C. ABS Control Module Wiring Harness Connector Replacement

NOTE:
Only ABS control module wiring harness connectors with heat damage (melted), green wire terminals or dull/discolored terminals, as determined by the inspection in Section B, require replacement.





1. Remove the secondary terminal lock from the original ABS control module wiring harness connector housing (Figure 8).

2. Some models may have two empty wire cavities in the ABS control module wiring harness connector housing. Insert the gray wire cavity plugs supplied with the repair kit into the correct cavities of the new ABS control module wiring harness connector.

3. The ABS control module wiring harness connector terminals that do not have heat damage, green corrosion or are only dull or discolored can be transferred to the new connector using the following process:

a. From the terminal side of the connector, insert a small pick into the connector next to the terminal and push on the terminal release arm while pulling on the wire.

CAUTION:
Remove only one wire from the original connector at a time and note which connector cavity the wire is to be transfer into.

b. Using the electrolyte detection and neutralizing spray, lightly spray the removed wire until the spray remains an orange color. This may require two or three applications.

c. Using compressed air, carefully dry the terminal and wire.

d. Insert the terminal into the proper connector cavity of the new connector housing.

e. Repeat Steps a. through d. on all wires that need to be transferred to the new connector housing.

4. The ABS control module wiring harness connector terminals with heat damage and/or green corrosion must be replaced using the following process:

a. Cut off the wire one inch back from the original ABS connector.

b. Remove one-half (1/2) inch (13 mm) of insulation from the wire on the harness that needs to be spliced.

c. Cut the replacement wire supplied in the connector repair kit to the required length. Then remove one-half (1/2) inch (13 mm) of insulation from the wire.

d. Place a piece of sealant lined heat shrink tubing on one side of the wire.





e. Place the strands of wire overlapping each other inside of the brass splice band (Figure 9).





f. Using crimp tool (Mopar P/N 05019912AA), crimp the brass splice band and wires together (Figure 10).

g. Solder the connection together using rosin core type solder. DO NOT use acid core solder.

CAUTION:
All splices must be properly soldered. Failure to properly solder these wiring connectors can cause the ABS to become inoperative in the future.





h. Center the shrink tubing over the splice joint. Using a heat gun, heat the surface of the shrink tubing until the shrink tubing is tightly sealed and sealant comes out of both ends of the shrink tubing (Figure 11).

5. After all of the terminals have been transferred or replaced, install the blue secondary terminal lock into the ABS control module wiring harness connector (Figure 8).





6. Using a small mirror (Snap-on GA295 or equivalent), inspect the ABS control module connector pins for green corrosion and the connector housing for heat damage (Figure 12).

> ABS control module connectors found with green corroded pins continue with Section D - ABS Control Module Replacement.

> ABS control module connector housings found with heat damage continue with Section D - ABS Control Module Replacement.

> ABS control module connectors found without heat damage or green corroded pins continue with Section E - Battery Tray Installation.