Attachment III - Technical Information
OVERVIEWThis procedure involves replacing the stop lamp switch and a short section of the stop lamp switch harness.
NOTE!
Some of the affected vehicles may have had TSB 02-05-01 performed. To identify those vehicles, the stop lamp switch harness will be spliced into the vehicle harness and may be secured with a tie strap to the brake pedal bracket.
This field service action must be Derformed even if the vehicle has already had TSB 02-05-01 completed.
NOTE:
Previous service procedures called for removal of the lower steering column cover. This step is not required and, therefore, should not be performed.
SERVICE PROCEDURE
1. Install a memory saver and disconnect the battery negative cable.
2. Position the stop lamp switch wire harness assembly down the left side of the steering column for easier access to the repair area as follows: See Figure 1.
a) Remove the stop lamp switch retainer pin. Retain the pin for reuse.
b) Remove the switch and the plastic grommet from the brake pedal/master cylinder pushrod. Discard the grommet.
c) Disconnect the adjustable pedal motor connector, if equipped, and the speed control deactivation switch.
d) Disengage the harness push-pin retainers (securing the plastic brace).
e) Pull the harness out of the steel retention clip (located on the brake pedal bracket above the steering column on adjustable pedal vehicles only).
f) Remove any tie straps that secure the harness.
g) Position the harness over the steering column and down.
NOTE:
^ If the vehicle has not had TSB 02-05-01 performed, go to Step 3, then skip to Step 6.
^ If TSB 02-05-01 has been completed on the vehicle (identified by a splice in the stop lamp switch harness), go to Step 4.
3. Cut off the stop lamp switch wire harness above the plastic brace and discard the switch and harness. See Figure 2.
4. It is possible that on some vehicles that have had the TSB performed, the splice may be located very high on the harness and access can be limited. In these situations, disengage the harness push-pin retainer located on the left side of the brake pedal bracket (next to the central junction box [CJB]). This will provide enough slack in the harness to allow beffer access to the repair area. See Figure 3.
5. Remove enough tape to expose the repair area. Then cut off the harness above the splices, leaving as much of the vehicle harness as possible (the cut off section will include the switch, harness and the TSB-installed splices). See Figure 4.
6. Strip approximately 1/4 inch of insulation from the wires on both the vehicle harness and the new harness, taking care not to nick or cut the wire strands. Peel back the electrical tape on the vehicle harness as necessary.
7. CAUTION: DO NOT use diagonal cutters to make the crimp. Use only a commercially available ratcheting-type crimp tool designed for use with insulated butt splice connectors to ensure a proper crimp.
Install one butt splice connector onto each stripped wire on the new harness as follows:
a) Insert the stripped wire into the barrel end of the butt splice connector, making sure the insulation on the wire does not enter the wire barrel.
b) Holding the wire in place, squeeze the tool handles together until the ratchet releases.
c) Test the integrity of the splice after crimping by pulling gently on the wires.
8. Connect the new harness to the vehicle harness matching wire colors (green stripe to green stripe, red stripe to red stripe) and crimping in the same fashion as described in the previous step.
9. Using a Rotunda Flameless Heat Gun 164-R5902 (or equivalent) equipped with a shield to prevent any damage to surrounding components, apply heat to the butt splice connectors. Rotate the wire assemblyto ensure complete shrinkage and heat until the outer shell of the connector shrinks into place and will shrink no further. The adhesive lining of the connector will melt and flow and should be visible at both ends of the connector.
10. Using vinyl electrical tape, secure the butt splices and the harness wires together in two or three locations. See Figure 5.
11. Install the new stop lamp switch as follows (See Figure 6):
a) Install the new plastic grommet onto the master cylinder pushrod.
b) Place one new plastic washer in the brake pedal arm post, then connect the pushrod to the post.
c) Position the new stop lamp switch onto the post, then install the other new plastic washer.
d) Install the retainer clip.
12. Position the harness back over the steering column and into place, then secure the push-pin retainer(s) to the brake pedal bracket. Be sure the excess wiring is positioned so it does not interfere with any moving components. Use the supplied tie straps to secure the wires. Install one to secure the plastic brace to the brake pedal bracket and the other to secure the wires as necessary. See Figure 7.
13. Connect the stop lamp switch electrical connector.
14. Connect the adjustable pedal motor connector, if equipped, and the speed control deactivation switch.
15. Connect the battery negative cable and remove the memory saver.
16. Check stop lamp and brake shift interlock operation.