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Power Distribution Center Disassembly and Assembly

Power Distribution Center Components:




The Power Distribution Center (PDC) cover, the PDC housing lower cover, the PDC relay wedges, the PDC relay cassettes and the PDC B(+) terminal stud module are available for service replacement. The PDC cover can be simply unlatched and removed from the PDC housing without the PDC being removed or disassembled. Service of the remaining PDC components requires that the PDC be removed from its mounting and disassembled.

DISASSEMBLY
PDC Housing Lower Cover
1. Remove the battery from the battery support.
2. Unlatch and remove the cover from the PDC.
3. Remove the two nuts that secure the two-holed eyelet of the battery wire harness PDC take out to the B(+) terminal studs near the front of the PDC.
4. Remove the battery wire harness PDC take out eyelet from the two PDC B(+) terminal studs.
5. Disengage the latches on the PDC housing mounts from the tabs on the PDC mounting stanchions on the battery support, and pull the PDC housing upward to disengage the mounts from the stanchions.
6. Where the right headlamp and dash wire harness exits the PDC, remove the tape that secures the wire harness to the trough formation on the PDC housing lower cover.

PDC Housing Lower Cover Remove/Install:




7. Using a trim stick or another suitable wide flat-bladed tool, gently pry the latches on each side and the front of the PDC housing that secure the housing lower cover to the PDC and remove the housing lower cover.

PDC B(+) terminal module
1. Remove the PDC housing lower cover.

PDC B(+) Terminal Module Latches:




2. From the top of the PDC housing, use a small screwdriver or a terminal pick tool (Special Tool Kit 6680) to release the two latches that secure the B(+) terminal module in the PDC.
3. Gently and evenly press the two B(+) terminal studs down through the bus bar in the PDC.

PDC B(+) Terminal Module Remove/Install:




4. From the bottom of the PDC housing, remove the B(+) terminal module from the PDC.

PDC Relay Wedge
1. Remove the PDC housing lower cover.
2. Remove each of the relays from the PDC relay wedge to be removed.
3. From the bottom of the PDC housing, use a small screwdriver or a terminal pick tool (Special Tool Kit 6680) to release the two latches (yellow) that secure the relay wedge to the PDC relay cassette.

PDC Relay Wedge Remove/Install:




4. From the top of the PDC housing, remove the relay wedge from the PDC relay cassette.

PDC Relay Cassette
1. Remove the relay wedge from the PDC relay cassette to be removed.

NOTE: It may be necessary to remove relay cassettes that are not being serviced from the PDC housing in order to obtain sufficient clearance to access the faulty relay cassette. The same service procedure is repeated as necessary to remove each of the interfering relay wedges and relay cassettes from the PDC housing.

PDC Relay Cassette Latches:




2. From the top of the PDC housing, use a small screwdriver or a terminal pick tool (Special Tool Wt 6680) to release the two latches that secure the relay cassette in the PDC.
3. Gently and evenly press the relay cassette down through the PDC housing.

PDC Relay Cassette Remove/Install:




4. From the bottom of the PDC housing, remove the relay cassette from the PDC.

CAUTION: Do not remove the wiring and terminals from the terminal cavities of the faulty PDC relay cassette at this time. Refer to the Assembly procedure that follows for the proper procedures for transferring the wiring and terminals to the replacement PDC relay cassette.

ASSEMBLY
PDC Relay Cassette
1. Move the faulty PDC relay cassette with its wiring away from the bottom of the PDC housing far enough to allow the replacement relay cassette to be installed into the PDC.
2. Using the faulty relay cassette as a guide, be certain that the replacement relay cassette is correctly oriented before installing it into the PDC housing.
3. From the bottom of the PDC housing, align and insert the replacement relay cassette into the PDC. Press the relay cassette up into the PDC until both of the latches are fully engaged.

CAUTION: Proper care must be taken to be certain that the wiring and terminals from the faulty PDC relay cassette are installed in the correct terminal cavities of the replacement relay cassette. To prevent mistakes it is recommended that the wiring and terminals be removed from the faulty relay cassette one cavity at a time, repaired or spliced as necessary, then installed securely into the correct cavity of the replacement relay cassette. If you are not absolutely certain into which cavity a terminal should be installed.

PDC Relay Cassette Terminal Remove/Install:




4. While pulling gently on the wire from the bottom of the faulty PDC relay cassette, use a terminal pick tool (Special Tool Kit 6680) from the top of the relay cassette to release the latch that secures the terminal in the relay cassette terminal cavity.
5. From the bottom of the faulty PDC relay cassette, remove the wire and terminal from the relay cassette terminal cavity.
6. Make all necessary repairs and splices to the wire for the removed terminal.
7. From the bottom of the PDC housing, align and insert the removed wire and terminal into the correct terminal cavity of the replacement relay cassette. Push the wire and terminal up into the relay cassette terminal cavity until it is fully engaged by the latch.
8. Repeat Step 4, Step 5, Step 6 and Step 7 one wire and terminal at a time until each of the wires and terminals have been transferred from the faulty PDC relay cassette into the replacement relay cassette.
9. Install the PDC relay wedge into the replacement PDC relay cassette.

PDC Relay Wedge
1. From the top of the PDC housing, align and insert the PDC relay wedge latch arms into the correct cavities in the relay cassette.
2. Gently and evenly press the PDC relay wedge down into the relay cassette until both of the latches are fully engaged.
3. Install each of the removed relays into the proper cavities of the PDC relay wedge.
4. Install the PDC housing lower cover.

PDC B(+) Terminal Module
1. From the bottom of the PDC housing, align and insert the B(+) terminal module into the PDC.
2. From the bottom of the PDC housing, align and insert the two studs of the PDC B(+) terminal module through the bus bar in the PDC.
3. From the bottom of the PDC housing, press the B(+) terminal module gently and evenly into the PDC until both of the latches are fully engaged.
4. Install the PDC housing lower cover.

PDC Housing Lower Cover
1. Align the PDC housing lower cover to the bottom of the PDC.
2. Press the PDC housing lower cover gently and evenly onto the PDC until each of the latches that secure the cover to the PDC is fully engaged.
3. Where the right headlamp and dash wire harness enters the PDC, tape the wire harness securely to the trough formation on the PDC housing lower cover.
4. Align the PDC housing mounts with the tabs on the PDC mounting stanchions of the battery support, and push the PDC housing downward until the latches in the PDC mounts are fully engaged on the stanchions.
5. Install the battery wire harness PDC take out eyelet over the two PDC B(+) terminal studs.
6. Install and tighten the two nuts that secure the two-holed eyelet of the battery wire harness PDC take outs to the B(+) terminal studs near the front of the PDC. Tighten the nuts to 11.3 Nm (100 in. lbs.).
7. Install the battery into the battery support.
8. Install the cover onto the PDC.
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