R61
R61
R61
Models
Subject
Anti-Lock Brake System (ABS) control module on about 151,000 of the above
vehicles may have a ground wire eyelet on the right front shock tower that allows
water to wick through the ground wire case and into the ABS module. Moisture in
the ABS module could disable the ABS and/or Electronic Stability Control (ESC)
system(s). The lack of a functioning ABS and/or ESC system(s) could change the
braking and/or handling characteristics of the vehicle and cause a crash without
warning.
Repair
The ground eyelets on the right shock tower must be sealed to stop water migration
through the ground wire case. The ABS control module and headlamp/dash wire
harness must also be inspected for moisture and repaired and/or replaced if
required.
Parts Information
Each Antilock Brake System Module package contains the following components:
Quantity Description
4 Screws, Attaching
12 Seals, Solenoid Valve Stem
Safety Recall R61 -- Antilock Brake System Control Module Page 3
Parts Return
Special Tools
Service Procedure
3. Remove and save the seven push-pins securing the cowl top screen at the ends.
Remove the cowl top screen (Figure 2).
COWL TOP
SCREEN
5. Remove and save the five push-pins securing the cowl screen to the wheelhouse
brace and cowl. Rotate the screw in the center of the cowl screen 90° clockwise
to release the screen. Remove the cowl screen (Figure 3).
SCREW
COWL
SCREEN
6. Release the plenum silencer from the bottom of the wheelhouse brace.
7. Remove and save the eight mounting bolts (four each side) securing the wheel
house brace to the strut towers (Figure 4).
PLENUM SILENCER
BOLTS BOLTS
WHEELHOUSE BRACE
12. Inspect the ABS module electrical connector terminals and the ABS module
receptacle for moisture or corrosion (Figure 7).
If moisture or corrosion is present, continue with Section B. Install
Ground Circuit Overlay.
13. Using electrical contact cleaner, clean the ABS module electrical connector.
14. Cut just the tip off the dielectric grease nozzle.
15. Apply a very light bead of dielectric grease on the face of the ABS module
electrical connector.
CAUTION: Do not apply excess amounts of dielectric grease. ABS control
module electrical connector terminal damage and/or poor electrical
connections may occur.
ABS MODULE RECEPTACLE
TYPICAL CORROSION
18. Remove the nuts securing the ABS control module and the two engine harness
ground eyelets and remove the
ABS MODULE GROUND HEAT SHRINK
eyelets from the ground studs WIRE EYELET TUBE
(Figure 8).
23. Remove the original heat shrink Figure 9 – Heat Shrink Tube
tube from the two ground wire
eyelets (Figure 9).
Safety Recall R61 -- Antilock Brake System Control Module Page 11
26. Position the ABS control module ground wire eyelet and the two engine ground
wire eyelets to the studs and install the two nuts. Tighten the ground wire
eyelet nuts to 7 ft. lbs. (10 N·m) (Figure 8).
Safety Recall R61 -- Antilock Brake System Control Module Page 12
28. Turn the ignition key to the “ON” position, verify the ABS light bulb check
functionality and start the engine.
If the ABS light is “ON” continuous after bulb check, and DTC C2200, is
present the ABS module must be replaced. Continue with Section B. Install
Ground Circuit Overlay.
If the ABS light is “ON” continuous after bulb check, and DTC’s other than
C2200 are present; refer to all current, normal diagnostics published in
DealerCONNECT and repair as necessary following normal warranty repair
guidelines then continue with Step 29.
If the ABS light is not “ON” continuous after bulb check, the ABS module
will not be replaced. Continue with Step 29.
29. Install the coolant reservoir and tighten the two bolts securely.
30. Install the power steering reservoir and tighten the bolt securely.
If the vehicle is equipped with a 3.6L engine, continue with Step 31.
32. Position the fresh air plenum and install the two mounting screws. Tighten the
screws securely (Figure 5).
33. Install the wheelhouse brace. Install and tighten the eight mounting bolts (four
each side) to 35 ft. lbs. (48 N·m) (Figure 4).
34. Secure the plenum silencer to the bottom of the wheelhouse brace.
35. Install the cowl screen. Install the push-pins securing the cowl screen to the
wheelhouse brace and cowl. Rotate the screw in the center of the cowl screen
90° counterclockwise to lock the screen in place (Figure 3).
37. Install the cowl top screen. Install the seven push-pins securing the cowl top
screen at the ends. Install the remaining push-pins (Figure 2).
39. Close the hood and return the vehicle to the customer.
Safety Recall R61 -- Antilock Brake System Control Module Page 14
6. Cut off the two black ABS TWO BLACK GROUND WIRES
electrical connector ground
wires at the end of the wire
harness sleeve (Figure 13).
9. Remove and save the bolt securing the power steering reservoir.
10. Remove and save the two bolts securing the coolant reservoir.
11. Position the power steering and coolant reservoirs to the side.
12. Pull the ground eyelets around to the front of the shock tower to gain access.
13. Remove the original heat shrink tubing from both ground eyelets (Figure 15).
14. Cut the two wire ABS module ground wire pigtail off at the wire harness take
out and tape over the cut end. These wires will no longer be used (Figure 15).
CAUTION: The ABS control module ground wire pigtail has only two
wires crimped in the ground eyelet. Do not cut the engine harness ground
wire pigtail which has three or more wires crimped in the ground eyelet.
ENGINE
GROUND
WIRE
EYELET
HEAT SHRINK
TUBE
19. Position the ABS module ground eyelet (NEW ground circuit overlay eyelet) to
the rear ground stud and the two engine ground eyelets to the forward ground
stud and install the two nuts. Tighten to 7 ft. lbs. (10 N·m) (Figure 18).
NOTE: When installing a ground ciruit overlay, the two ground wire
eyelets must be oriented as shown in Figure 18.
20. Secure the ground circuit overlay to the main wire harness bundle using four
supplied tie straps (Figure 19).
21. Loop the extra ground overlay wire length and secure it with one of the
supplied tie straps to the main wire harness bundle as shown (Figure 19).
NOTE: Be sure to position the overlay wire to the rear of the main wire
harness bundle to avoid interference with the coolant bottle mounting.
TIE STRAP
LOCATIONS
22. Using electrical contact cleaner, clean the ABS module electrical connector.
23. Cut just the tip off the dielectric grease nozzle.
24. Apply a very light bead of dielectric grease on the face of the ABS control
module electrical connector.
CAUTION: Do not apply excess amounts of dielectric grease. ABS module
connector terminal damage and/or poor electrical connections may occur.
26. Route the ABS electrical connector and position the connector to the ABS
module securing the wire harness retaining clips to the frame rail.
27. Connect the right front wheel speed sensor electrical connector.
28. Insert the ABS electrical connector into the socket of the ABS control module
and close the cover, locking the electrical connector in place.
CAUTION: Before installing the ABS control module harness electrical
connector on the ABS control module, be sure the seal is properly installed
in the electrical connector.
CAUTION: Be sure the electrical connector lock is fully engaged.
Safety Recall R61 -- Antilock Brake System Control Module Page 21
If the ABS light is “ON” continuous after bulb check, and DTC C2200 is
present the ABS module must be replaced. Continue with Section C.
Replace ABS Control.
If the ABS light is “ON” continuous after bulb check, and DTC’s other than
C2200 are present; refer to all current, normal diagnostics published in
DealerCONNECT and repair as necessary following normal warranty repair
guidelines then continue with Step 30.
If the ABS light is not “ON” continuous after bulb check, continue with
Step 30.
30. Install the coolant reservoir and tighten the two bolts securely.
31. Install the power steering reservoir and tighten the bolt securely.
If the vehicle is equipped with a 3.6L engine, continue with Step 32.
33. Position the fresh air plenum and install the two mounting screws. Tighten the
screws securely (Figure 5).
34. Install the wheelhouse brace. Install and tighten the eight mounting bolts (four
each side) to 35 ft. lbs. (48 N·m) (Figure 4).
35. Secure the plenum silencer to the bottom of the wheelhouse brace.
36. Install the cowl screen. Install the push-pins securing the cowl screen to the
wheelhouse brace and cowl. Rotate the screw in the center of the cowl screen
90° counterclockwise to lock the screen in place (Figure 3).
Safety Recall R61 -- Antilock Brake System Control Module Page 22
38. Install the cowl top screen. Install the seven push-pins securing the cowl top
screen at the ends. Install the remaining push-pins (Figure 2).
40. Close the hood and return the vehicle to the customer.
Safety Recall R61 -- Antilock Brake System Control Module Page 23
3. Lift the ICU and mounting bracket upward to near the top of the slots in the
bracket then position the ICU on top of the frame rail to gain access to the four
ABS module attachment screws.
4. Thoroughly clean all surfaces of the ICU and brake tubes. Use only a solvent
such as Mopar® Brake Parts Cleaner or equivalent.
Safety Recall R61 -- Antilock Brake System Control Module Page 24
5. Remove and discard the four screws attaching the ABS control module to the
Hydraulic Control Unit (HCU) (Figure 21).
CAUTION: When removing the ABS control module from the HCU, be
sure to completely separate the two components (approximately 1.5 inches
(38 mm)) before removing the ABS control module. Otherwise, damage to
the pressure sensor or pump motor connection may result, requiring HCU
replacement. Do not to touch the sensor terminals on the HCU side or the
contact pads on the ABS side as this may result in contamination and
issues in the future.
SCREW LOCATIONS
6. Separate the ABS control module from the HCU (Figure 21 and 22).
7. Clean any debris off the mating surfaces of the HCU and ABS control module.
8. NEW solenoid valve stem seals are provided in the ABS control module kit.
Remove the twelve old and install the twelve NEW solenoid valve stem seals to
keep out moisture and debris; do not reuse solenoid valve stem seals
(Figure 22).
HCU
12. Insert the ABS control module wiring harness electrical connector into the
socket of the ABS control module and close the cover, locking the electrical
connector in place.
13. Loosen the two ICU mounting screws as necessary allowing the ICU mounting
bracket to slide down over the mounting screws and hang the assembly in place.
Tighten the two ICU mounting screws to 17 ft. lbs. (23 N·m) (Figure 19).
Safety Recall R61 -- Antilock Brake System Control Module Page 27
14. Install the coolant reservoir and tighten the two bolts securely.
15. Install the power steering reservoir and tighten the bolt securely.
17. Position the fresh air plenum and install the two mounting screws. Tighten the
screws securely (Figure 5).
18. Install the wheelhouse brace. Install and tighten the eight mounting bolts (four
each side) to 35 ft. lbs. (48 N·m) (Figure 4).
19. Secure the plenum silencer to the bottom of the wheelhouse brace.
20. Install the cowl screen. Install the five push-pins securing the cowl screen to the
wheelhouse brace and cowl. Rotate the screw in the center of the cowl screen
90° counterclockwise to lock the screen in place (Figure 3).
22. Install the cowl top screen. Install the seven push-pins securing the cowl top
screen at the ends. Install the remaining push-pins (Figure 2).
25. Connect the wiTECH scan tool to initialize the ABS and perform the following:
b. Perform the “ABS Verification Test” and road test the vehicle.
NOTE: The ABS Module must be initialized using the wiTECH scan tool.
If not initialized, the ABS indicator lamp will flash continuously. Because
the ABS module was replaced, there may be an active Dynamic Sensor
DTC. There will be no indication if the Steering Column Control module
(SCCM) is replaced, but the ABS initialization should be run to make sure
there are no SCCM DTCs. To initialize the ABS Module and clear offsets
have wheels pointing straight ahead and follow the directions on the
wiTECH scan tool. The drive test requires a 90° turn. If the Dynamics
Sensor was replaced, test drive the vehicle by turning the vehicle left or
right in a curving manner at vehicle speeds between 6 and 15 mph (10 and
25 km/h).
e. Verify all accessories are turned off and the battery is fully charged.
f. Verify that the ignition is “on”, with the wiTECH scan tool, erase all
Diagnostic Trouble Codes (DTCs) from all modules. Start the engine and
allow it to run for two minutes and fully operate the system that was
indicating the failure.
g. Turn the ignition “off” and wait five seconds. Turn the ignition “on” and
using the wiTECH scan tool, read DTCs from all modules.
h. If any Diagnostic Trouble Codes (DTC’s) are present, refer to all current,
normal diagnostics published in DealerCONNECT and repair as necessary
following normal warranty repair guidelines.
Safety Recall R61 -- Antilock Brake System Control Module Page 29
NOTE: For Sensor Signal Plausibility and Pump Motor DTC’s, the
ABS control Module must verify that the failure conditions are no
longer present in the current ignition cycle before it can turn off the
failure lamp(s). This may require the vehicle to be driven for several
minutes above 9 mph (15 km/h). Once it has been determined that the
failure condition is no longer present the lamp(s) will be turned off.
i. If there are no DTCs present after turning ignition on, road test the vehicle
for at least five minutes. Slowly turn the steering wheel from lock to lock.
Test drive the vehicle by turning the vehicle left or right in a curving manner
at a speeds between 10 and 25 km/h (6 and 15 mph). Perform several anti-
lock braking stops.
j. Using the wiTECH scan tool verify that there are no active or stored DTC’s.
27. Close the hood and return the vehicle to the customer.
Safety Recall R61 -- Antilock Brake System Control Module Page 30
Claims for vehicles that have been serviced must be submitted on the
DealerCONNECT Claim Entry Screen located on the Service tab. Claims
submitted will be used by FCA to record recall service completions and provide
dealer payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Inspect and Repair: Clean and Grease ABS
Connector and Add Heat Shrink
(2.0L and 2.4L Only) 08-R6-11-82 0.6 hours
All involved vehicle owners should be notified of the service requirement by their
Dealer. Owners are requested to schedule appointments for this service. A sample
copy of the owner notification letter is attached.
All involved vehicles have been entered into the Global Recall System (GRS) and
Vehicle Information Plus (VIP) for Dealer inquiry as needed.
GRS provides involved Dealers with an updated VIN list of their incomplete
vehicles. Completed vehicles are removed from GRS within several days of repair
claim submission.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule
appointments for this repair.
Additional Information
If you have any questions or need assistance in completing this action, please
contact your International Service and Parts Manager.
Global Service & Parts - International
FCA US LLC
ANTILOCK BRAKE SYSTEM CONTROL MODULE
______________________________________________________________________________________
The problem is... Anti-Lock Brake System (ABS) control module on your vehicle may have a
ground wire eyelet on the right front shock tower that allows water to wick
through the ground wire case and into the ABS module. Moisture in the ABS
module could disable the ABS and/or Electronic Stability Control (ESC)
system(s). The lack of a functioning ABS and/or ESC system(s) could change
the braking and/or handling characteristics of the vehicle and cause a crash
without warning.
What your dealer FCA will repair your vehicle free of charge. To do this, your dealer will seal the
will do... ground eyelet on the right shock tower to stop water migration through the ground
wire case. The ABS module and headlamp/dash wire harness must also be inspected
for moisture and repaired and/or replaced if required. The work will take about 2
hours to complete. However, additional time may be necessary depending on service
schedules.
What you must Simply contact your Chrysler, Jeep, or Dodge distributor/dealer right away to
do to ensure your schedule a service appointment. Ask the dealer to hold the parts for your vehicle or
safety... to order them before your appointment. Please bring this letter with you to your
dealer.
If you need If you have trouble getting your vehicle serviced, please contact the distributor/dealer
help... nearest your location. A representative will assist you in getting your vehicle
serviced. This information can be found in the Customer Assistance section of your
Owner's Manual.
We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thank you for your
attention to this important matter.