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TSB 05-07-90

RWAL Valve Harness Replacement Faults Caused By Water Contamination

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Models: 1989-1990 Pickup, Ramcharger, Dakota, Cab& Chassis

• AD - Ram Pickup/Ram Cab & Chassis/Ramcharger (RWD, 4WD) Power Ram Cab & Chassis (4WD)
• AN - Dakota/Dakota Sport/Dakota Convertible/Dakota Cab & Chassis

Symptoms:

The amber ANTILOCK, and red BRAKE warning lamp illuminate and a Code 4 or 9 is present during diagnosis of the Rear Wheel Antilock Brake System (RWAL) on a subject vehicle. A possible cause is water contamination of the 4-way connector at the hydraulic valve (located inside the left frame rail near the rear of the vehicle) and/or water contamination in the 50-way connector.  

Parts:

8 - Tie Straps    PN 6015756
1 - Kit              PN 83506517             Kit Contents:

• 1 - Jumper Harness
• 4 - Insulators (connectors)
• 4 - Locking Wedges
• 1 - Connector Grease  

Repair:

It is important to completely read this bulletin prior to performing this repair procedure. This procedure involves the replacement of part of the existing RWAL harness with a service jumper harness that runs directly from the Instrument Panel side of the 50-way bulkhead connector to the RWAL valve.

1.    Disconnect the battery cables.

2.    Disconnect 2-way harness connector to RWAL sensor jumper harness.

3.    Disconnect 4-way harness connector to RWAL valve and remove the end seal and inspect for water or moisture inside connector.

4.    Disassemble, clean and dry as required, the 4-way connector on the RWAL valve side.  

5.    Apply grease (supplied) to the connector, both on the front and behind the rear end seal on the RWAL Valve side. This step is done even if no water is present.

6.    On the wire harness side cut off the 2 & 4-way connectors and wires flush with the wiring harness. Tape over exposed wires with friction tape.

7.    Attach service jumper harness to the 4-way RWAL Valve connector and to the 2- way RWAL sensor jumper connector.

8.    Route service harness forward along frame rail to bulkhead area as follows:

AN-Body - Tie strap service harness to brake & fuel lines periodically. Loop back excess wire length and tie strap to brake lines near fuel tank area.

AD-Body - Tie strap service harness to existing chassis wiring periodically. Locate basket handle clip on service harness to floor pan clip. Loop back excess wire length and tie strap to chassis harness near fuel tank area.

9 .    Route eyelet (ground) lead along engine compartment harness to existing RWAL ground location.

10.   Replace existing RWAL ground with ground supplied by service jumper. Tape existing ground to harness.

11.   Drill a 3/4" hole in the dash panel from the engine compartment side, making sure both sides of the dash are clear. See (Figure 1) for location of the holes for AN & AD-Body.

12.   Feed service jumper wires through hole and insert grommet.

13.   Insert terminals into insulator (provided) and wedges in cavities as shown by the diagram (Figure 2).

14.   Disconnect the 50-way bulk head connector by turning the jack screw. Depress tabs and pull I/P side of connector into passenger compartment.

15.   Remove required wedges and circuits indicated by the diagram and insert circuits into supplied insulators as shown in (Figure 3).

16.   Reinstall wedges and reconnect bulkhead connector.

17.   Connect service jumper and I/P wiring.

18.   Reconnect battery cables and test system.

19.   Verify a system self check and road test vehicle for proper operation of the system. If a Code 4 or 9 is still present, follow the diagnostic procedures outlined in the RWAL Brake Diagnostic Procedures Manual (PN 81-699-9006).

Notes:

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No. 05-30-12-90 . . . . . . . . . . . . . . . . 1.4 Hrs.

FAILURE CODE: 23 - Contacts Corroded