Wiring Harness - Connector Repair Package

NO: 08-21-96 Rev.A

GROUP: Electrical

DATE: Oct. 18, 1996

SUBJECT:
Wiring Harness Connector Repair Packages

NOTE : THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-21-96, DATED JUL. 26, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.

MODELS:

1996 (AB) Ram Van/Wagon
1996 (AN) Dakota
1996 (BR) Ram Truck
1996 (XJ) Cherokee
1996 (ZJ) Grand Cherokee
1997 (TJ) Wrangler

NOTE : THIS BULLETIN APPLIES TO THE 1996 VEHICLES LISTED ABOVE AND 1997 WRANGLERS BUILT PRIOR TO JULY 15TH, 1996 (MDH 0715XX).

**ALSO, CHEROKEES (XJ) BUILT ON JULY 15TH, 1996 (MDH 0715XX) OR AFTER WERE BUILT WITH 1997 STYLE WIRING HARNESSES AND CONNECTORS AND ARE NOT EFFECTED BY THIS BULLETIN.**

DISCUSSION:

Intermittent electrical complaints can be caused by poor electrical connections and can be very difficult to diagnose. Once diagnosed, the repair can be anywhere from simply reconnecting an electrical connector to complete wiring harness replacement. The following drivetrain electrical connector repair components have recently been made available to aid in drivetrain electrical repairs without replacing a complete harness. If you have determined that a customer complaint could be related to a poor electrical connection, use the following diagnosis to inspect the electrical connectors.

DIAGNOSIS:

This bulletin involves only electrical connections to the following components:

Throttle Position Sensor (TPS)
Manifold Absolute Pressure (MAP) Sensor
Oxygen (02) Sensor
Crankshaft Position (CKP) Sensor
Distributor "Sync" Position Sensor
Vehicle Speed Sensor (VSS)
Fuel Injector
Ignition Coil
Idle Air Control (IAC) Motor
Purge Solenoid
Transmission Solenoid (8-way)
Engine Coolant Temperature (ECT) Sensor and Gauge Sending Unit

Inspection of the connector begins with a thorough inspection of the insulator. If the insulator's locking tab is broke, replace the insulator. If the insulator's end seal or seal ring is damaged, replace the seal. Gently pull on the wires of the connector one at a time. If the wire pulls out of the insulator, remove and inspect the wedge lock. Also, inspect the locking tab inside the insulator. Replace the wedge lock if there are any signs of damage. Replace the insulator if the locking tab is damaged.

Inspect all wire terminals for corrosion. If corrosion is evident, replace the terminal ends and both insulator seals. To verify how secure the terminal fits to the component, insert and remove the harness side connector terminal onto the mating terminal of the component. Then, rotate the terminal 900,1800, and 2700 while inserting and removing the terminal onto the pin of the component.

NOTE : YOU WILL NEED TO INDIVIDUALLY CHECK EACH TERMINAL-TO-PIN CONNECTION FOR ANY MULTI-TERMINAL CONNECTOR.

If any connection is loose, replace the harness side connector terminal after verifying a good connection with the new terminal. For information regarding service procedures of electrical connectors, refer to Section 8W of the appropriate Service Manual.

PARTS REQUIRED:

POLICY: Information Only