Repair Procedure

THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.

1. Disconnect and isolate the battery negative cable.

2. Open the glove box.

3. Locate the three screws in the bottom of the glove box bin. Remove only the center screw.

4. Depress the two sides of the glove box bin far enough so that the rubber stop bumpers located on each side of the bin will clear the metal stops located on the bracket on each side of the glove box opening.

5. While holding the sides of the glove box bin depressed, roll the glove box downward until the stop bumpers are beyond the stops, then release the sides of the bin.

6. Grasp the upper outboard corners of the glove box door securely with both hands.








7. Pull the door firmly and quickly away from the instrument panel to unsnap the three glove box hinge hooks (Figure 1) from the three hinge pins on the instrument panel (Figure 2).

8. Remove the glove box from the instrument panel.

9. Locate the blower motor fan voltage reduction relay located on the wiring harness just left of the glove box opening.

10. Leaving the relay attached, remove the connector from the relay.

11. Using electrical terminal removal tool 6680-4S, remove circuit C72 10GY from the relay connector.

12. Using electrical terminal removal tool 6680-4S, remove circuit C7 10BK/TN from the relay connector.

13. Cut off the terminals from each wire.

14. Remove one (1) inch of insulation from each wire.

15. Place a piece of heat shrink tubing, p/n 04778570, on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area.





16. Spread the strands of wire apart on each exposed portion of the wire (Figure 3 - Example 1).

13. Push the two ends of the wires together until the strands of wire are close to the insulation (Figure 3 - Example 2).

14. Twist the wires together (Figure 3 - Example 3).

15. Solder the connection together using rosin core type solder only.

CAUTION:
DO NOT USE ACID CORE SOLDER.





16. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Figure 4).

17. Tape the wiring repair to the relay harness.

18. Re-install the connector onto the relay. Ensure that the harness does not rattle against any object in the instrument panel.

19. Position the glove box to the instrument panel with the bin inserted into the glove box opening far enough so that the rubber stop bumpers located on each side of the bin are behind the metal stops located on the bracket on each side of the glove box opening.

20. Start on the outboard side of the glove box, insert the first glove box hinge hook over the first hinge pin on the instrument panel.

21. Use a slight twisting action on the glove box door to insert the second hinge hook under the second hinge pin.

22. Finally, again using a slight twisting action on the glove box door, insert the last hinge hook over the last hinge pin.

23. Install and tighten the center screw in the bottom of the glove box bin. Tighten the screw to 2.2 N.m (20 in. lbs.).

24. Close the glove box and then reopen it to check for proper hinge operation.

25. Remove fuse "D" (10 amp - red fuse) from the fuse/relay block. The fuse/relay block is attached to the backside of the junction block located on the left side of the instrument panel.

26. Connect the battery negative cable and reset the clock.