Attachment II - Repair Procedure
A. VEHICLE INSPECTION PROCEDURE1. Verify that the vehicle is within one of the following ranges:
^ 2001 - 2004 Tribute vehicles equipped with ABS built from April 17, 2000 through December 19, 2003
VIN Range: 4F2*U** 1* 1K M00199 - M72183
VIN Range: 4F2*U** 1* 2K M00002 - M66656
VIN Range: 4F2*Z** 1* 3K M00001 - M56581
VIN Range: 4F2*Z** 1* 4K M00004 - M34822
- If the vehicle is within the above range, proceed to Step 2.
- If the vehicle is not within the above range, return the vehicle to the customer or inventory.
2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for Campaign Label Recall 4507C attached to the vehicle's bulkhead. Refer to eMDCS System - Warranty Vehicle Inquiry Results table below.
NOTE:
Be sure to verify Recall number as the vehicle may have multiple Recall labels.
eMDCS System - Warranty Vehicle Inquiry Results as shown.
ABS MODULE CONNECTOR INSPECTION AND REPAIR OVERVIEW
This program includes making sure the wiring harness connector is properly sealed against moisture/contamination, and inspecting the ABS module for evidence of corrosion resulting from an inadequately sealed connector.
During the inspection, we expect that most of the affected vehicles will not have any evidence of corrosion in the ABS module. However, the ABS wiring harness connector still needs to be inspected for missing or improperly seated seals and/or incorrect connector number.
If the ABS module is corroded, the ABS module and connector must be replaced.
A flow chart has been developed to help direct you to the proper repair.
B. INSPECTION
1. Record customer's pre-set radio stations.
2. Disconnect negative battery cable.
3. Locate ABS module connector under brake master cylinder.
4. Disconnect ABS module 25-pin connector by sliding lock mechanism out (towards passenger side of vehicle) and pulling connector off module.
NOTE:
When disconnecting the ABS module connector, be sure the blue connector lock stays engaged with the harness connector and does not remain in the module. Remove it from the module if necessary and make sure the white 0-ring seal is properly installed.
5. Disconnect the speed sensor harness, then remove the two (2) harness retainers from the studs and position the harness above the air cleaner assembly to provide access for inspection of the connector.
6. Inspect the ABS module connector pins for corrosion.
^ If corrosion is present, proceed to REPAIR PROCEDURE "B".
7. Remove the tie strap from the connector dress cover, then slide the cover off the connector.
CAUTION:
Do not cut any of the harness wires or the wire insulation when cutting off the tie strap.
8. Verify the wire seals are present on the four (4) heavier gauge wires.
9. Verify the number "054" is stamped on the slide-lock end of the mat cover (wipe mat cover clean if necessary to view).
NOTE:
Mat covers with any other number will be missing plugs in the unused pin locations.
^ If the module is not corroded, AND all the wire seals are present, AND all the wire seals are fully seated, AND the number on the mat cover is 054", proceed to REPAIR PROCEDURE "A".
^ If any of the wire seals are missing, OR if the number on the mat cover is not "054", proceed to REPAIR PROCEDURE "C".
^ Verify all four (4) heavier gauge wire seals are fully seated in the cavities. Each seal should sit approximately 1-2 mm (1/16 in) below the top of the round cavity. If any of the wire seals are not seated properly, proceed to REPAIR PROCEDURE "D".
REPAIR PROCEDURE A
1. Reinstall dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply dielectric grease to the ABS module connector, position and connect the harness as follows:
a) Reinstall dress cover.
b) Use ONLY dielectric grease.
^ With the tip of the applicator tube snipped off, position the end of the tip between the four (4) large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to just cover the four (4) flat pins.
NOTE:
DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a "hydro lock" condition which will not allow the connector to fully seat or lock in place.
2. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module.
3. Reconnect negative battery cable.
4. Turn the ignition key to the RUN position. Allow the ABS to carry out a preliminary self-check (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately three (3) seconds).
^ If the yellow ABS indicator is not illuminated after three (3) seconds, proceed to next step.
^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Technical Assistance Hotline.
5. Re-enter customer's radio pre-set stations and proceed to "C. CAMPAIGN LABEL INSTALLATION".
REPAIR PROCEDURE B
PROCEDURE TO REPLACE ABS MODULE
NOTE:
Module configuration or reprogramming is not required when installing a new ABS module.
1. Disconnect the 2-wire electrical connector at the ABS module.
2. Safely raise the vehicle on a hoist, then remove the four (4) ABS module screws and the ABS module.
3. Position the new module and install the bolts.
Tightening torque: No more than 18 in-lbf. (2 Nm)
4. Lower vehicle on hoist and reconnect 2-wire connector to the ABS module.
5. Proceed to "PROCEDURE TO REPLACE VEHICLE HARNESS CONNECTOR".
IMPORTANT SERVICE INFORMATION:
When performing the service pigtail installation, it is critical that the crimp tool and flameless heat gun be used. USING DIFFERENT TOOLS MAY RESULT IN A POOR REPAIR.
PROCEDURE TO REPLACE VEHICLE HARNESS CONNECTOR
1. Remove the tape and the convolute from the vehicle harness from the ABS module connector to 90 degree harness elbow".
2. Measure 75 mm (approximately 3 in) from the end of the elbow towards the ABS module connector, then using suitable wire cutters, cut the harness (all wires) to the same length.
3. Strip approximately 1/2 in. (12.7 mm) of insulation from each of the cut wires in the harness.
CAUTION:
The harness contains a 16-gauge red wire and a 20-gauge red wire with a pink tracer. DO NOT cross these wires when splicing in the service pigtail. As an assembly aid, the 16-gauge red wire on the service pigtail is identified by a small tag.
Also, it is possible that some discoloration of the insulation may occur. Sets of wires may appear to have the same color insulation when in fact all wires in the ABS module harness are different except for the two (2) black ground circuit wires. Be sure to carefully examine each wire to avoid crossing circuits when splicing wires.
NOTE:
^ The harness contains two (2) black wires of the same size. Both are grounds (circuit 57). Crossing these wires has no adverse effect on vehicle operation.
^ The service pigtail kit contains the connector with wires matching color and size of the original vehicle harness, three (3) different sizes of butt splice connectors for the different wire sizes and a piece of heat shrink tubing to cover each splice.
4. Working with one wire at a time, match the wires from the service pigtail to the correct wires from the vehicle harness. Insert the stripped end of each wire into the butt splice connector and crimp using the crimp tool provided.
NOTE:
Be sure to place the butt splice connector against the connector depth stop" on the crimp tool for proper crimping.
5. Crimp each wire from the vehicle harness side.
6. Using rosin core solder, solder only the vehicle harness wires to the butt splice connector.
7. After soldering the wires, center each piece of heat shrink tubing over the splice. Then, using a flameless heat gun, shrink one piece of tubing at a time until the adhesive flows out of both ends. Continue until all wires are insulated.
NOTE ON PROPER HEAT SHRINKING
The heat shrink tubing seals best if heat is applied to one end allowing time (only a few seconds) to begin the shrink process until you see the adhesive flow out of the end. At this point, slowly move the heat source across the tubing shrinking it as you move towards the other end, finally allowing adhesive to flow out providing a waterproof seal.
8. Install the supplied convolute tubing over the spliced area and secure with electrical tape. Apply tape to the entire length of the convolute and be sure to secure the convolute to the elbow at one end, and as close as possible to the ABS connector on the other.
9. Reinstall dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply dielectric grease to the ABS module connector, position and connect the harness as follows:
a) Reinstall dress cover.
b) Use ONLY dielectric grease.
^ With the tip of the applicator tube snipped off, position the end of the tip between the four (4) large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the four (4) flat pins.
NOTE:
DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a "hydro lock" condition which will not allow the connector to fully seat or lock in place.
10. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module.
11. Reconnect negative battery cable.
12. Turn the ignition key to the RUN position. Allow the ABS to carry out a preliminary self-check (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately three (3) seconds).
^ If the yellow ABS indicator is not illuminated after three (3) seconds, proceed to next step.
^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Technical Assistance Hotline.
13. Re-enter customer's radio pre-set stations and proceed to "C. CAMPAIGN LABEL INSTALLATION".
REPAIR PROCEDURE C
IMPORTANT SERVICE INFORMATION: When performing the service pigtail installation, it is critical that the crimp tool and flameless heat gun be used. USING DIFFERENT TOOLS MAY RESULT IN A POOR REPAIR.
PROCEDURE TO REPLACE VEHICLE HARNESS CONNECTOR
1. Remove the tape and the convolute from the vehicle harness from the ABS module connector to 90 degree harness "elbow".
2. Measure 75 mm (approximately 3 in) from the end of the elbow towards the ABS module connector, then using suitable wire cutters, cut the
harness (all wires) to the same length.
3. Strip approximately 1/2 in. (12.7 mm) of insulation from each of the cut wires in the harness.
CAUTION:
The harness contains a 16-gauge red wire and a 20-gauge red wire with a pink tracer. DO NOT cross these wires when splicing in the service pigtail. As an assembly aid, the 16-gauge red wire on the service pigtail is identified by a small tag.
Also, it is possible that some discoloration of the insulation may occur. Sets of wires may appear to have the same color insulation when in fact all wires in the ABS module harness are different except for the two (2) black ground circuit wires. Be sure to carefully examine each wire to avoid crossing circuits when splicing wires.
NOTE:
^ The harness contains two (2) black wires of the same size. Both are grounds (circuit 57). Crossing these wires has no adverse effect on vehicle operation.
^ The service pigtail kit contains the connector with wires matching color and size of the original vehicle harness, three (3) different sizes of butt splice connectors for the different wire sizes and a piece of heat shrink tubing to cover each splice.
4. Working with one wire at a time, match the wires from the service pigtail to the correct wires from the vehicle harness. Insert the stripped end of each wire into the butt splice connector and crimp using the crimp tool provided.
NOTE:
Be sure to place the butt splice connector against the connector depth stop" on the crimp tool for proper crimping.
5. Crimp each wire from the vehicle harness side.
6. Using rosin core solder, solder only the vehicle harness wires to the butt splice connector.
7. After soldering the wires, center each piece of heat shrink tubing over the splice. Then, using a flameless heat gun, shrink one piece of tubing at a time until the adhesive flows out of both ends. Continue until all wires are insulated.
NOTE ON PROPER HEAT SHRINKING
The heat shrink tubing seals best if heat is applied to one end allowing time (only a few seconds) to begin the shrink process until you see the adhesive flow out of the end. At this point, slowly move the heat source across the tubing shrinking it as you move towards the other end, finally allowing adhesive to flow out providing a waterproof seal.
8. Install the supplied convolute tubing over the spliced area and secure with electrical tape. Apply tape to the entire length of the convolute and be sure to secure the convolute to the elbow at one end, and as close as possible to the ABS connector on the other.
9. Reinstall dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply dielectric grease to the ABS module connector, position and connect the harness as follows:
a) Reinstall dress cover.
b) Use ONLY dielectric grease.
^ With the tip of the applicator tube snipped off, position the end of the tip between the four (4) large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the four (4) flat pins.
NOTE:
DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a "hydro lock" condition which will not allow the connector to fully seat or lock in place.
10. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module.
11. Reconnect negative battery cable.
12. Turn the ignition key to the RUN position. Allow the ABS to carry out a preliminary self-check (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately three (3) seconds).
^ If the yellow ABS indicator is not illuminated after three (3) seconds, proceed to next step.
^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Technical Assistance Hotline.
13. Re-enter customer's radio pre-set stations and proceed to C. CAMPAIGN LABEL INSTALLATION".
REPAIR PROCEDURE D
1. If the seals are not fully seated, reseat any seals not fully seated with a blunt tool.
NOTE:
DO NOT use anything sharp such as a screwdriver, awl or punch that could penetrate the seal and allow moisture to enter the terminal.
2. Reinstall dress cover and use electrical tape to secure the cover at the same location where the original tie strap was removed. Apply dielectric grease to the ABS module connector, position and connect the harness as follows:
a) Reinstall dress cover.
b) Use ONLY dielectric grease.
^ With the tip of the applicator tube snipped off, position the end of the tip between the four (4) large flat pins at the bottom of the ABS module connector. Squeeze out enough grease to completely cover the four (4) flat pins.
NOTE:
DO NOT spread the grease around the connector. Applying an excess amount of grease into the connector cavity will cause a "hydro lock" condition which will not allow the connector to fully seat or lock in place.
3. Reposition the harness to its original position, install the retainers to the studs to secure the harness and connect it to the ABS module.
4. Reconnect negative battery cable.
5. Turn the ignition key to the RUN position. Allow the ABS to carry out a preliminary self-check (indicated by illuminating the yellow ABS warning indicator in the instrument cluster for approximately three (3) seconds).
^ If the yellow ABS indicator is not illuminated after three (3) seconds, proceed to next step.
^ If the yellow ABS warning indicator stays illuminated after the self-test, contact the Technical Assistance Hotline.
6. Re-enter customer's radio pre-set stations and proceed to C. CAMPAIGN LABEL INSTALLATION".
C. CAMPAIGN LABEL INSTALLATION
Complete a Campaign Label" with the Recall 4507C written on the sticker and affix it to the vehicle's bulkhead. Refer to illustration under "A". VEHICLE INSPECTION PROCEDURE".