kit slide the Black 50mm heat shrink tube on wire pigtail, positioned away from splice band (Fig 10).
16. Holding the installed pig tail and the remaining portion of the cut circuit together, use splice band from service kit and crimp using "B Style" Crimping Tool from essential tools (Fig. 11).
CAUTION:
Use Caution to Avoid dropping the Splice Band. Place a piece of cardboard under splice operation. If a Splice Band is Dropped it is Crucial that dropped Splice Band is retrieved before continuing with the repair.
17. Apply lead-free solder to the crimp (Fig. 12). Avoid accidentally heating up the heat shrink tube in the process
CAUTION:
Use Caution when Soldering the Crimp Band to NOT Let any Solder Drip into the Cover or PDC Area. Visually inspect for good solder (even flow no burrs).
18. Center the heat shrink tube evenly over the splice. Apply heat to shrink the tube and create a seal (Fig 13).
NOTE:
Avoid other wires when heating heat shrink to avoid melting surrounding wire.
19. Verify 10 gauge circuits are not broken (visual inspection).
20. Reinstall the lower PDC cover: Align all 9 clips; push on cover to seat. Ensure no wires are pinched between bottom cover and the PDC.
21. From Service kit insert the 25 Amp White Fuse into fuse location 6 (Fig. 14).
22. Connect wire harness and check for continuity, using multimeter. Place one probe on the B+ stud of the PDC. With the other probe verify continuity with cavities 28 through 33, 0 ohms for all test points (Fig. 15).
23. Reinstall the PDC back onto the bracket (3 tabs).
24. Place revised fuse location stickers on PDC box to indicate change of fuse location (Fig. 16).
a. Sticker 14 goes in number 6 location.
b. Sticker 6 goes in number 14 location.
25. Reinstall the Negative battery connection to the vehicle battery in trunk. Torque the M6 nut to 7 Nm +/- 1.
26. With IGN in run, engine off, scan vehicle using wiTECH and clear all stored codes.
27. Start the vehicle and verify the ABS, Brake Light and ESP lamps in the cluster go off after the initial bulb check.
28. With the vehicle running, verify the operation of the AC. Verify the AC light comes on and compressor clutch is in engaged.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.