Campaign - Door Handle Cable Lube/Connector Lube
05-036October 4, 2005
Applies To:
2005 Odyssey - See VEHICLES AFFECTED
Product Update: Front Door Inner Handle Cable Freezes, Wire Harness Connectors Need More Dielectric Grease
(Supersedes 05-036, dated August 13, 2005)
Updated information is shown with black bars and asterisks.
BACKGROUND
NOTE:
As a convenience to you and your customers, two separate repairs are included in this product update. This allows you to complete both on a single customer visit.
Repair 1 (affecting all vehicles):
In cold weather, moisture trapped inside the driver's or front passengers door inner handle cable freezes. This condition can cause improper operation of the door latch. In rare cases, it can prevent one or both doors from opening or properly closing.
Repair 2 (affecting most vehicles):
Insufficient dielectric grease in the driver's door wire harness connectors and two under-hood fuse/relay box wire harness connectors can lead to corrosion of the connector terminals. Corrosion on the terminals can cause a variety of electrical problems.
VEHICLES AFFECTED
CUSTOMER NOTIFICATION
All vehicles within the affected VIN ranges are also affected by S/B 05-035, Safety Recall: Front Impact Sensor Corrosion Causes the SRS Indicator to Stay On. And many vehicles are also affected by S/B 05-037, Product Update: MIL Comes On With DTC P2647 Because of this, customer notifications for the two product updates are not being sent out initially.
When a vehicle comes in for the safety recall, check if either or both product updates also apply. If they do, complete the safety recall and the product update(s) on the same visit. Later this year, customer notifications for the product updates will be sent out for any vehicles not yet repaired.
To verify that a vehicle is eligible, do an iN VIN status inquiry.
In addition to the VIN status inquiry, check for a punch mark above the seventh character of the engine compartment VIN. A punch mark in that location means this product update has already been completed.
CORRECTIVE ACTION
All vehicles: Lubricate both front door inner handle cables.
Most vehicles: Apply additional dielectric grease to the driver's door wire harness connectors and two under-hood fuse/relay box wire harness connectors.
See VEHICLES AFFECTED for the VIN ranges.
REQUIRED MATERIALS
REQUIRED SPECIAL TOOLS
WARRANTY CLAIM INFORMATION
REPAIR PROCEDURE
1. *With the driver's and front passenger's windows up, remove the driver's and front passenger's door panels:*
^ Refer to page 20-8 of the 2005 Odyssey Service Manual, or
^ Online, enter keyword DOOR, and select Front Door Panel Removal/Installation from the list.
2. Remove the plastic covers from the doors.
3. Lubricate the driver's door inner handle cable:
^ Wearing a rubber glove, place a small amount of Dow Corning 111 Valve Lubricant & Sealant onto the tip of your index finger.
^ Push in on the handle end of the cable wire while you lift up the wire at the latch end (move all slack to the latch end). Hold the wire in this position by pressing on it from the handle end. Do not bend or khk the wire.
^ At the latch end of the cable, wipe the lubricant on the exposed wire.
^ Move the wire back and forth to work in the lubricant.
^ Push the wire toward the latch end a final time, then wipe a thin coat of lubricant on the exposed end of the wire.
^ Release the wire, and apply the excess lubricant to the cable cap on the latch end. This helps to seal the wire.
4. Repeat step 3 on the front passenger's door.
5. Based on the VIN, go to the appropriate step:
^ If the vehicle is within the VIN ranges for greasing the door and fuse/relay box connectors, go to step 8.
^ If the vehicle is not within the VIN ranges for greasing the door and fuse/relay box connectors, go to step 6.
6. Reinstall the plastic covers on the door(s), making sure the covers are completely sealed along the edges.
7. Reinstall the door panels, then go to step 32.
8. Make sure you have the anti-theft codes for the audio unit and the navigation system, then disconnect the negative cable from the battery.
9. Remove the rubber boot from the plastic retainer on the driver's door wire harness connector.
10. *Using a pocket screwdriver, carefully push in the two tabs on the plastic retainer, then remove the retainer from the door connector.
NOTE:
The retainer is not available separately. If you break either of its tabs, the entire door wire harness will need to be replaced.
11. Disconnect the blue, 17P connector (C632) and the white, 20P connector (C633) from the door connector.*
12. Add grease to the door connector:
^ Attach the grease gun to adapter A, then pump the gun until grease comes out of the adapter.
^ Plug adapter A into the door connector, then pump the grease gun 20-22 times while holding the adapter to the connector.
13. Inspect the wire side of the connector, making sure all its terminal cavities are packed with the grease.
14. Wipe off any excess grease from the wire side of the connector. The connector should look like this example shown.
15. *Add grease to the blue, 17P connector (C632):
^ Attach the grease gun to adapter B, then pump the gun until grease comes out of the adapter.
^ Slide the connector into adapter B, then pump the grease gun 10-15 times. Make sure the grease fills each terminal cavity in the connector (refer to step 13).
^ Remove the connector from the adapter.
^ Spread the excess grease over the terminal side of the connector, then wipe off any remaining grease (refer to step 14).*
16. Add grease to the white, 20P connector (C633):
^ Attach the grease gun to adapter C, then pump the gun until grease comes out of the adapter.
^ Slide the connector into adapter C, then pump the grease gun 10-15 times. Make sure the grease fills each terminal cavity in the connector (refer to step 13).
^ Remove the connector from the adapter.
^ Spread the excess grease over the terminal side of the connector, then wipe off any remaining grease (refer to step 14).
17. Reinstall the plastic retainer on the door connector, then reconnect C632 and C633, and reinstall the the rubber boot.
18. Wipe off any grease on or around the boot.
19. Remove the two bolts holding the under-hood fusel relay box in place.
20. Release the fuse/relay box from the vehicle:
^ Push the release tab back
^ Detach the rear wire harness from the bracket.
21. Carefully turn over the fuse/relay box, and remove its lower cover. Make sure not to break any of the lower cover tabs.
22. Disconnect connector F (20P gray) and connector H (18P gray) from the bottom of the fuse/relay box.
23. Add grease to connector F:
^ Attach the grease gun to adapter D, then pump the gun until you see grease coming out of the adapter.
^ Slide connector F onto adapter D, then pump the grease gun 12-16 times while holding the connector on the adapter. Make sure the grease fills each terminal cavity in the connector (refer to step 13).
^ Remove the connector from the adapter.
^ Spread the excess grease over the terminal side of the connector, then wipe off any remaining grease (refer to step 14).
24. Add grease to connector H:
^ Attach the grease gun to adapter E, then pump the gun until grease comes out of the adapter.
^ Slide connector H onto adapter E, then pump the grease gun 12-16 times while holding the connector on the adapter. Make sure the grease fills each terminal cavity in the connector (refer to step 13).
^ Remove the connector from the adapter.
^ Spread the excess grease over the terminal side of the connector, then wipe off any remaining grease (refer to step 14).
25. Reconnect connector F and connector H to the fuse/relay box. Make sure the connections are secure.
26. Reinstall the fuse/relay box in the reverse order of removal. Make sure that all the lower tabs are secure and that none of the fuse/relay box wires are pinched.
27. Reinstall the plastic covers on the doors, making sure the covers are completely sealed along the edges.
28. Reinstall the door panels.
29. Reconnect the negative cable to the battery.
30. Enter the anti-theft codes for the audio unit and the navigation system.
31. On vehicles with power sliding doors, reset the power sliding door control unit:
^ Refer to page 22-437 of the service manual, or
^ Online, enter keyword RESET, then select Power Sliding Door Control Unit Reset (With Power Slide Door) from the list.
32. Center-punch a completion mark above the seventh character of the engine compartment VIN.
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