Door Ajar Lamp/Dome Lamp - Intermittent Operation

NUMBER: 08-46-99

GROUP: Electrical

DATE: Dec. 31, 1999

SUBJECT:
Door Ajar Switch Corrosion/Harness Repair

OVERVIEW:
This bulletin involves replacing the door ajar switch and splicing a repair connector onto the harness.

MODELS:
1995 - 1997 (FJ) Avenger/Sebring/Talon

SYMPTOM/CONDITION:
Some vehicles may exhibit a condition where the door ajar warning light and dome light may work intermittently or may become inoperative. The condition may be caused by corrosion in the door ajar switch. This corrosion may extend into the switch connector and destroy the connector terminals.

DIAGNOSIS:
Open and close both doors to inspect for intermittent or inoperative door ajar/dome light operation. If intermittent operation is experienced or an inoperative condition exists and the fuse for that circuit is OK, perform the Repair Procedure.

PARTS REQUIRED:

1 MR124303 Switch, Black
1 MR124302 Switch, Blue
1 MR490265 Package, Connector Repair
AR 04778570 Tubing, Heat Shrink

EQUIPMENT REQUIRED:
Digital Volt Ohm Meter (DVOM)
Soldering Iron
Rosin Core Solder

REPAIR PROCEDURE:

1. Inspect both door ajar switches for continuity. Operate each switch repeatedly and replace any switch p/n MR124303 (black) or MR124302 (blue) that shows an intermittent or open circuit when the plunger is in its extended position.

2. On the same side that received switch replacement, inspect the door ajar switch connector and harness for corrosion. If corrosion of the harness connector is noted, proceed with the remaining instructions in this TSB. If no corrosion is found, reinstall the door ajar switch and confirm proper operation.

3. If corrosion is found, cut the connector from the harness along with an appropriate amount of wire to remove all the corrosion.

4. Strip 1 inch of insulation from each wire end and place a piece of heat shrink tubing p/n 047778570 over each wire.

5. Strip 1 inch of insulation from each wire of the connector package p/n MR490265. Attach the new connector wires to the door harness wires by twisting them together.

6. Solder each connection using rosin core solder.

7. Center the heat shrink tubing installed in step 4 over the soldered connections. Heat the tubing until it is tightly sealed and sealant flows from each end.

8. Reinstall the door ajar switch(s) and confirm proper door ajar/dome lamp operation.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No: 08-80-24-90 One Side 0.3 Hrs.

FAILURE CODE: 61 - Intermittent Operation