ABS - Warning Light ON Continuously
NO: 05-22-94GROUP: Brakes
EFFECTIVE DATE: Dec. 2, 1994
SUBJECT:
Antilock Brake System (ABS) Warning Light Illuminated due to Wheel Speed Sensor Connector
MODELS:
1994 - 1995 (AS) Town & Country/Caravan/Voyager
1994 - 1995 (ES) Chrysler Voyager (European Market)
SYMPTOM/CONDITION:
Yellow ABS warning light is on continuously while the ignition switch is in the "ON" position. The antilock feature of the brake system is disabled while the ABS warning light is on. The vehicles brake system will perform as a non-ABS equipped vehicle normally would during this condition.
DIAGNOSIS:
Use the Mopar Diagnostic System (MDS) or Scan Tool (DRB II/III) to check for ABS Diagnostic Trouble Codes (DTC's). Record any DTC's found on the repair order for future reference and repair as necessary. If an ABS wheel speed sensor DTC is discovered:
1. Disconnect the 2 way connector of the suspect wheel speed sensor.
2. Using a new male terminal as a pin gauge, P/N 4625196, probe the female terminals of the body harness connector. There should be resistance/interference felt between the male and female terminals.
3. If resistance/interference is felt, use the Scan Tool with the Antilock Brake Diagnostic Procedures for further diagnostics.
4. If no resistance/interference is felt at one or both terminals, perform the repair procedure.
PARTS REQUIRED:
1 4797997 Kit, Terminal Repair
Kit Consists Of:
1 4625196 Terminal, Male
1 Connector/Wire Assembly
2 4778570 Tube, Heat Shrink
REPAIR PROCEDURE:
This bulletin involves replacing ABS wheel speed sensor connectors that have oversized or spread female terminals.
1. Cut off the suspect body harness connector and discard.
2. Remove 1 in. of insulation from the ends of the two body harness wheel speed sensor wires and the new connector/wire assembly.
3. Place a heat shrink tube, P/N 4778570, over one wire of the new connector/wire assembly and spread the strands of the wire.
4. Spread the strands of one of the body harness wheel speed sensor wires. Push the strands together with the strands prepared in step 3 and twist together.
5. Solder the wires together with ROSIN core solder.
6. Center the shrink tubing over the bare portion of the wires and heat with a heat gun until the tubing is tightly sealed and sealant comes out of both ends of the tubing.
7. Repeat steps 3 - 6 for the other wires.
8. Connect the body harness to the wheel speed sensor.
9. Test drive the vehicle and verify proper operation of the ABS.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-14-18-97 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment