Transfer Case - 4WD Indicator Lamp Stays ON/Ignition ON
NO.: 21-20-92GROUP: Transmission
DATE: Dec. 22, 1992
SUBJECT:
Four-Wheel-Drive Indicator Lamp Stays Illuminated
MODELS:
1989-1991 (AN) Dakota/Dakota Sport
SYMPTOM/CONDITION:
The four-wheel-drive indicator lamp stays illuminated at all times when the ignition is in the ON position and the front axle will not disengage. This condition may be caused by a vacuum switch malfunction resulting from moisture and contamination entering through the vacuum switch air vent line and transfer case vent line.
PARTS REQUIRED:
1 Filter, Transfer Case Vent Hose 83503729
1 Filter, Transfer Case Switch Vent Hose 83503737
1 Switch, Vacuum (w/auto trans.) 53001101
1 Switch, Vacuum (w/man. trans.) 4210979
2 Clamp, Hose 2448761
1 Cap, Vacuum Nipple 3580171
REPAIR PROCEDURE:
This bulletin involves flushing and refilling the transfer case fluid, installing a filter (breather) in both the vacuum switch air vent line and the transfer case vent line.
1. Drain the contaminated transfer case fluid. Flush the transfer case with Mopar ATF Plus or Dextron II transmission fluid and then refill it to the specified level.
2. Disconnect the transfer case vent hose (Figure 1) that is routed from the nipple on the transfer case to the vent box located on the right inner fender.
3. Cut the vent transfer case vent hose 4-6 inches (101.6 mm - 152.4 mm) back from the vent box (Figure 2). Blow compressed air through the vent hose to remove any contaminates in the hose and then reconnect the hose at the transfer case.
4. Slide the hose clamp PN 2448761 onto the vent hose. Insert the transfer case vent hose filter PN 83503729 into the vent hose where the hose was cut off and secure it with the hose clamp (Figure 3). The vent hose must remain in the tie strap located on the dash panel.
5. Install the vacuum nipple cap PN 35880171 on the open port in the vent box.
6. Remove the vacuum switch vent line from the vent box located on the right inner fender. Remove the vent line from the vacuum switch located on the transfer case (Figure 4). Replace the vacuum switch with a new switch PN 53001101 (w/auto trans.) or PN 4210979 (w/manual trans.).
7. Cut the vacuum switch hose 4-6 inches (101.6 mm - 152.4 mm) back from the vent box (Figure 5). Blow compressed air through the vent hose to remove any contaminates in the hose and then reconnect the hose at the transfer case.
8. Insert the transfer case vent hose filter PN 83503729 into the vent hose where the hose was cut off (Figure 6). The vent hose must remain in the tie strap located on the dash panel.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operations No. 21-03-58-92 0.5 Hrs.
Failure Code: P8 - Service Adjustment